Ebsray Z Series Guide

Publication # 2190-06
EBSRAY PUMPS
INSTALLATION, OPERATION
& MAINTENANCE INSTRUCTIONS
Z SERIES
MODELS ZB120 & Z580

2
CONTENTS
SECTION 1 – GENERAL............................................................................................................................. 3
INTRODUCTION.............................................................................................................................. 3
1.1 CAUTION ................................................................................................................................... 3
1.2 WARNING.................................................................................................................................. 3
1.3 TRANSPORTATION AND PACKING........................................................................................ 3
1.4 INSPECTION ON RECEIPT – SHORTAGES............................................................................ 3
1.5 HANDLING................................................................................................................................. 3
SECTION 2 – INSTALLATION .................................................................................................................... 4
2.1 LOCATION................................................................................................................................. 4
2.2 FOUNDATIONS......................................................................................................................... 4
2.3 PUMP PIPING CONNECTIONS................................................................................................4
2.4 STRAINER PROTECTION......................................................................................................... 4
SECTION 3 – OPERATION ......................................................................................................................... 5
3.1 DESCRIPTION........................................................................................................................... 5
3.2 PUMPING PRINCIPLE............................................................................................................... 5
3.3 LUBRICATION........................................................................................................................... 5
3.4 STARTUP CHECKLIST ............................................................................................................. 5
3.5 OPERATIONAL CHECKS.......................................................................................................... 5
SECTION 4 – MAINTENANCE.................................................................................................................... 5
4.1 SPARE PARTS....................................................................................................................... 5
4.2 PREPARATION FOR DISASSEMBLY................................................................................... 5
4.3 DISASSEMBLY....................................................................................................................... 6
4.4 INSPECTION.......................................................................................................................... 6
4.5 REASSEMBLY – PRELIMINARY........................................................................................... 6
4.6 REASSEMBLY........................................................................................................................ 6
SECTION 5 - PARTS DESIGNATION......................................................................................................... 7
SECTION 6 – TROUBLE SHOOTING......................................................................................................... 8
6.1 PUMP FAILS TO PRIME OR DELIVER LIQUID.................................................................... 8
6.2 LOW OUTPUT........................................................................................................................ 8
6.3 EXCESSIVE POWER CONSUMPTION................................................................................. 8
6.4 PUMP IS NOISY..................................................................................................................... 8
6.5 LEAKAGE ............................................................................................................................... 8
EBS-RAY PUMPS Pty. Limited
628 Pittwater Road
Brookvale NSW 2100 Australia
Phone: [phone]
Fax: [phone]
www.ebsraypumps.com.au
or Contact Ebsray Representative:
.

SECTION 1 – GENERAL
INTRODUCTION
This publication is intended to assist those involved with
the installation, operation and maintenance of EBSRAY
Models ZB120 and Z580 Internal Gear 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 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. Do not drop pumps
and do not expose pumps to excessive heat or corrosive
materials. Baseplate mounted units should be lifted from
under the baseplate below both the pump and driver
ensuring compliance with the relevant lifting codes.
DETERMINATION OF MAINTENANCE REQUIREMENTS
EBSRAY Z Series Pumps are used for a wide range of applications and as such, maintenance requirements will vary between
applications. Under ideal/good operating conditions, providing pump is not run dry, internal inspection is generally not required
unless either performance drops off or unusual noises, vibrations or leaks occur. During inspection, check bearings and other
components for wear or damage.
Any reduction in performance (either flow, differential pressure or efficiency) will indicate either a system, Pumpset or pump
anomaly. Regular observation during operation will quickly identify symptoms such as leaking seals. Development of unusual
noises or vibration may indicate system/hydraulic problems, excessive wear, mechanical damage or foreign objects I the pump

4
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.
2.2 FOUNDATIONS
Baseplate units 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.
2.3 PUMP PIPING CONNECTIONS
All piping should be supported independently of and line up
accurately with the pump ports. NOTE: Pumps with
screwed connections should employ a pipe joint close to
both the suction and discharge ports to facilitate ease of
maintenance.
NEVER DRAW PIPING INTO PLACE BY USE OF FORCE
AT THE PORT CONNECTIONS OF THE PUMP.
The threaded port connections have parallel BSP threads
(ZB120 – ½”BSP & Z580 ¾”BSP) and EBSRAY
recommends using parallel threaded hydraulic fittings
which seal via an O-Ring against the machined top of the
pump body.
CAUTION: If using tapered thread pipe/fittings or if
using PTFE thread sealing tape, extreme care is
required to ensure that fittings are not over tightened.
Over tightening tapered connections may cause body
to fracture.
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 start-up 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.
Fig 1 Fig 2
ANGULAR MISALIGNMENT - Refer Fig.1 should be
corrected before ECCENTRICITY - Refer Fig.2.
Using feeler gauge readings at 90o intervals as shown in
Fig 3, the amount of correction necessary can be easily
determined to bring shaft axes in line.
Fig 3
Misalignment due to ECCENTRICITY as shown in Fig.2
can now be corrected. Adjustment by use of shims under
the driver or pump will effectively correct error in the
vertical plane. Movement of one of the ends horizontally
will correct error in the horizontal plant. NOTE: If both
coupling halves are of identical diameter, concentricity may
be checked with a straight edge at 90ointervals as shown
in Fig 4
..
Fig 4

5
SECTION 3 – OPERATION
3.1 DESCRIPTION
The EBSRAY Z Series range pumps uses the Internal Gear
Principle 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 and non-corrosive
applications. Accordingly material, speed and power
specifications vary and it is important to use such
equipment strictly adhering to the manufacturers’
recommendations.
3.2 PUMPING PRINCIPLE
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 fulfill this efficient
displacement cycle. Power is applied to the Outer Rotor ‘A’
and transmitted to the meshing 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 Fig5
Fig 5
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 withdrawl 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’. This sealing crescent
establishes a labyrinth between the high and low pressure
sides, minimizing 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
minimize tooth wear.
The Inner Rotor ‘B’, remains in almost hydraulic balance
requiring only minimal torsional load to effectively follow the
Outer Rotor ‘A’.
3.3 LUBRICATION
No ‘in service’ lubrication is required on EBSRAY’s Z
Series pumps.
3.4 STARTUP CHECKLIST
 Alignment of couplings.
 Direction of rotation.
 Free rotation of shaft.
 Do not start pump against closed discharge valve
or with suction valved throttled.
 DO NOT RUN PUMP DRY.
3.5 OPERATIONAL CHECKS
Inspect pump frequently during the first few hours of
operation for such conditions as excessive heating of
bearings, vibration or unusual noises etc.
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 located on the
nameplate of the pump.
2. Advise the Quantity required, Description and Cat No .
Refer to Section 5.
3. Advise complete delivery instructions, transportation,
etc
Note: Model No. Suffixes
No suffix indicates fitted with Mechanical Seal
‘P’ fitted with Packed Gland
‘V’ fitted with Bypass Valve
‘PV’ fitted with Packed Gland and Bypass Valve
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. Note pump and Bypass Valve orientation relative to
direction of rotation.
5. Disconnect porting connections.
6. Remove pump from installation.

6
4.3 DISASSEMBLY
CAUTION: Take care not to damage components by
prising or levering in order to release fits.
1. If fitted, remove Bypass Valve Adjusting Screw Cap,
Gaskets, Locknut, Adjusting Screw, Spring and Bypass
Valve.
2. Remove Gland Nut.
3. If fitted with packed gland, remove Gland. If fitted with
mechanical seal, carefully remove Gland complete with
Locating Pin, O-Ring and Seal Seat. Take care to
avoid damage to the Seal Seat.
4. Remove Cover and Cover Gasket.
5. Push Rotor on Shaft assembly through body.
6. a. If fitted with packed gland – remove packing.
b. If fitted with mechanical seal – remove
remaining mechanical seal components from
Body.
4.4 INSPECTION
Inspect components for damage or excessive wear. Note
that the typical wear pattern of components in EBSRAY’s
Rotary Internal Gear pumps tends 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 life and could be used provided any
burrs or sharp edges are removed prior to reassembly.
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.
Table of Standard ‘A’ Clearances (mm)
Std Running Clearances ZB120 Z580
Diametral – Outer Rotor to Body 0.013-0.038 0.069-0.101
Axial – Rotors to Cover 0.026-0.050 0.026-0.076
Diametral – Shaft to Bearing 0.008-0.025 0.008-0.030
Diametral – Rotor Pin to Bearing 0.013-0.033 0.013-0.035
Carbon Bearing Clearances when fitted
Diametral – Shaft to Carbon Bearing 0.008-0.025 0.008-0.025
Diametral – Rotor Pin to Carbon Bearing 0.010-0.020 0.026-0.050
Notes:
1. Dimensions stated are design parameters.
2. Efficient suction and discharge performance are achieved
when the pump is maintained within these dimensions,
however adequate performance may still be achieved with the
clearances and dimensions outside those stated if application
parameters allow.
4.5 REASSEMBLY – PRELIMINARY
1. Ensure all parts are clean and free from burrs, etc. Do
not round off sharp edges of rotors as this may affect
performance.
2. Lightly smear all O-Rings and lapped faces of
mechanical seals with a compatible, good quality
lubricant before assembling.
3. Ensure correct orientation of components.
4.6 REASSEMBLY
Note: Factory fitted carbon bearings (when used) are a
press fit – post machined to ensure concentricity and
correct sizing to achieve correct running clearances. If
replacing carbon bearings ensure proper fitting techniques
are employed.
1. Position Rotor on Shaft assembly in Body
2. Measure depth from Body face to Rotor tooth.
3. Measure the depth of Cover step.
4. Determine the gasket thickness required to obtain the
correct running clearance.
5. Fit Inner Rotor over Inner Rotor Pin in Cover and with
the required Gaskets, fit Cover assembly to Body.
6. If fitting Packed Gland:
Fit required packing ensuring that gaps in each ring are
staggered. Fit Gland and Gland Nut.
Note: Do not overtighten Gland. Gland should be
adjusted on commissioning to allow a small amount of
seepage.
5. If fitting Mechanical Seal:
a. Slide Circlip onto Shaft, slide Circlip Retainer along
shaft and push on until the Circlip locates in the
circlip groove.
b. Slide the remaining seal components along the
shaft in the following order: Spring, Drive Washer,
O-Ring and Seal Face.
c. Fit the O-Ring to the Seal Seat then fit the Gland to
the Seal Seat ensuring it seats correctly over the O-
Ring and that the Locating Pin is correctly engaged.
d. Fit the gasket to the Gland then slide the Seal
Seat/Gland assembly along the Shaft and lock into
position with the Gland Nut.
6. Ensure freedom of rotation of shaft.
7. If fitted with Bypass Valve
a. Insert Bypass Valve into housing in Cover.
b. Insert Spring into housing
c. Screw Bypass Valve Adjusting Screw into housing
d. After adjusting Bypass Valve pressure setting, lock
and seal Adjusting Screw by fitting, in the following
order, Gasket, Locknut, Gasket and Adjusting
Screw Cap.
Note:
To increase bypass pressure screw Bypass Valve
Adjusting Screw IN
To decrease bypass pressure screw Bypass Valve
Adjusting Screw OUT
CAUTION: Do not exceed specified pump/system design
pressures.

7
SECTION 5 - PARTS DESIGNATION
CAT
No DESCRIPTION QTY CAT No DESCRIPTION QTY
1 BODY 1 32 CIRCLIP RETAINER 1
3 COVER (Plain or Bypass) 1 33 GASKET-Mechanical Seal 1
5 GASKET-Cover 1 Set 34 SEAL SLEEVE 1
7 SETSCREW- Cover 1 Set 36 ROTOR ON SHAFT 1
9 SPRING WASHER- Cover 6 48 VALVE 1
17 GLAND-Packed 1 53 SPRING-Bypass 1
20 GLAND NUT 1 54 LOCKNUT-Bypass 1
21 PACKING SET 1 Set 55 ADJUSTING SCREW 1
22 SEAL FACE 1 56 ADJUSTING CAP 1
23 SEAL SEAT 1 57 GASKET-Adjusting Cap 2
24 SEAL WASHER 1 60 INNER ROTOR 1
25 SPRING-Seal 1 61 INNER ROTOR BEARING 1
28 LOCATING PIN 1 62 INNER ROTOR PIN 1
29 O-RING-Seal Seat 1 69 ROTOR BEARING 1
30 O-RING-Seal Face 1 95 WOODRUFF KEY 1
31 CIRCLIP 1

8
SECTION 6 – TROUBLE SHOOTING
6.1 PUMP FAILS TO PRIME OR DELIVER
LIQUID
1. No liquid in tank
2. Pump not rotating
3. Incorrect direction of rotation
4. Excessive suction restrictions
5. Blocked suction pipe
6. System discharge head too high – check system
head, friction losses and Bypass Valve setting.
7. Air leaks and/or pockets in suction line.
8. Viscosity of liquid not within specified duty
points.
9. Excess internal clearances
6.2 LOW OUTPUT
1. Incorrect pump speed.
2. Cavitation or vaporization on suction side of
pump.
3. Obstruction is suction or discharge pipe.
4. Air leaks and/or pockets in suction line.
5. Bypass Valve pressure setting too low
6. Differential pressure higher than specified duty
point.
7. Viscosity of liquid lower than specified duty
point.
8. Excess internal clearances.
6.3 EXCESSIVE POWER CONSUMPTION
1. Differential pressure/head higher than rating –
check for obstruction.
2. Liquid properties not as specified – check
specific gravity and viscosity.
3. Rotating parts binding.
4. Misalignment between pump and driver
5. Obstruction in pipelines, clogged strainers,
partially open valves.
6.4 PUMP IS NOISY
1. Cavitation due to insufficient NPSH available
2. Air leakage in suction piping
3. Rotating parts binding or damaged
4. Misalignment between pump and driver
5. Pump running dry
6. Obstruction in suction line
6.5 LEAKAGE
1. Along shaft – Mechanical Seal Fitted
a. Mechanical Seal damaged or worn
b. Gland Nut not sealing correctly against seal
gasket
2. Along Shaft – Packed Gland fitted
a. Hydraulic packing old, worn or lost
resiliency.
b. Gland Nut too loose – Note: Do NOT
overtighten, some seepage is required
c. Damaged shaft in packing zone
3. From Cover
a. Cover screws not tight
b. Damaged Gaskets between faces.
4. From Bypass Valve
a. Bypass Valve Adjusting Screw Cap loose
b. Damaged gaskets between faces.