Ebsray E Series Guide

Publication # 2080-04
EBSRAY PUMPS
INSTALLATION, OPERATION
& MAINTENANCE INSTRUCTIONS
E SERIES
MODEL E20HD

2
SECTION 1 – GENERAL
INTRODUCTION
This leaflet is intended to assist those involved
with the installation, operation and
maintenance of EBSRAY Model E20HD
Internal Gear Positive Displacement Pumps.
The design, materials and workmanship
incorporated in the manufacture of EBSRAY
pumps make them capable of reliable
operation over a long working life. Correct
installation is essential. Service life is
enhanced by periodic inspection and careful
maintenance.
1.1 CAUTION
INSTALLATION AND SERVICING OF THIS
EQUIPMENT SHOULD BE PERFORMED BY
QUALIFIED COMPETENT PERSONNEL IN
ACCORDANCE WITH RELEVANT
STATUTORY REGULATIONS OR CODES,
IN CONJUNCTION WITH THESE
INSTRUCTIONS.
When the equipment supplied utilises
components other than those manufactured
by EBSRAY e.g. couplings, speed reducers,
electric motors etc, reference should be made
to the original manufacturer's data before
installation or servicing is commenced. Failure
to observe these details may void the
warranty.
1.2 WARNING
The pump must be operated within the original
selected design parameters of speed,
temperature, pressure and viscosity. Should
any change be contemplated, please confer
with EBSRAY in order to verify the suitability of
such a change.
1.3 TRANSPORTATION AND PACKING
Standard domestic packing is suitable for
shipment in covered transports. Ports must be
sealed to exclude ingress of solids. When
received on site the pump should be stored in
a dry covered area.
If storage is required for other than a short
period prior to installation, special
preservatives and protective wrappings will be
required.
1.4 INSPECTION ON RECEIPT -
SHORTAGES
On receipt of equipment, check all items
against the dispatch documents and inspect
for damage. Any damage or shortage incurred
during transit should be noted on the packing
note and on both your own and the carrier's
copy of the consignment note and a claim
should be made immediately on the transport
company.
Should a shortage be evident on receipt, notify
EBSRAY immediately giving full details and
packing note number.
1.5 HANDLING
Care should be used in moving pumps. A sling
should be placed under or around a bare shaft
pump to minimise stress on the shaft or pump
flanges. Baseplate mounted units should be
lifted from under the baseplate below both the
pump and driver ensuring compliance with the
relevant lifting codes.
SECTION 2 – INSTALLATION
2.1 LOCATION
The pumping unit should be placed as close
as practicable to the source of supply
remembering to keep within the NPSH
requirement of the pump. Ensure floor area
and headroom allotted is sufficient for
inspection and maintenance. Allow sufficient
space and ventilation for motor cooling
requirements. Be sure to allow for crane or
hoist access if required.
2.2 FOUNDATIONS
Baseplate mounted pumpsets should be
accurately installed. When on a concrete
foundation ensure that it has been poured on
a solid footing. NOTE: Position foundation
bolts to match baseplate foundation plan.
Pumps/pumpsets must be securely bolted
down.

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2.3 PUMP PIPING CONNECTIONS
All piping should be supported independently
of and line up accurately with the pump ports.
SEVERE DAMAGE COULD RESULT IF
PIPING IS DRAWN INTO PLACE BY USE
OF FORCE AT THE PORT CONNECTIONS
OF THE PUMP.
2.4 STRAINER PROTECTION
The pump suction should always be protected
by an efficient suction strainer of adequate
size to accommodate the liquid viscosity
conditions without causing excessive suction
resistance.
2.5 ALIGNMENT
Alignment of the pump and driver is of
extreme importance for trouble free
mechanical operation. Baseplate mounted
units are accurately aligned at the factory. To
ensure this has been maintained during
transit, alignment MUST BE checked once
before startup and again after the unit has
been run under actual operating conditions.
NOTE: The following procedures are typical
only and reference should be made to data for
specific coupling types.
Figure 1 Figure 2
ANGULAR MISALIGNMENT as shown in
Fig.1 should be corrected before eccentricity.
Refer Fig.3; Use feeler gauge reading at 90°
intervals, the amount of correction necessary
can be easily determined to bring shaft axes in
line.
Figure 3
Misalignment due to ECCENTRICITY as
shown in Fig.2 can now be corrected. Refer
Fig.4; adjustment by use of shims under the
driver or pump will effectively correct error in
the vertical plane. Movement of Pump or
Driver horizontally will correct error in the
horizontal plane. NOTE: If both coupling
halves are of identical diameter, concentricity
may be checked with a straight edge at 90°
intervals.
Figure 4
2.6 SEAL DRAIN
The pump is fitted with 1/4” BSP(RC) threaded
seal drain connections. If pipe work is fitted to
these connections, ensure the pipe work is
connected such that the area behind the seal
is maintained at atmospheric pressure at all
times. Serious damage can occur if the seal
drains become blocked and/or any pressure is
allowed to build up behind the mechanical
seal.

4
SECTION 3 - OPERATION
3.1 DESCRIPTION
The EBSRAY internal gear principle is based
upon the use of an outer rotor 'A', idler gear,
termed inner rotor 'B' and a crescent shaped
spacer 'C' which is cast integral with the cover.
Thus only two moving parts fulfil this efficient
displacement cycle. Power is applied to the
outer rotor 'A' and transmitted to the meshing
idler or inner rotor 'B'. The rotor teeth cells
which are not involved in the meshing cycle
are sealed by the crescent 'C', body and
cover. (Refer Fig.5)
3.2 PUMPING PRINCIPLE
When rotation is started there is an increase in
cell volume as the teeth come out of mesh.
This creates a partial vacuum and the
pressure differential thus created initiates
movement of the liquid through the suction
port 'D', filling the teeth cells of the two
displacement rotors. When the tooth meshing
withdrawal cycle is complete and the tooth cell
volume is filled with liquid, transfer to the
pressure or discharge side is effected as the
liquid is carried past the crescent sealing
member 'C'.
Figure 5
This sealing crescent establishes a labyrinth
between the high and low pressure sides,
minimising fluid slip. When the teeth mesh on
the pressure side the liquid is forced from the
teeth cells and flows through the discharge
port 'E'. A noteworthy feature of this simple
principle is the absence of high tooth contact
pressures when compared with conventional
gear pumps, many of which employ costly
external timing gears to minimise tooth wear.
The inner rotor 'B', or idler remains in almost
hydraulic balance requiring only minimal
torsional load to effectively follow the outer
drive rotor.
3.3 APPLICATIONS
The field of applications for Internal Gear
rotary positive displacement pumps is
extensive. These pumps are used to handle
many kinds of liquids over a wide range of
capacities and pressures, associated with
viscous or non-viscous, hot or cold and
corrosive or non-corrosive conditions.
Accordingly material, speed and power
specifications vary and it is important to use
such equipment strictly adhering to the
manufacturers' recommendations.
3.4 LUBRICATION
Lubrication of the inner rotor bearing is
dependent upon the pumpages' lubricating
qualities. The outer rotor on shaft is supported
on tapered roller bearings. These bearings are
lubricated with Premium Lithium Complex
Multi-purpose Grease, ISO VG 220 NLGI # 2
grease (Mobilgrease XHP222 or equivalent).
Regreasing cycle: add 3 grams of grease to
each bearing every 3000 hours.
3.5 STARTUP CHECKLIST
Alignment of couplings.
Direction of rotation.
Freedom of rotation of shaft.
Do not start pump against closed discharge
valve or with suction valve throttled. Ensure
bypass valve (if fitted) is operational and set to
the correct pressure. DO NOT EXCEED
SYSTEM OR PUMP DESIGN PRESSURE AS
EQUIPMENT FAILURE COULD RESULT. DO
NOT RUN PUMP DRY. FAILURE TO
REMOVE AIR/VAPOUR COULD PREVENT
PUMP FROM PRIMING AND RESULT IN
PUMP DAMAGE.
3.6 OPERATIONAL CHECKS
Inspect pump frequently during the first few
hours of operation for such conditions as
excessive heating of bearings or stuffing box,
vibration, unusual noises etc.

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3.7 VALVE
Some configurations of EBSRAY's Model
E20HD pump incorporate an integral valve,
which is fully adjustable. This feature, when
fitted protects the pump from excessive
pressure rise within the limits of the spring
pressure range. However fluid temperature will
rise if differential pressure is high and bypass
conditions are maintained for extended
periods.
The valve can be configured upon assembly
for either CW or CCW rotation.
On commissioning, the bypass valve if fitted
and not preset in the factory, should be set in
accordance with the predetermined pump
differential pressure required.
SECTION 4 – MAINTENANCE
PRIOR TO ANY DISASSEMBLY OR
SERVICE, VERIFY THAT ALL
REQUIREMENTS OF STATUTORY
REGULATIONS OR CODES ARE MET AND
THAT SPECIFIC SITE REQUIREMENTS
ETC ARE SATISFIED.
Some minor maintenance tasks and
inspections can be performed with the pump
'in line' so long as complete isolation,
depressurising and purging procedures have
been completed. However for major
maintenance it is recommended that the pump
be removed from the installation.
4.1 SPARE PARTS
1. When ordering spare parts, to ensure
a minimum of delay and correct
replacement to original specification
ALWAYS quote the pump Serial
Number which is located on the
nameplate of the pump.
2. Advise the name, item number and
quantity required. (Refer to Drawing
No. A300001H)
3. Advise complete delivery instructions,
transport company etc.
4.2 PREPARATION FOR DISASSEMBLY
1. Obtain the appropriate Work Permit if
required.
2. Isolate pump from liquids in suction
and discharge lines, depressurise and
purge out any toxic, flammable,
corrosive or air hardening liquids.
3. Isolate power supply to motor.
4. Disconnect porting connections.
5. Remove pump from installation.
6. Mark relevant mating components for
correct reassembly orientation.
4.3 DISASSEMBLY
1. Remove pump coupling half and key.
2. Remove cover assembly complete
with 'O' Ring, inner rotor pin, inner
rotor and inner rotor bearing.
3. Remove end cap complete with shims
and lip seal.
4. Remove lockwasher, locknut and
spacer from shaft.
5. Undo locknuts on the adjustment
screws and loosen them. Tighten
bearing carrier capscrews so carrier
sits flush on body.
6. Note: Bearings are an interference fit
on shaft.
With pump in a vertical position,
support body with a minimum of
100mm clearance below for rotor to
push out. Press on drive end of shaft
so that rotor comes through pump
end of body to disengage shaft from
bearing inner races. Take care not to
allow rotor to drop on a hard surface
after disengaging from bearings.
7. Remove bearing carrier capscrews
and separate bearing carrier from
body.
8. Remove lip seal from bearing carrier
pump end.
9. Remove drive end bearing assembly,
lip seal and bearing spacer by
pushing through from pump end of
bearing carrier.

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10. Remove internal circlip.
11. Remove pump end bearing.
12. Remove adaptor plate complete with
stationary seal face and 'O' Rings from
body.
13. Remove mechanical seal rotary
assembly by unlocking two grubscrews
and withdrawing from shaft.
14. Release pressure on bypass spring by
releasing locknut and rotating
adjusting screw anti-clockwise.
15. Remove bypass valve adjusting cover
assembly complete with retaining
washer and bypass spring.
16. Remove bypass valve blanking cover.
17. Unlock bypass valve seat locknut.
18. Withdraw bypass valve seat complete
with bypass valve.
4.4 INSPECTION
Inspect components for damage or excessive
wear. Note that typical wear of components in
EBSRAY's rotary internal gear positive
displacement pumps tend to compensate
each other and working clearances are to
some extent maintained by this compensation.
If pump performance has been satisfactory,
existing components although worn, may still
have adequate service life and could be used
provided any burrs or sharp edges are
removed prior to reassembly.
It is recommended that all 'O' Rings and oil
selas be replaced when pump has been
disassembled.
Check mechanical seal faces for wear or
damage.
Major refurbishing of the pump should be
done in line with reconditioning to an 'as new'
status as replacing or repairing one
component will have an effect on other
components and the working clearances of
the pump.
4.5 REASSEMBLY- PRELIMINARY
For dimensions & clearances, refer to
table of clearances and figure 6.
1. Ensure all parts are clean before
assembly. Remove any burrs.
2. If replacing inner rotor pin:
Press in until home ensuring
squareness to cover.
3. If replacing inner rotor bearing:
Press in. Machine or ream to achieve
required clearance on inner rotor pin
ensuring squareness and concentricity
with inner rotor O.D.
4. Carry out preliminary sizing checks:
a) Outer rotor in body radial clearance
Note: If checking by feeler gauge
method allowance or compensation
must be made for eccentricity caused
by:
1) Weight of rotor.
2) Clearances in shaft bearings.
3) Lack of support at drive end.
To measure clearance insert feeler
gauge at two opposite measurement
points 'X' and 'X'. Add the two
clearances together and divide by 2.
This will give the radial clearance 'X'.
b) Inner rotor width, outer rotor tooth
depth and cover crescent length must
be a matched dimension.
c) Clearance between inner rotor and
cover crescent remembering to make
allowance for inner rotor pin to bearing
clearance.
5. Ensure all suction/pressure circulation
tube assemblies are clear of any
obstructions.
6. EBSRAY recommend replacement of
all gaskets, seals and 'O' Rings at
every overhaul, to ensure positive
sealing.

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Table of Clearances Refer to diagram below - All clearances in millimetres
Running Clearances STANDARD
X Radial - Outer Rotor to Body 0.038 - 0.071
Y Axial - Rotors to Cover 0.05
Z Diametral - Rotor Pin to Bearing 0.038 - 0.063
V Radial - Inner Rotor to Crescent 0.025 - 0.050
Figure 6
4.6 REASSEMBLY
(Refer Drawing No. A300001H)
Note: Ease of assembly of the pump is
facilitated by assembling with the shaft
in the vertical plane.
1. Fit two 'O' Rings and six springs to
mechanical seal shaft sleeve,
assemble mechanical seal rotating
face over springs ensuring
engagement of drive pins.
Note: Use of lubricant on 'O' Rings and a
dab of grease on each spring will aid
installation.
2. Assemble mechanical seal
sub-assembly over shaft, apply a
medium strength thread locking
adhesive (Loctite 243 or equivalent) to
the two grubscrews and lock into
position ensuring grubscrews locate in
groove of shaft.
3. Fit mechanical seal stationary face and
'O' Ring to adaptor plate complete with
it's 'O' Ring and assemble into body.
Ensure lapped seal faces oppose each
other. Lubrication of seal faces is
recommended.
4. Assemble body over rotor/shaft/
mechanical seal sub-assembly.
5. Press lip seal into bearing carrier
pump end ensuring correct orientation
per drawing.
6. Place 'O' Ring on groove at pump end
of bearing carrier.
7. Lower bearing carrier over shaft end
and position on body with grease
tappings at 10 o'clock and 4 o'clock
as viewed from drive end.
8. Fit adjustment screws with locknuts to
bearing carrier. Fit bearing carrier
capscrews and tighten so that carrier
sits flush on body, ensuring that 'O'
Ring is seated in body groove.

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9. Pack pump end bearing fully with
grease and press fit the bearing over
shaft end into bearing carrier until
inner cone is fully seated against
shaft shoulder.
CAUTION: Do not over grease the
bearings by filling the bearing
cavity with grease as this can
cause overheating and damage to
the bearings.
10. Fit bearing spacer to shaft. Fit internal
circlip in groove in bearing carrier.
Press oil seal into place against
internal circlip, ensuring correct
orientation as per drawing.
11. Pack drive end bearing fully with
grease and press fit on shaft.
12. Place pump in horizontal position and
firmly attach bracket to a baseplate or
bench.
13. Fit spacer, lockwasher and locknut on
shaft. Tighten and secure locknut by
bending lockwasher tab into locknut.
14. Fit shims on end cap. Shim quantity
should be as originally factory set. If
shims are being replaced, begin with
0.6mm’s of shims and follow steps 15
and 16 to set bearing clearance. Align
grease tapping drain hole in end cap
with the 4 o'clock grease tapping on
bearing carrier. Fit end cap with
capscrews.
15. Using suitable turning device, rotate
shaft by hand to ensure no restriction
to rotation of shaft.
16. Using a dial indicator, measure bearing
clearance by pushing the shaft back
and forth within body, continually
rotating shaft by hand between
measurements. Adjust shim quantity
until clearance is set to 0.05 to 0.08
mm.
17. Loosen bearing carrier capscrews and
slowly tighten adjustment screws until
rotor is pulled back in body. Assemble
inner rotor over inner rotor pin and fit
cover assembly to body complete with
'O' Ring.
18. Loosen adjustment screws and slowly
and evenly tighten bearing carrier
capscrews whilst rotating the shaft
slowly by hand using a suitable
turning device. When slight drag is felt
by hand the point of contact of outer
rotor to cover has been sensed
(0.0mm axial clearance).
19. Ensuring the bearing carrier flange is
parallel with the body, measure the
gap between bearing carrier flange
and body i.e. establish a datum point
for setting axial clearance.
20. Back off bearing carrier capscrews
and evenly screw in the adjustment
screws until the gap between the
bearing carrier flange and body
equals the original gap plus the
desired axial clearance (0.05 mm as
shown in the table of clearances).
Evenly tighten the bearing carrier
capscrews and once again check the
gap, ensuring the bearing carrier
flange is parallel to the body. Axial
clearance should now be established.
21. Turn shaft by hand with a suitable
turning device to ensure smooth
rotation.
22. Fit grease nipples and grease
reservoirs with elbow fittings to
bearing carrier. Orientate reservoirs
so that they will be in a vertical
position depending on whether the
pump is mounted in a shaft horizontal
or shaft vertical position.
23. Apply 10 grams of grease through
each grease nipple.

9
Bypass Valve Assembly:
Note: For correct orientation of bypass valve
- adjusting screw should be on the
same side of the pump as the suction
port as determined by rotation and
direction of flow.
24. Fit bypass valve seat to bypass
housing and using a low strength
thread-locking adhesive (Loctite 243 or
equivalent), lock into position with
locknut.
25. Fit bypass blanking cover complete
with 'O' Ring.
26. Position bypass valve in housing.
27. Fit 'O' Ring to adjusting cover and fit
retaining washer.
28. Position spring on retaining washer
and fasten cover to housing ensuring
end of spring locates on top of valve.
Note: The bypass valve will require setting
when the pump is re-commissioned.
For increased bypass pressure rotate
adjusting screw in clockwise direction.
For decreased bypass pressure rotate
adjusting screw in anti-clockwise
direction.
SECTION 5 - TROUBLE SHOOTING
5.1 PUMP FAILS TO PRIME OR DELIVER
LIQUID
1. No liquid in tank.
2. Incorrect direction of rotation.
3. Speed too low:
(a) If motor driven, check speed, line
voltage and phases.
(b) If engine driven, check governor
setting and engine speed.
4. System discharge head too high -
check system head, friction losses and
bypass valve setting.
5. Excessive suction restrictions - check
NPSH available (inadequately sized
suction piping may cause high friction
losses, vapour pressure of liquid may
be too high). Check with vacuum or
compound gauge.
6. Air leaks and/or air pockets in suction
line - check suction piping.
7. Bypass valve open due to obstruction
under seat of valve or setting too low.
8. Suction filter/strainer blocked or
leaking air.
9. Pump cannot clear vapour due to
excessive discharge pressure e.g.
static head.
5.2 LOW OUTPUT
1. Discharge head too high.
2. Entrained air or gases in liquid
pumped.
3. Strainer offering excess resistance to
flow.
4. Suction and/or discharge pipes of
insufficient diameter, causing
excessive friction loss.
5. Bypass valve pressure setting too low -
Increase pressure by screwing in
adjusting screw. DO NOT exceed
pump or system design pressure,
overload motor etc.
6. Insufficient NPSH available.
7. Excess axial clearance setting of rotor
to cover.
8. Excess clearances in pump due to
wear.
9. Suction lift too high, i.e. static lift
excessive, air leak in suction line.

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5.3 EXCESSIVE POWER CONSUMPTION
1. Differential pressure higher than rating.
2. Liquid properties not as specified -
check viscosity.
3. Rotating parts bind - check for proper
clearances or foreign matter in pump.
4. Bearings worn - inspect and replace as
required.
5. Obstructions in pipelines, clogged
strainers, partially open valves.
6. Pump speed too high.
7. Voltage too low.
5.4 PUMP IS NOISY
1. Cavitation is taking place - increase
NPSH by:
(a) Removing suction line restrictions
created by:
(i) Inadequate pipe sizes /
excessive line lengths.
(ii) Incorrect selection of valves,
fittings etc.
(iii) Strainer not permitting free flow
of liquid to pump.
(b) Increasing static head in suction
vessel.
(c) Reducing product viscosity.
2. Rotating parts bind - check for proper
clearances.
3. Pump and driver misaligned - check
coupling and realign as required.
5.5 MISCELLANEOUS
1. Grease leaking out of reservoirs -
Bearings may be over greased.
Reservoirs should be in vertical
positions when the pump is installed.
EBSRAY PUMPS PTY. LTD.
628 Pittwater Rd
Brookvale NSW 2100
AUSTRALIA
Phone: [phone]
Fax: [phone]

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SECTION 6 - PARTS DESIGNATION
E20HD Parts - Refer To drawing No: A300001H
CAT # DESCRIPTION QTY
1 BODY 1
2 COVER 1
3 'O' RING 1
4 CAP SCREW 4
5 SEAL FACE
(
rotatin
g)
1
6 SEAL SEAT
(
stationar
y)
1
7 SPRING-SEAL 6
8 DRIVE PIN 3
9 SEAL SLEEVE 1
10 GRUBSCREW 2
11 'O' RING 1
12 'O' RING 1
13 'O' RING 1
14 ADAPTOR PLATE 1
15 'O' RING 1
16 ROTOR/SHAFT ASSEMBLY 1
21 INNER ROTOR 1
22 INNER ROTOR BEARING 1
23 INNER ROTOR PIN 1
24 VALVE 1
25 VALVE COVER 1
26 ‘O’ RING 1
27 SOCKET HEAD CAPSCREW 4
28 BLANKING COVER 1
29 ‘O’ RING 1
30 SOCKET HEAD CAPSCREW 4
31 VALVE SEAT 1
32 LOCK NUT 1
33 SPRING
(
BYPASS VALVE
)
1
34 ADJUSTING SCREW
(
BYPASS VALVE
)
1
35 LOCKNUT 1
36 SPRING CAP 1
37 ‘O’ RING 1
38 OIL SEAL 1
47 SPACER-BEARING I.D. 1
48 LOCKWASHER 1
49 LOCKNUT 1
50 OIL SEAL 1
51 ADJUSTING SCREW
(
BEARING CARRIER
)
3
51A NUT 3
52 BEARING CARRIER 1
53 SOCKET HEAD CAPSCREW 4
54 SOCKET HEAD CAPSCREW 3
55 GREASE NIPPLE 2
56 GREASE RESERVOIR 2
57 SPACER-LOCKNUT 1
58 SHIMS A/R
59 END CAP 1
60 ‘O’ RING 1
61 INTERNAL CIRCLIP 1
62 OIL SEAL 1
63 ELBOW 2
64 ROLLER BEARING 2

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