TYPE DP-15 to 100B

HEAVY DUTY SUBMERSIBLE PUMPS

INSTALLATION,
OPERATION &
MAINTENANCE
INSTRUCTIONS
TOYO PUMPS NORTH AMERICA CORPORATION
2853 Douglas Road
Burnaby, British Columbia
CANADA V5C 6H2

Telephone:
Fax:
Parts Fax:
Email:

(604) 298-1213
(604) 298-7773
(604) 298-1224
info@toyopumps.com
Published April, 2000

TABLE OF CONTENTS
SECTION I

INTRODUCTION ..............................................................1
I-A
GENERAL ............................................................................1
I-B

SECTION II

INSTALLATION................................................................2
II-A
II-B
II-C
II-D
II-E
II-F

SECTION III

ELECTRICAL........................................................................5
OIL RESERVOIR ..................................................................5
BEARING LUBRICATION.......................................................5
MOISTURE SENSOR ............................................................5
MAINTAINED CAPACITY.......................................................5

DISASSEMBLING AND ASSEMBLING PROCEDURES ...................6

V-A
V-B
V-C
V-D
V-E
V-F

SECTION VI

STARTING A SUBMERSIBLE PUMP.......................................4

MAINTENANCE ...............................................................5
IV-A
IV-B
IV-C
IV-D
IV-E

SECTION V

CHECK UPON ARRIVAL ........................................................2

STORAGE............................................................................2
HANDLING ..........................................................................2
PRESTARTING CHECKS .......................................................2
MOISTURE DETECTOR INSTALLATION..................................3
THEMISTOR MOTOR OVERLOAD PROTECTION......................3

OPERATION ...................................................................4
III-A

SECTION IV

SAFETY...............................................................................1

DISASSEMBLY OF LEAD INLET SECTION...............................6

DISASSEMBLY OF PUMP SECTION .......................................6
DISASSEMBLY OF SHAFT SEALED SECTION..........................6
DISASSEMBLY OF MOTOR SECTION.....................................7
INSPECTION AND PARTS REPLACEMENT GUIDELINES..........7
SUBMERSIBLE PUMP REASSEMBLY ....................................8

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
INTRODUCTION

I-B. SAFETY
I-A. GENERAL
Do not install this equipment other than in
accordance with the instructions contained in this
manual.
The descriptions and instructions in this manual
cover the standard design of the equipment and
the more popular options when possible. This
manual does not cover all design details and
variations, nor does it provide for every
contingency which may be encountered. When
information cannot be found in this manual,
contact the nearest Toyo branch office.
This instruction book should be read completely
before starting installation, operation, or
maintenance. The equipment is capable of
trouble-free operation when properly installed,
operated, and maintained. These instructions
present the basic information and methods
required for proper installation and maintenance.
This pump has been designed to provide safe and
reliable service; however, it is both a pressure
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.

It is assumed that your safety department has

established a safety program based upon a
thorough analysis of industrial hazards. Before
installing, operating or performing maintenance
on the pump and associated components described
in this manual, it is suggested that the safety
program be reviewed to ensure that it covers the
hazards arising from high speed rotating
machinery.
In general, all personnel should be guided by all
the basic rules of safety associated with the
equipment and the process.
It should be understood that the information
contained in this manual does not relieve
operating and maintenance personnel of the
responsibility of exercising normal good
judgment in operation and care of the pump and
its components.
Toyo Pumps reserves the right to change the
design, construction, or material of any part
without incurring the obligation of installing such
changes on pumps already delivered.

TOYO PUMPS NORTH AMERICA CORPORATION

2

SECTION
INSTALLATION

II

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.

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

3

Submersible pumps should not be operated in

fluids above 40o C (104o F) without special ClassH 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.

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
Start the pump in air briefly to check rotation
(counterclockwise when viewed from the agitator
end.)

It is very important to ensure that adequate fluid

velocity in the discharge pipe is maintained
during high density operation or settling of
material in the pipe may cause blockage.

Caution

WARNING
Extended operation in air may burn out
the motor.

Never stop the pump while pumping slurry

through the lines. This will plug the lines and
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.

Ensure that the motor casing is submerged during

operation to prevent motor damage due to
overheating.

Lower the pump into the pumping material slowly.

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.

Prior to pump shutdown, lift the pump into clear

fluid for several minutes to completely flush the
system of any slurry.

TOYO PUMPS NORTH AMERICA COPRORATION

5

SECTION
IV
MAINTENANCE

IV-C. BEARING LUBRICATION

IV-A. ELECTRICAL
1. Check periodically that the voltage is kept at
the rated level and that voltage is balanced
between the phases. See Table 3 for motor specs.
2. Measure the insulation resistance of the motor
monthly. If the resistance value becomes less than
20 Mega ohms, check moisture content of stator
and motor sealing.

Every 1000 hours apply EP2 grease to the motor

bearings. Carefully inspect the packing before
replacing the grease inlet covers.

IV-D. MOISTURE SENSOR

If moisture sensor is tripped, go through normal
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.
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)
Pump Model

DP15-3

Oil Capacity
(US Gal.)

1.14

Pump Model

DP30B3
1.16

Oil Capacity
(US Gal.)

DP15B3
1.14

DP50-3
1.80

DP20-3

DP20B-3

DP30-3

1.14

1.14

1.16

DP100B3
6.61

DP100BL3
7.53

DP50B3
1.80

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.

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.
* DP-15B, DP-20B
20 ft/lb
DP-15 to DP-40B (except*) 50 ft/lb
DP-50 to DP-100B
75 ft/lb

TOYO PUMPS NORTH AMERICA CORPORATION

6

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.

V-B. DISASSEMBLY OF PUMP

SECTION

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.

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.

V-A. DISASSEMBLY OF LEAD

INLET SECTION
1. Remove (1) cap nuts and take off the (8) lead
cover.

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.

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.
.

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) Oring 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

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.
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.

3. Epoxy Resin
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.

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

DP-15 / DP15B

DP-20 / 20B

DP-30 / 30B

DP-50 / 50B

DP-100B

Output

Volts

Full

Breaker

Eff

Power

Direct

Starting

Speed

(HP)

(V)

Load

Settings

(%)

Factor

Starting

Time

(RPM)

(A)

(A)

Current (A)

(sec)

460

20

27

87.5

0.790

118

0.5

1170

575

16

22

86

0.800

87

460

27

36

88.5

0.785

201

0.5

1160

575

21

28

88

0.810

141

460

40

54

88

0.785

260

0.6

1185

575

32

43

87

0.795

203

460

63

85

90.5

0.815

359

0.5

1185

575

50

68

90

0.820

310

460

124

167

92.5

0.820

558

0.9

885

575

103

139

91

0.800

610

15

20

30

50

100

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

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)

750 (29.5)

825 (32.5)

840 (33.1)

1020 (40.2)

1065 (41.9) 1365 (53.7)

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)

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)

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)

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)

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)

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)

840 (33.1)

Dimensions in mm (inches)

910 (35.8)

955 (37.6)

Measurements are approximate only.