Zenith® Pumps

Installation,Care and Maintenance

Zenith®

Chemical DutyGear Pumps

B-9000Gear Pumps

2

Zenith®

Thoroughly read and understand this entire manual before installation and operation of pump.

Benefits

Specifications

In 1926, Zenith Pumps was approachedby the synthetic fiber industry to designa pump that would provide precise,pulseless and repeatable flow whileensuring ultimate product quality. Theoptions then were the same as those inthe chemical process industry today—diaphragm, lobe, coarse gear, piston,plunger and screw pumps. Each hasproblems with pulsation, flow inaccura-cies, multiple seal areas and slip, whichrequire constant calibration, high main-tenance and extended downtimes.

Zenith Pumps met the challengeand designed a rotary external gearpump of unique precision and simplicity.

Manufacturing techniques were devel-oped to hold tolerances to ±.00005",minimizing internal clearances andassuring accurate and precise metering.The pump’s simplistic design of onlythree moving parts – two metering gearsand a drive shaft – provided long lifeand reduced maintenance.

For years, engineers have relied onZenith to provide precision fluid han-dling solutions for their most difficultpumping applications. Zenith gearpumps can be found wherever precise,pulseless, and repeatable metering offluids is required.

High Accuracy — Stable, repeatableflows are assured even under varyingconditions of temperature, viscosity andpressure.

Precision Construction — Ground andlapped components allow for operatingclearances to .00015" and provide highvolumetric efficiency.

Minimum Pulsation — Unique designoffers virtually pulseless flow withoutvalves or flexible elements to hinder performance.

Active Flowmeter Concept —Unparalleled mechanical precision,combined with the closed loop set point

accuracy, ensures an exact volume per revolution without expensive flowmeters.

Low Cost of Ownership — With onlythree moving parts and 400 series stainless steel construction, the pumpprovides excellent corrosion resistancefor most chemical processes, and isthrough-hardened to 54 Rc or better formaximum life.

Experience — Zenith has over 74years of application experience withengineers available 24 hours a day tosupport your precision fluid meteringneeds.

Capacities (cc/rev): 0.05, 0.3, 0.6, 1.2,2.4, 4.5, 9.0, 15, 30, 45, 90

Recommended Speed:.05 to 30 cc/rev, up to 500 RPM45 & 90 cc/rev, up to 300 RPM

Flow Range:up to 27,000 cc/Minute, (7 GPM)

Inlet Pressure: 300 psi (20 Bar) Max.

Outlet Pressure: 1000 psi (70 Bar) Max.

Differential Pressure:20 to 1000 psi. (viscosity dependent)

Temperature:0° F (-18° C) Minimum400° F (205° C) Maximum (with magnetic

coupling seal)645° F (340° C) Maximum (dependant on

shaft seal materials)

Seals: Single Mechanical, Double Lip, Packed or Magnetic

Rotation:Clockwise (CW) facing drive shaft

Port Connections:Metric thread or SAE 61 Standard

Optional Port Adapters:M12 X 1/4" NPT . . . . . . . . . 0.05 – 2.4 cc/rev1/2" SAE X 1/2" NPT . . . . . . 4.5 – 9.0 cc/rev3/4" SAE X 3/4" NPT. . . . . . . 15 – 30 cc/rev1-1/4" SAE X 1-1/4" NPT. . . 45 – 90 cc/rev

Optional Band heaters:150 Watt, 115 VAC . . . . 0.05 – 2.4 cc/rev325 Watt, 115 VAC . . . . 4.5 – 9.0 cc/rev650 Watt, 230 VAC . . . . . 15 – 30 cc/rev1500 Watt, 230 VAC . . . 45 – 90 cc/rev

3

Design Zenith’s B-9000 Series precision meter-ing pumps utilize a rotary external spurgear which dispenses an exact volumeof fluid per shaft revolution (cc/rev).

Precision ground and lapped con-struction, including alignment dowels,allows for close control of operatingclearances. This ensures precise, pulseless and repeatable flow undervarying process conditions.

Integrated closed loop speed con-trol and a compact motor driver systemmaintains up to .01% accuracy of setpoint speeds and also accepts automat-ed interfaces.

The B-9000 Series is constructed of400 series stainless steel, providingexcellent bearing qualities (hardness 54Rc) and corrosion resistance for mostchemical processes. The pump offersincreased uptime while minimizing main-tenance due to its simple design of onlythree moving parts.

The B-9000 Series is a new genera-tion of Zenith’s traditional B-Series pump.While maintaining precise flow charac-teristics, its optimum gear designreduces bearing loads, while increasingspeed capability. The pump allowsdirect piping and shaft engagement andincludes a single mechanical shaft seal,(other seal types available).

Operation Fluid enters the pump through the inletport located in the front plate and fillsthe gear pocket. As the gears rotate, aprecise amount of fluid is trapped by theside walls of the gear pockets and gearteeth.

The metered fluid is transported bythe rotation of the gears to the dischargeside of the pump where the gear teethcome into mesh. This action forces thefluid out of the gear teeth and throughthe outlet port located in the front plate.The pressure developed is determinedby the pump size, the gear clearances,pump speed, fluid viscosity and imped-ance to flow.

Pump speed is limited by practicalconsiderations. If a high viscosity fluid isbeing metered and pump speed isincreased beyond a certain point, thefluid may not be able to fill the gearteeth spaces, and the pump will notobtain enough fluid to maintain normalvolumetric efficiency. Lack of sufficientfluid is called starvation or cavitation.This can be remedied by increasing theinlet pressure or reducing pump speed.See table 1 on page 5.

Metering of thin fluids requires a different approach. Since the pumpdepends upon the metered fluid forlubrication of internal bearing surfaces,speeds are normally limited. Thesebearing surfaces include the bearingareas in the front and rear plates, andthe driver gear turning about the arbor.Accelerated wear and even seizure maybe the result of high speeds, especiallyif attended by low lubricity or a fluidcontaining abrasive particles. In certainapplications, it is recommended to use apump of larger capacity operated at a

lower speed. Contact our ApplicationsEngineering Department for assistance.

Pump efficiency depends on fourbasic variables: fluid viscosity, gearclearances, differential pressure andpump speed. The less viscous the fluid,the more likely it is to flow through agiven orifice. In a Zenith pump, this orifice is the gear clearance. Differentialpressure forces the fluid through thisclearance at a steady rate, regardless of the pump speed. Thus, the slip isconstant for a given amount of time. Theactual delivery of fluid is the measureddelivery minus the slip. If we increasethe pump speed we increase the mea-sured delivery, while the slip remainsconstant, causing the pump to becomemore efficient. Likewise, if we slow thepump down, the pump becomes lessefficient. Slip is repeatable and pre-dictable, and pump operation can beadjusted to compensate and, thus,accuracy is very high. See Graph 1 onpage 5.

Zenith B-9000 Series pumps aredesigned for operating temperaturesless than 645°F. When operating at temperatures above ambient, heat jackets should be used, and pumpsshould be heated slowly and uniformlyto avoid warpage and internal componentinterference.

The 400-Series stainless steels usedin the construction of the B-9000 Seriespumps provide sufficient corrosion resistance for most standard chemicalprocesses. The material hardness willprovide a high degree of wear resistanceas well. However, processes involvingcorrosive or abrasive fluids shouldalways be reviewed by Zenith.

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Operation(continued)

Magnetic Coupling PumpsIn normal operation, the magnetic polesof the outer drive magnet remain alignedwith the magnetic poles of the innerpump magnet. The motion of the motoris smoothly transferred to the pumpshaft. If the torque load on the pumpexceeds the magnetic couplingstrength, then the outer magnets willrotate past the inner magnets and themagnetic poles will misalign. The outermagnet will increase to a no-load motorspeed while the inner magnet remainsrelatively motionless. Excessive noiseand vibration can be observed as thepoles of a decoupled magnet move pastone another.

The pump should be stopped immediately if the magnets decouple.Continued operation of the motor withthe magnets decoupled will reduce thefuture strength of the coupling. Themagnets will not properly realign untilthe motor has been stopped. Beforerestarting the motor, one should deter-mine the cause of the decoupling andremedy the problem. Decoupling doesnot necessarily indicate a pump failure.It indicates that an instantaneous torquerequirement of the pump has exceededthe strength of the magnetic couplingsupplied with the system.

Without disassembly of the pump itcan be difficult to determine whether themagnetic coupling or the pump internalsare operating incorrectly. The followingis a list of examples that could result inmagnet decoupling:

• Blockage or restriction in the dis-charge side of the system

• Discharge pressure in excess ofnominal conditions

• Too rapid acceleration or decelera-tion of the drive system

• An increase in fluid viscosity

• Foreign particles impinging uponpump internal components

• Increased friction due to a poorlylubricating process fluid

The decoupling characteristic of mag-nets can be a safety feature, preventinginadvertent pump/motor overloads.Magnets should be chosen so that theirdecoupling torque is greater than thepump input torque. This should includeany transient, starting, and stoppingconditions in addition to steady statevalues.

The decoupling torque can vary withdifferent fluids, temperatures, operatingpressures, and magnet sizes. Accuratesizing of magnets for a specific applicationrequires precise knowledge of severaloperating conditions. Check with yourZenith representative to see which 9000-MD system is appropriate.

General Magnetic CouplingPrecautions

Both the inner and outer magnetic rotors are very powerful. Handle themwith care.

Danger! Persons with cardiac pacemakersshould stay at least 8 feet from the magnetic product at all times.

Do not position hands or fingers so thatthey may become trapped between thetwo magnetic rotors, or between onemagnet and a metal object.

Do not position the magnets near oneanother unless assembling the pump tothe system. Both rotors should be fas-tened to their respective shafts beforebringing them into proximity.

Do not place the magnets near any elec-tronic equipment or media that is sensi-tive to magnetic fields (computers,diskettes, credit cards, etc.)

When storing and assembling the magnetic coupling, make sure that nosmall metallic fasteners, pieces or otherforeign objects adhere to the rotors orbarrier cap.

If the magnets de-couple, stop the drivesystem for the pump immediately.Determine the cause of the excessivetorque requirement and remedy theproblem prior to re-starting the system.

WARNING

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Key:∆P = Pressure (psi)µ = Viscosity (cp)N = Speed (rpm)

0.000.001 0.01 0.1 1 10 100

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.90

1.00

∆P/(µ•N)

Dera

ting

Fact

or 0.3 cc/rev

45 cc/rev90 cc/rev

2.4 cc/rev

0.6 cc/rev1.2 cc/rev

4.5 & 15 cc/rev

9 & 30 cc/rev

.05 cc/rev

B-9000 or H-9000 Pump Performance

Inlet Pressure Loss (psi) = Viscosity(cps) • Displacement(cc/rev) • Shaft Speed(rpm) • [(Specific Gravity • W1)+W2]

Note: This sizing procedure should be used as a guideline for estimating pump type, pump size and system requirements. Please consult Zenith to confirm pump and system selection prior to placing a purchase order.

Flowrate = pump capacity (cc/rev) x rpm x performance factor

cc/rev W1 W20.3 4.29E-06 2.32E-060.6 1.93E-06 2.47E-061.2 1.21E-06 2.77E-062.4 9.34E-07 3.38E-064.5 3.00E-07 3.46E-079.0 2.24E-07 4.19E-0715.0 1.11E-07 7.47E-0830.0 8.61E-08 9.28E-0845.0 3.38E-08 1.65E-0890.0 2.49E-08 2.02E-08

Table 1

Graph 1

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Installation Pumps should always be carefullyunpacked and inspected. If any itemsare missing or damaged, the freight carrier and Zenith should be notifiedimmediately.

While the pump is composed ofstainless steel, it is a precision instrument.Dropping or hitting the pump with a non-yielding material can cause seriousdamage to the components. All materialsare through-hardened to maximum hardness resulting in a brittle material.Treat them as you would any other precisiongaging instrument.

Zenith pumps are shipped filled withmineral oil. If necessary, flush the pumpthoroughly with a cleaning solvent.

Prior to start-up, the pump must belubricated by either priming the pumpwith the process fluid, or by pouring asuitable lubricant into the inlet port.Rotate the drive shaft until lubricantappears at the discharge port.

The following is a general installationprocedure for Zenith B-9000 Seriesmetering pumps. The procedure mayvary slightly depending on the exactmodel purchased. For special applications,considerations, or technical assistance,please contact our ApplicationsEngineering Group.

It is not recommended to flushdownstream process equipment utilizingZenith precision metering pumps. Mostfluids used as flushing agents, such assolvents and water, have a low viscosityand have poor lubricating qualities.

Catastrophic failure may occurunder certain operating conditions. If itis necessary to flush the system, the following suggestions are recommendedto prevent premature pump failure:

1. If possible, flush the system using alubricating fluid.

2. Minimize the differential pressureacross the pump ports to a maximumof 25 psi.

3. Reduce the pump speed to anacceptable level (approximately 10 rpm)

4. Flush the pump for the shortest allowable time, yielding effectivecleansing of the system, and nolonger than necessary.

5. It is recommended to use a bypassaround the pump as illustrated inFigure A. This will allow for highvelocity flushing of the system while

minimizing risk to the metering pump.During the flush cycle, fluid will passthrough and around the pump. Thiswill allow the system to be flushedquickly and effectively.

To prepare the pump for use:

1. Always flush the piping system beforeconnecting it to the pump.

2. Filters should be installed upstreamof the pump inlet port. The filter shouldideally be sized to one half of thepumps gear clearances but, must notrestrict the flow of fluid to the inlet port.

3. Turn pumps by hand before start-upto ensure free rotation.

4. For applications above ambient tem-peratures, if using heaters, heat thepump slowly and evenly (includingthe seal arrangement) prior to introducing fluid into the pump. Thisprevents thermal shock and materialdistortion.

5. Make sure that process fluid is in thepump before starting. Apply positivepressure to the pump inlet whenmetering high-viscosity fluids.

Start Up

1. Note: The pump should never be allowedto run dry or be allowed to run with non-lubricating fluids such as water. Allowenough time for all components ofthe system to reach process temperature before starting thepump. Apply inlet pressure to thepump, allowing time to ensure thatthe process fluid has entered thepump to provide lubrication for thebearing areas.

Pump

Valve

Bypass

Figure A

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Installation(continued)

2. Before starting, remove all flowrestrictions downstream of the pumpto allow initial operation with as low aback pressure as possible.

3. Start the pump at the slowest speed pos-sible and, if possible, with a lubricatingfluid. Zenith B-9000 pumps must never berun without a fluid. Watch the point ofdischarge for evidence of fluid. If nodischarge is seen after a reasonablelength of time, shut down the pumpand check for obstructions in the sys-tem and proper pump rotation. Theterm “sufficient length of time” is sub-jective, and cannot be quantifiedbecause of differences in installation.If, for example, a connection can bebroken within a few inches of thepump outlet port, the flow would beevident with several seconds. If thedistance between the pump outletand the point of final discharge islong, more time would be neededbefore flow is confirmed.

Note: The pump will discharge a cloud ofbubbles when it is started, but thiswill subside when the air is purgedfrom the pump. This is a normalpart of pump startup.

4. When satisfactory operation isachieved, the pump and system cangradually be brought up to normaloperating speed and pressure.

4. Listen for any sounds of distresswhen first starting the pump and turnthe pump off immediately if any areheard. Investigate for causes of distress.

5. If, at any time during operation, thepump does not appear to be runningsmoothly, stop the pump immediatelyto avoid serious internal damage.

Cleaning,Inspection and Repair

Remember: Zenith metering pumps aremade for exact duty. In order to develophigh pressure and minimize slip, theclearance between the metering gearsand their housing must be as small aspossible, yet large enough to allow ade-quate lubrication. All parts are machinedto extreme accuracy. Critical dimensionsare held between one and two ten-thousandths of an inch (.0001"/.0002").Accurate performance is dependentupon proper handling. Please handlethe pumps with extreme care, and if pos-sible, set aside a separate clean area forpump maintenance and repair.

It is recommended that pump usersinstitute a program for dimensionalinspection of critical parts in order tokeep maintenance and operating coststo a minimum. By noting the performance

of a pump immediately before removingit from service and correlating the per-formance to measured component wear,the maximum limit for the pump’s criticalcomponents can be established.Additionally, the service life of the pumpcan be predicted and downtime can bescheduled accordingly.

If necessary, any Zenith precisionmetering pump requiring maintenance canbe returned to the factory for completerepair and overhaul. For a large numberof pumps, Zenith offers a contract repairservice which helps to reduce repaircosts and delivery time. Zenith Pumpsalso offers pump maintenance seminars.For more information concerning Zenithpump repair services, please contact ourCustomer Service Department.

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Lapping orBlocking

To remove nicks, burrs and scour marksfrom pump parts, place two layers of400-Grit Emery Cloth on a lapping blockor plate. A granite flat is also suitable.Apply light pressure to the part and turnit using a figure 8 motion approximatelyten times until a smooth finish appears.Areas that are commonly lapped are thesides of metering gears and the insidefaces of front, gear and rear plates. Afterlapping is completed the parts are readyto be cleaned with a safe industrial solvent.

Always use clean, lint free rags andcompressed air to clean components.Paper towels are not acceptable

because they can leave small pieces ofpaper and dust on the pump parts. Use chemical brushes to clean betweengear teeth, bores and reliefs. After allcomponents are “hospital clean”, thepump can be reassembled.

If cleaned parts are not to bereassembled for a period of time, theyshould be coated with a rust preventativefluid, such as mineral oil, to prevent rusting.

New and replacement parts shouldalways be deburred and cleaned usingthe above procedures.

B-9000 SeriesDisassembly

Note: As parts are disassembled, placethem carefully on a clean surface suchas a soft cloth. Do not allow them toknock together. Pay close attention to theorder in which parts are removed. Thiswill aid in the reassembly of the pump.

Instructions below assume the pumphas been removed from the system, forexample, magnetically driven pumpswith adapter plates have been disen-gaged from the housings.

Caution: Please review the precautionslisted on Page 4 for MagneticallyCoupled Pumps.

1. Remove the square key (17). For Magnetically Coupled Pumps skip to step 3d.

2. For mechanical face seal and doublelip seal pumps, remove the sockethead screws (18) from the sealhousing (11). For packing sealpumps, remove the hex headscrews (15) from the packing gland(14), then lift off the packing gland.

3. Lift off the seal housing (11) andremove the seal.

a) Mechanical Face Seal Pumps:

• The ceramic seat may be removedfrom the housing by pushing it outwith finger pressure. If it is stuck,use two small Allen keys or othersmall pins to press the seat fromthe housing using the two accessholes on the housing face.

• Remove the o-ring (15) from therecessed area in the seal housing(NOTE: .05 through 2.4 cc/rev models do not have the o-ring).

• On the .05 through 2.4 cc/rev models, set screws will have to beremoved to allow removal of themechanical seal (13) from the driveshaft (2). On models larger than 2.4cc/rev, first remove the carbon sealface from the seal, then pull themechanical seal (13) from the driveshaft (2). Some materials of theseal (face) are brittle in nature, useextreme caution so as not to dam-age the seal or its components.

b) Double Lip Seal Pumps:

• Press the lip seal (51) from the sealhousing using finger pressure, orby pressing on the seal using aplastic tool.

c) Packing Seal Pumps:

• Remove the packing seal rings (13)from the Inside of the seal housing(11).

• Remove the collar plate (12) fromthe drive shaft (2).

d) Magnetically Coupled Pumps:

• If applicable, remove the screwsthat secure the barrier cap to theadapter plate. Remove the barriercap and its O-Ring. NOTE: Therecould be process fluid contained inthe barrier cap.

• Loosen setscrew at the bottom ofthe inner rotor with appropriateAllen wrench. NOTE: Beware ofstrong magnetic forces. Slide theinner rotor off the shaft.

• Remove the square key from thepump shaft.

• Remove the four socket headscrews/washers that are securing

9

Inspection and PartPreparation

After the parts have been cleaned,they should be inspected for nicks,burrs and stubborn residue. The gearsand the edges of the gear plate pocketsare the most likely areas to be damagedbecause of sharp edges. An illuminatedmagnifier facilitates examination.

1. All flat surfaces of plates and gearsshould be “blocked”. Blocking is theact of rubbing the flat surface of a parton 400-grit, 500-grit or 3/0 abrasivepaper, which is supported on amachinist’s or inspector’s surfaceplate. A few light but firm rubs usuallyare enough to remove residue andminor metal disturbances. Rememberto use a figure 8 pattern to retain flat-ness and perpendicularity of holeswhen lapping plates.

1. Heavy disturbances or residue onfront or rear plates (NOT the gearplate!) may require stronger blockingon 320-grit or even 240-grit abrasivepaper followed by blocking on a finerabrasive paper. Deep score marks ormetal transfer cannot be removed byblocking, and the surfaces must beground. When surfaces are ground,care must be taken to maintain theperpendicularity of the precision

ground holes with the inner plate sur-face. The gear plate should never beground; to do so would reduce theaxial gear clearance to the pointwhere interference might occur whenthe pump is reassembled. Gears canbe ground as well, but interchange-ability and clearances are altered.Grinding gears is NOT recommended!

2. Gears, shafts and arbors should belightly polished on the O.D.

3. Any nicks in the gear teeth should beremoved by carefully stoning theparts with a fine India oilstone or anArkansas stone.

4. The edges of the gear’s I.D., bearingholes and dowel holes should belightly stoned with a round Arkansasstone to remove any nicks. Then polishthe I.D. with a small piece of fineabrasive paper, 400-grit or finer.

5. After all preparation has been com-pleted, remove the abrasive grainand loose residue in an ultrasoniccleaner or other suitable cleaningmethod. Abrasive grain is larger insize than the pump clearances.

6. At this point, dimensional inspectionmay be made if desired.

B-9000 SeriesDisassembly(continued)

the adapter plate to the pumpbody. Lift the adapter plate off thepump body and retrieve the O-Ring.

4. Loosen and remove the socket headscrews (19) and (20) from the backof the rear plate (7).

5. Remove the rear plate (7). Alwaysuse the pry slots to prevent scratchingprecision tapped surfaces.

6. Remove the gear plate (3), beingcareful to note the alignment of anymarkings on the plate. Always usethe pry slots to prevent scratchingthe plates.

Caution: Do not allow metering gears tobe lifted out with the gear plate. Theymay drop, causing damage to the gearteeth. Note that the slip-fit dowels (10)may come off with the gear plate.

7. Remove the retaining ring (16) fromthe shaft (2) which holds the drivinggear (5) in place.

8. Remove the driving gear (5).

9. Remove the round key (4).

10. Remove the drive shaft (2) from thefront plate (8).

11. Remove the driven gear (6) from thearbor (9).

12. Remove the slip-fit dowels (10) byturning and pulling simultaneously.

13. If the arbor (9) is to be replaced orthoroughly checked, press out byusing an arbor press, pressingtoward the inside of the pump (theshortest press distance).

14. Replace sleeve bearings (32 & 34)in front and rear plates as necessaryand hone in the plate to the originalnew part specifications. ContactZenith for dimensions. NOTE: .05through 2.4 cc/rev models do nothave sleeve bearings.

10

Diagram 2

.05 - 2.4 cc/rev B-9000

4.5 & 9 cc/rev B-9000

Diagram 1

18 SHCS M4x0.7

11 Seal Housing

13 Type 8-IT Mechanical Seal

21 Dryseal Type Plug

2 Drive Shaft

7 Rear Plate

19 SHCS M8x1.25

10 Hollow Dowel

6 Driven Gear

9 Arbor

Retaining Ring 16

Key 4

Driving Gear 5

Gear Plate 3

Front Plate 8

Interpret per ASME-Y14.5M 1994

Square Key 17

18 SHCS M6x1

11 Seal Housing

13 Type 502 Mechanical Seal

2 Drive Shaft

31 Front Plate

33 Rear Plate

19 SHCS M10x1.5

20 SHCS M6x1

32 Sleeve Bearing

10 Hollow Dowel

6 Driven Gear

9 Arbor

34 Sleeve Bearing

Rear Plate Assembly 7

Retaining Ring 16

Round Key 4

Driving Gear 5

Gear Plate 3

Front Plate Assembly 8

Interpret per ASME-Y14.5M 1994

O-Ring 15

Square Key 17

11

15 & 30 cc/rev B-9000

Diagram 3

45 & 90 cc/rev B-9000

Diagram 4

18 SHCS M8x1.25

11 Seal Housing

2 Drive Shaft

31 Front Plate

33 Rear Plate

SHCS M16x2 19

20 SHCS M6x1

32 Sleeve Bearing

10 Hollow Dowel

6 Driven Gear

9 Arbor

34 Sleeve Bearing

Rear Plate Assembly 7

Retaining Ring 16

Front Plate Assembly 8

Mechanical Seal 13

Round Key 4

Driving Gear 5

Gear Plate 3

Interpret per ASME-Y14.5M 1994

O-Ring 15

Square Key 17

18 SHCS M8x1.25

11 Seal Housing

13 Mechanical Seal

2 Drive Shaft

31 Front Plate

33 Rear Plate

19 SHCS M12X1.75 Grade 12.9

20 SHCS M6x1

32 Sleeve Bearing

10 Hollow Dowel6 Driven Gear

9 Arbor

34 Sleeve Bearing

Rear Plate Assembly 7

Retaining Ring 16

Round Key 4

Driving Gear 5

Gear Plate 3

Front Plate Assembly 8

Interpret per ASME-Y14.5M 1994

O-Ring 15

Square Key 17

12

B-9000 SeriesAssembly

Use both pages of the assembly draw-ing during the reassembly process toassure correct orientation of all parts.

Considerable care should be takento prevent wedging or jamming of parts.Never force the parts together. They willdrop into place if properly aligned.

Note: If the pump will not turn freelyafter each component is installed,then the last piece installed needsadditional attention or replacement.

Provide a can of compatible lubricant,preferably SAE-50 motor oil or mineral oil.If the pump is to be used at temperaturesgreater than 212°F (100°C), lubricantshould be chosen for high temperatureservice. Shaft, arbor, dowels, and gearsshould be lubricated prior to assembly.Take care to remove excess fluid frombetween the plate surfaces using a cleantowel. Threads should be lubricated witha temperature-rated, anti-seize compound.For service under 212°F (100°C), a moly-disulfide-based grease may be used.During assembly, considerable careshould be taken to prevent wedging orjamming of close-fitting components.Never force the parts together. They willdrop into place if properly aligned.

Caution: Please review the precautionslisted on Page 4 for MagneticallyCoupled Pumps.

1. Place the front plate (8) on a flat surface with the inner surface of the plate facing up.

2. If the arbor (9) was removed, pressarbor into the front plate (8) usingthe driven gear (6) as a guide forpressing the arbor perpendicular(upright) into the plate.

3. Push the slip-fit dowels (10) into thedowel holes in the front plate (8).

4. Place the driven gear (6) on thearbor (9).

5. Place the gear plate (3) over thedowels (10) and driven gear (6). On .05 through 2.4cc/rev models,the gear plate may be installed ineither direction. On models largerthan 2.4cc/rev, align the clearancehole for the fastener (19) with thecorresponding tapped hole on the front plate.

6. Install the drive shaft (2) from theopposite side of the front plate.

7. Install the round key (4) into the keyway on the drive shaft.

8. Slide the driving gear (5) onto thedrive shaft and into the gear plate.Take care to align the keyway in thegear with the key (4). The key mayneed to be held down to prevent itfrom being damaged by the gear.

9. Install the retaining ring (16) on therear plate end of the drive shaft (2).

10. Install the rear plate (7).

11. Install the socket head screws (19)through the rear plate (7) and torqueto 50% of recommended torque(see table page 14) using a cross-ing pattern. Check for free rotationof the gears. If acceptable, continueto torque to full recommendedtorque. Again, check for free rotationof the gears.

12. Install the socket head screw (20)through the rear plate (7) and torqueto recommended value.

13. Install the seal onto the drive shaft (2).

NOTE: To facilitate assembly of the shaftseal, place the pump on a flat surfacewith the shaft in a vertical position.

a) Mechanical Face Seal Pumps:

• The mechanical seal (13) will beinstalled onto the drive shaft (2) withthe carbon end facing away fromthe front plate (8). Take care whenpressing the seal onto the shaft, asthe elastomer can be damaged bythe keyway or shaft edge.

• On the .05 through 2.4 cc/rev models,align the set screws with the groovesmachined in the drive shaft (2), thentighten the set screws. On largermodels, the seal will slide up theshaft until it rests against the collar.

• On 4.5 cc/rev and larger models,install the o-ring (15) into the recessin the seal housing (11). If necessary,use heavy silicone grease to keepthe o-ring in place.

• On 4.5 cc/rev and larger models,install the carbon seat into themechanical seal with the exposedrib of the seat toward the ceramicseat of the seal assembly. Thenotches of the carbon seat shouldmate with the tabs of the mechani-cal seal. Use heavy silicone greaseto keep the seat fitted to themechanical seal.

13

B-9000 SeriesAssembly(continued)

• Install the ceramic seat into the sealhousing (11) with the o-ring of theseat away from the mechanical seal.

• Gently slide the seal housing (11)over the drive shaft (2) until the sealhousing is in place and lined-up withthe bolt holes on the front plate (8).

• Install the socket head screws (18)into the seal housing (11) and tightento the recommended torque. NOTE:On the .05 through 9 cc/rev models,tighten the screws using a crossingpattern.

b) Double Lip Seal Pumps:

NOTE: The seal assembly tool (52) isrequired for lip seal installation.

• The inner diameter of the lip seal(51) must first be shaped beforeinstalling onto the drive shaft (2).Slide the lip seal over the sealassembly tool (52) with the springsof the lip seal being the last sideinserted. The lip seal should beallowed to sit for 10-15 minutes toallow for expansion of the lips.

• After the lips have expanded, the lipseal (51) should be slid off of theseal assembly tool (52), flippedover, and then reinserted onto theseal assembly tool so that thesprings are the first side inserted.

• Once reinserted onto the seal assem-bly tool (52), coat the outer rim of thelip seal (51) with a lip seal lubricant.

• The lubricated lip seal (51) and theseal assembly tool (52) to which it isattached should be directed into theseal housing (11) so that the springof the lip seal faces away from therear of the seal housing. The sealassembly tool should be insertedcompletely into the seal housing andguided through the drive shaft holeuntil the lip seal touches and is flushwith the rear wall of the seal housing.Make sure there is no gap betweenthe lip seal and the seal housing.

• Place the open end of the sealassembly tool (52) over the pumpdrive shaft (2). NOTE: Make sure thatthe key (17) is not in place on the driveshaft. Slide the lip seal (51) and sealhousing (11) along the seal assemblytool until it smoothly glides over thedrive shaft. Continue until the sealhousing is in place and lined-up withthe bolt holes on the front plate (8).

• Install the socket head screws (18)into the seal housing (11) and tight-en to the recommended torque.NOTE: On the .05 through 9 cc/revmodels, tighten the screws using acrossing pattern.

c) Packing Seal Pumps:

• Slide the collar plate (12) over thedrive shaft (2).

• Install four new packing rings (13)into the packing housing (11).

• Gently slide the packing housing(11) over the drive shaft (2). If necessary, use the flat side of thepacking gland (14) to push thepacking housing into place to prevent the packing rings frombeing pushed out of the packinghousing.

• Use the packing gland (14) toslightly compress the packing rings(13) and properly position the pack-ing housing (11).

• Remove the packing gland (14),taking care not to move the packinghousing (11). Install the socket headscrews (18) through the packinghousing (11) and the collar plate(12) into the front plate (8). Tightento the recommended torque.

• Place the packing gland (14) intoposition over the packing housing(11). Install the hex head bolts (15)through the packing gland andtighten finger tight.

d) Magnetically Coupled Pumps:

• Insert the smaller O-Ring into thegroove on the adapter plate, usingcompatible grease to retain the O-Ring into the groove.

• Install the plate with the O-Ring facing the pump body using thefour socket head screws and sealing washers.

• Insert the square key onto the pumpshaft, then slide the inner magnetonto the shaft. Refer to certifiedpump assembly drawing to deter-mine the correct height/placementof the magnet. NOTE: This is criticalto the pumps proper operation.

• Secure the inner magnet by tightening the setscrew upon the square key.

continued

14

Size Recommended(Metric Alloy Steel) Torque (in -lbs)*

M4 31M6 108M8 262M10 519M12 910M16 2250

Trouble Probable Cause Remedy

Pump will not turn 1) Drive malfunction Verify that drive powered. Assure that alarm circuits areclear. Check motor drive current and speed settings.

2) Process conditions Check process conditions changed for proper temperature,

pressures, viscosities and materials.

3) Entrained particle Disassemble and clean pump; replace any damaged parts.

4) Possible internal Disassemble and clean damages pump; replace any damaged

parts. Consult factory.

Excessive seal 1) Worn seal face(s) Replace seals.assembly leakage

2) Improperly positioned Check seal and faces for seal or faces proper position.

3) Excessive inlet Reduce inlet pressure. pressure

Reduced pump 1) Worn gear(s) Replace worn gear(s).efficiency

3) Process conditions Consult factory for gear changed clearance recommendations

for new process conditions.

Trouble-shooting

Possible malfunctions of the pump with their causes and remedies are listed in the following table.

Screw Torque

B-9000 SeriesAssembly(continued)

• Place the larger O-Ring into theexposed face of the adapter plate.Lower the barrier cap into positionover the inner magnet. If applicablemount the barrier cap by installing/tightening the eight socket headscrews.

14. Install the square key (17) into thedrive shaft keyway.

*Lubricated values/if non-lubricated increase by 33%.

FAILURE, IMPROPER SELECTION OR IMPROPER USEOF THE PRODUCTS AND/OR SYSTEMS DESCRIBEDHEREIN OR RELATED ITEMS CAN CAUSE DEATH,PERSONAL INJURY AND PROPERTY DAMAGE.

This document and other information from ZenithPumps, its subsidiaries and authorized distributors provide productand/or system options for further investigation by users having technical expertise. It is important that you analyze all aspects of your application and review the information concerning the product or system in the current product catalog. Due to the variety of operating conditions and applications for these products or systems,the user, through its own analysis and testing, is solely responsible for making the final selection of the products and systems and assuring that all performance, safety and warning requirements of the application are met.

The products described herein, including without limitation, product features, specifications, designs, availability and pricing, are subject to change by Zenith Pumps and its subsidiaries at anytime without notice.

WARNING

© Copyright 2000 Zenith Pumps B-9000 C&M 12/04

Zenith® Pumps1710 Airport Road

Monroe, NC 28110Phone: 704-289-6511 • Fax: 704-289-9273

zenithpumps@colfaxcorp.com • www.zenithpumps.comA Colfax Buisiness Unit

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