TYPE DP-15 to 100B

HEAVY DUTY SUBMERSIBLE PUMPS

INSTALLATION,
OPERATION &
MAINTENANCE
INSTRUCTIONS
TOYO PUMPS NORTH AMERICA CORPORATION
2853 Douglas Road Telephone: (604) 298-1213
Burnaby, British Columbia Fax: (604) 298-7773
CANADA V5C 6H2 Parts Fax: (604) 298-1224
Email: info@toyopumps.com

Published April, 2000

 TABLE OF CONTENTS
SECTION I INTRODUCTION ..............................................................1
I-A GENERAL ............................................................................1
I-B SAFETY...............................................................................1

SECTION II INSTALLATION................................................................2
II-A CHECK UPON ARRIVAL ........................................................2
II-B STORAGE............................................................................2
II-C HANDLING ..........................................................................2
II-D PRESTARTING CHECKS .......................................................2
II-E MOISTURE DETECTOR INSTALLATION..................................3
II-F THEMISTOR MOTOR OVERLOAD PROTECTION......................3

SECTION III OPERATION ...................................................................4

III-A STARTING A SUBMERSIBLE PUMP.......................................4

SECTION IV MAINTENANCE ...............................................................5

IV-A ELECTRICAL........................................................................5
IV-B OIL RESERVOIR ..................................................................5
IV-C BEARING LUBRICATION.......................................................5
IV-D MOISTURE SENSOR ............................................................5
IV-E MAINTAINED CAPACITY.......................................................5

SECTION V DISASSEMBLING AND ASSEMBLING PROCEDURES ...................6

V-A DISASSEMBLY OF LEAD INLET SECTION...............................6
V-B DISASSEMBLY OF PUMP SECTION .......................................6
V-C DISASSEMBLY OF SHAFT SEALED SECTION..........................6
V-D DISASSEMBLY OF MOTOR SECTION.....................................7
V-E INSPECTION AND PARTS REPLACEMENT GUIDELINES..........7
V-F SUBMERSIBLE PUMP REASSEMBLY ....................................8

SECTION VI RECOMMENDED SPARE PARTS...........................................9

§ GENERAL PERFORMANCE CURVES

§ ELECTRICAL INFORMATION
§ DIMENSIONAL DRAWING
§ GENERAL SEAL AND LOWER BEARING ARRANGEMENT
§ TYPICAL CROSS SECTIONAL DRAWING
§ EXPLODED VIEW AND PARTS LIST
§ DP15/DP15B, DP15-3D2/DP15B-3D2 (DRAWING #
A6231, A5623-A5628)
§ DP15/DP15B Series 5 (DRAWING # A6295-A6297)
§ DP20/DP20B, DP20-3D2/DP20B-3D2 (DRAWING #
A6230, A5631-A5635, A5629)
§ DP30/DP30B, DP30-3D2/DP 30B-3D2 (DRAWING #
A6241, A5636-A5641)
§ DP50/DP50B, DP50-3D2/DP50B-3D2 (DRAWING #
A6242, A5642-A5647)
§ DP75/DP75B, DP75-3D2/DP75B-3D2 (DRAWING #
A6242, A5648-A5653)
§ DP100 (DRAWING # A5654-A5656)
§ MOISTURE SENSOR RELAY & ELECTRODE ARRANGEMENT
 TOYO PUMPS NORTH AMERICA CORPORATION
1

SECTION I -
INTRODUCTION

I-B. SAFETY
I-A. GENERAL It is assumed that your safety department has
established a safety program based upon a
Do not install this equipment other than in
thorough analysis of industrial hazards. Before
accordance with the instructions contained in this
installing, operating or performing maintenance
manual.
on the pump and associated components described
in this manual, it is suggested that the safety
The descriptions and instructions in this manual
program be reviewed to ensure that it covers the
cover the standard design of the equipment and
hazards arising from high speed rotating
the more popular options when possible. This
machinery.
manual does not cover all design details and
variations, nor does it provide for every
In general, all personnel should be guided by all
contingency which may be encountered. When
the basic rules of safety associated with the
information cannot be found in this manual,
equipment and the process.
contact the nearest Toyo branch office.
It should be understood that the information
This instruction book should be read completely
contained in this manual does not relieve
before starting installation, operation, or
operating and maintenance personnel of the
maintenance. The equipment is capable of
responsibility of exercising normal good
trouble-free operation when properly installed,
judgment in operation and care of the pump and
operated, and maintained. These instructions
its components.
present the basic information and methods
required for proper installation and maintenance.
Toyo Pumps reserves the right to change the
design, construction, or material of any part
This pump has been designed to provide safe and
without incurring the obligation of installing such
reliable service; however, it is both a pressure
changes on pumps already delivered.
vessel and a piece of rotating machinery.
Therefore, the operator(s) must exercise good
judgement and proper safety practices to avoid
damage to the equipment and surroundings to
prevent personal injury. The instructions in this
manual are intended for personnel with a general
training in operation and maintenance of
centrifugal pumps.
 TOYO PUMPS NORTH AMERICA CORPORATION
SECTION II -
INSTALLATION
II-A. CHECK UPON ARRIVAL
The unit should be inspected immediately upon
arrival, and any irregularities arising due to
shipment should be reported to the carrier.
Care should be taken when unpacking pumps. A
copy of this instruction book as well as instruction
sheets for other various components may be
included in the shipment. Put these papers in a
safe, accessible place for ready reference when
required. It is important that the entire contents of
this booklet be studied before installation.
Pump parts and accessories may be packed inside
shipping container, or attached to skids in
individual packages. Inspect all container, crates,
and skids before discarding.
II-B. STORAGE
The pump is protected against corrosion for the
period of shipment and installation only.
If the pump is not to be installed at once, find a
clean, dry location for storage. Unit should be
stored in an approximately level position with no
strains applied. Protective coverings should be
left in place. The pump can be left in its shipping
container or skid for storage.
The pump's grease-lubricated bearings are shipped
with grease installed, therefore, no special
preservation measures are required. The oil
chamber is shipped full and does not require
filling before storage.
II-C. HANDLING
Use care when moving pumps. Rough handling of
the pump can cause breakage.
2
Make sure that any equipment used to lift the
pump or any of its components is capable of
supporting the weights encountered. Make sure
that all parts are properly rigged before attempting
to lift.
II-D. PRESTARTING CHECKS
1. Power Supply: Check and confirm that the
power supply voltage and frequency are the same
as stated on the pump name plate.
2. Grounding: Connect the pump's green
electrical lead to ground.
3. Pump Rotation: Correct rotation is
counterclockwise as viewed from the suction
intake. Check that pump rotation corresponds to
the rotation specified on name plate.
In case of incorrect rotation, switch two of the
three power leads in the cabtyre cable.
Rotation in air over extended periods can cause
damage to the pump's oil seals.
WARNING
Reverse rotation of the pump will cause
the cutter fan to unscrew and may
damage the impeller.
4. Protection of Electric Motor: We
recommend the use of magnetic breakers to protect
against over current.
If decreased starting torque is desired, start the
pump in air and then lower the pump slowly after
it reaches its rated speed. Note that this sometimes
causes an air lock which can be rectified by
lowering the pump deep enough into the water.
 TOYO PUMPS NORTH AMERICA CORPORATION
Submersible pumps should not be operated in
fluids above 40o C (104o F) without special Class-
H motor winding or a water jacket for motor
cooling.
If the pump must be operated with the motor
section in air, make sure that the motor
temperature does not rise above 60o C (140o F). If
the temperature rises over this level either run
water over the motor or submerge the motor
section periodically.
WARNING
Overheating the motor will definitely
decrease motor life.
5. Cabtyre Cable: If additional cabtyre cable
is required, please consult the factory.
WARNING
If incorrect size cable is used or cable
distance is excessive, voltage may be
reduced and motor damage could
occur.
Never use the cable as a rope or locate it where it
may get damaged by heavy equipment.
II-E. MOISTURE DETECTOR
INSTALLATION
A moisture sensor is standard in this DP
submersible agitator pump. When connected to
the relay box it provides a warning signal in the
event that water enters the oil chamber.
3
The moisture detector supplied with the pump is a
solid state relay control with a Toyo electrode
mounted within the oil chamber housing. This is a
very high sensitivity relay capable of detecting
small amounts of water as an emulsion in the oil.
We recommend that the relay be hooked up to
some kind of alarm or light (not supplied), rather
than directly to the motor starter. This is because
shutdown of the pump during heavy operation
will plug the pipeline. Upon tripping of the alarm,
maintenance should be scheduled within 1 or 2
days to replace the lower seals, shaft sleeve B and
possibly the lower bearing. The sooner
maintenance is performed, the fewer parts will be
required.
Pumps are equipped with moisture sensors and
thermistors. Toyo uses a two-cable arrangement.
The power cable contains three phase wires and a
ground. The control cable contains one conductor
for the moisture sensor (small black wire), two
conductors for the thermistors (small red & white
wires), and a ground (small green wire).
The moisture sensor lead (small black wire) is
attached to relay input number 8 and the ground
(small green wire) in the accessory cable is
attached to relay input number 5. The normally
open portion of the load relay should be powered
using inputs 2 and 7 for 115 V.A.C. The enclosed
drawing for direct operation describes the
electrical connections required.
II-F. THERMISTOR MOTOR
OVERLOAD PROTECTION
Thermistors are standard on all pumps within this
size range. The thermistors use the two spare wires
encased in the moisture sensor cabtyre to operate
an overheat relay part #3UN21 or ABB-C105.02.
See enclosed wiring diagram for electrical
connections.
 TOYO PUMPS NORTH AMERICA CORPORATION
4

SECTION III - OPERATION

III-A. STARTING A
SUBMERSIBLE PUMP It is very important to ensure that adequate fluid
velocity in the discharge pipe is maintained
Start the pump in air briefly to check rotation
during high density operation or settling of
(counterclockwise when viewed from the agitator
material in the pipe may cause blockage.
end.)

Caution
WARNING Never stop the pump while pumping slurry
Extended operation in air may burn out through the lines. This will plug the lines and
the motor. the pump may become buried and have to
be dug out.

Start the pump in clear fluid to prime discharge
hoses, etc. Ensure that no hoses are kinked as the
pump will not force them open to start flow.
Where flexible hose is required, we recommend
the use of non-collapsible hose.
Lower the pump into the pumping material slowly.
Ensure that the motor casing is submerged during
operation to prevent motor damage due to
overheating.
Prior to pump shutdown, lift the pump into clear
fluid for several minutes to completely flush the
system of any slurry.

Slurry density can be observed by watching an

ammeter for current loading. Higher current means
higher specific gravity and thus higher density.

Pumping density can be controlled by raising and

lowering the pump into the material.
 TOYO PUMPS NORTH AMERICA COPRORATION
5

SECTION IV -
MAINTENANCE
IV-C. BEARING LUBRICATION
IV-A. ELECTRICAL
Every 1000 hours apply EP2 grease to the motor
1. Check periodically that the voltage is kept at bearings. Carefully inspect the packing before
the rated level and that voltage is balanced replacing the grease inlet covers.
between the phases. See Table 3 for motor specs.

2. Measure the insulation resistance of the motor IV-D. MOISTURE SENSOR

monthly. If the resistance value becomes less than
20 Mega ohms, check moisture content of stator If moisture sensor is tripped, go through normal
and motor sealing. shutdown procedure then immediately check and
replace the shaft seals as necessary.

IV-B. OIL RESERVOIR

1. Check lubrication oil level in oil reservoir at
least every 500 hours. To fill, set pump
horizontally, remove the oil inlet cover and fill to
capacity.
2. If water (cloudy condition) and sludge have
contaminated the oil reservoir, check and replace
the shaft seals.
3. If pump is run intermittently, the oil reservoir
should be examined more often.
IV-E. MAINTAINED CAPACITY
The amount of liquid being pumped will lessen as
wear occurs between the faces of the impeller and
the impeller disc. To maintain full pump capacity,
the impeller clearance must be adjusted
periodically. Each application is different and it is
necessary to determine the amount of wear for a
certain time limit before setting up a schedule for
adjustment.
1. Loosen the impeller disc set nuts.

4. If the pump has not been operated for a long
period of time, the oil reservoir should be
examined shortly after startup to ensure there has
been no deterioration of seals.
5. Use SAE #30W non-detergent or turbine oil
for oil lubrication of the pump. (Refer to table
below)
2. Turn impeller clearance adjusting bolts to
move the suction cover up until it touches the
impeller. Turn the bolts in the opposite direction
to lower the suction cover 0.04" (1 mm) which
gives the recommended operating clearance.
3. Tighten the set nuts to the torque values listed
below.

Pump Model DP- DP- DP- DP- DP- * DP-15B, DP-20B 20 ft/lb
15-3 15B- 20-3 20B-3 30-3
3
DP-15 to DP-40B (except*) 50 ft/lb
Oil Capacity 1.14 1.14 1.14 1.14 1.16 DP-50 to DP-100B 75 ft/lb
(US Gal.)

Pump Model DP- DP- DP- DP- DP-

30B- 50-3 50B- 100B- 100BL-
3 3 3 3
Oil Capacity 1.16 1.80 1.80 6.61 7.53
(US Gal.)
 TOYO PUMPS NORTH AMERICA CORPORATION
SECTION V - DISASSEMBLING AND ASSEMBLING
PROCEDURES
Use a location that is dry and dust free. Prepare
several small boxes for disassembled small parts,
plus rags, chain block or crane, solvent and tools.
NOTE: For models DP-15 to DP-50B the numbers
marked with ( ) in the following descriptions
correspond to the part numbers in the typical cross
sectional drawing. For models DP-100B, DP-100BL
use the applicable construction drawing number
which may be slightly different.
V-A. DISASSEMBLY OF LEAD
INLET SECTION
1. Remove (1) cap nuts and take off the (8) lead
cover.
2. To detach the (7) power leads of the cabtyre
cable from the motor lead wire, take off the vinyl
tape and the insulation tape and remove the
connecting screw with a screwdriver.
3. The (7) cabtyre cable is fixed with the epoxy
resin inside the (8) lead cover. Remove it by
breaking it with a screwdriver, etc.
4. Remove the (3) packing gland by removing the
(106) cap nuts.
5. Remove the (4) rubber packing, the (5)
packing set ring, the (6) cable protection tube and
packing gland from the (7) cabtyre cable.
6. Remove the (88) set screw and take off the (17)
set plate and the (18) distance plate from the motor
lead wires.
.
6
V-B. DISASSEMBLY OF PUMP
SECTION
1. The (81) cutter fan is threaded on the shaft,
therefore remove it by hitting it counterclockwise as
viewed from the strainer end. Use caution when
hitting the vanes as they are hard and brittle.
2. Remove the (79) set bolts and take off the (80)
strainer.
3. Remove the (69) cap nuts and take off the (74)
suction cover with the (73) impeller disc.
4. Remove the (83) impeller nut by using a
wrench and pull the (72) impeller from the shaft.
5. Remove the (55) key.
6. Remove the (67) cap nuts and take off the (71)
casing. Be careful not to damage the threaded
section of the bolts.
V-C. DISASSEMBLY OF
SHAFT SEALED SECTION
1. Remove the (21) set bolt and take off the (66)
oil inlet cover, then pour out the oil.
2. Remove the (35) set bolts and take off the (61)
oil seal housing B.
3. Remove the (54) distance sleeve, the (53) O-
ring and the (51) shaft sleeve B from the shaft.
4. Remove the (64) set bolts and remove the (60)
oil chamber with the (48) bearing lock plate B.
 TOYO PUMPS NORTH AMERICA CORPORATION
8

V-F. SUBMERSIBLE PUMP 3. Epoxy Resin

REASSEMBLY
In general, reassembly is a reversal of the
disassembly procedures, however, take note of the
following items.
1. Bearings
(a) Shrinkage fit - the maximum oil or induction
heating temperature should be 120o C.
2. Oil Seal and Rareflon Seal Installation
Pack lip seals with grease. Insert seals into the
housing with a jig to apply even force. Do not
apply unbalanced force or hammer the seals. If the
seals are deformed they will be destroyed.
If the electrical cable sealing inside the lead cover
has been damaged, remove the sealing compound
and replace it with epoxy. Hardening time is 24
hours at 25o C (77o F) or at least 4 hours at 60o C
(140o F).
4. Oil Reservoir
See page 5 for oil capacity.
5. Impeller Clearance
Adjust the clearance between the impeller and the
impeller disc to 0.040" (1 mm) with the adjust and
set bolts in the suction cover.

Install the shaft sleeve onto the shaft. Apply a

coating of grease onto the sleeve, then slide the
seal housing with seals onto the shaft sleeve.

WARNING
Do not insert the shaft sleeve onto the
shaft after the seal housing is already
installed. This will immediately destroy
the seals.

Check for seal leakage by applying pressure (about

40 psi) to the oil inlet hole to confirm zero pressure
loss over 1 minute.
 TOYO PUMPS NORTH AMERICA CORPORATION
9

SECTION VI - RECOMMENDED SPARE PARTS

To insure against possible long and costly

downtime periods, especially on critical services,
it is advisable to have spare parts on hand. A list
of spare parts is found in the parts list. Repair
order will be handled with a minimum of delay if
the following directions are followed:

1. Give model number and serial number. These

can be obtained from the nameplate on the pump.

2. Write plainly the name and part number of

each part required. These names and numbers
should agree with those on the sectional
drawings.

3. Give the number of parts required.

4. Give complete shipping instructions.

Some parts have long life and therefore do not

have to be carried in stock. These items should be
checked at regular intervals, and when
replacement is indicated, the parts should be
ordered.
 ELECTRICAL INFORMATION

Table 3

Pump Model Output Volts Full Breaker Eff Power Direct Starting Speed
(HP) (V) Load Settings (%) Factor Starting Time (RPM)
(A) (A) Current (A) (sec)
DP-15 / DP15B 15 460 20 27 87.5 0.790 118 0.5 1170
575 16 22 86 0.800 87
DP-20 / 20B 20 460 27 36 88.5 0.785 201 0.5 1160
575 21 28 88 0.810 141
DP-30 / 30B 30 460 40 54 88 0.785 260 0.6 1185
575 32 43 87 0.795 203
DP-50 / 50B 50 460 63 85 90.5 0.815 359 0.5 1185
575 50 68 90 0.820 310
DP-100B 100 460 124 167 92.5 0.820 558 0.9 885
575 103 139 91 0.800 610
 HEAVY DUTY SUBMERSIBLE AGITATOR PUMPS
TYPE DP
DIMENSIONS

DP-15 DP-15B DP-20 DP-20B DP-30 DP-30B DP-50 DP-50B DP-100B

A 1295 (51.0) 1295 (51.0) 1310 (51.6) 1310 (51.6) 1390 (54.7) 1390 (54.7) 1575 (62.0) 1575 (62.0) 1875 (73.8)

B 750 (29.5) 840 (33.1) 825 (32.5) 840 (33.1) 910 (35.8) 955 (37.6) 1020 (40.2) 1065 (41.9) 1365 (53.7)

C 1100 (43.3) 1100 (43.3) 1100 (43.3) 1100 (43.3) 1200 (47.2) 1200 (47.2) 1350 (53.2) 1350 (53.2) 1650 (65.0)

D 350 (13.8) 350 (13.8) 380 (15.0) 380 (15.0) 415 (16.3) 415 (16.3) 460 (18.1) 460 (18.1) 600 (23.6)

E 445 (17.5) 445 (17.5) 515 (20.3) 445 (17.5) 635 (25.0) 510 (20.1) 560 (22.1) 560 (22.1) 760 (29.9)

F1 500 (19.7) 560 (22.1) 495 (19.5) 560 (22.1) 515 (20.3) 580 (22.8) 635 (25.0) 655 (25.8) 745 (29.3)

F2 143 (5.6) 203 (8.0) 143 (5.6) 203 (8.0) 143 (5.6) 203 (8.0) 203 (8.0) 223 (8.8) 223 (8.8)

G 100 (3.9) 150 (5.9) 100 (3.9) 150 (5.9) 100 (3.9) 150 (5.9) 150 (5.9) 200 (7.9) 200 (7.9)

H 240 (9.5) 255 (10.1) 280 (11.0) 255 (10.1) 320 (12.6) 310 (12.2) 340 (13.4) 340 (13.4) 430 (16.9)

I 298 (11.7) 333 (13.1) 313 (13.1) 333 (13.1) 333 (13.1) 363 (14.3) 383 (15.1) 413 (16.3) 563 (22.2)

Dimensions in mm (inches) Measurements are approximate only.