Zenith Heat Pump Pumps User Manual

®
Zenith Pumps  
PEP-II Series  
Gear Pumps  
Installation,  
Care and  
Maintenance  
Zenith  
Polymer  
Extrusion  
Gear Pumps  
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®
Zenith Pumps and The Extrusion Process  
ZENITH  
PEP-II  
PUMP  
ELECTRIC  
HEAT PLATE  
ZENITH  
ADDITIVE  
INJECTION  
SYSTEM  
EXTRUDER  
CHANGER  
P
DISCHARGE  
PRESSURE  
P
T
PUMP  
INLET  
TEMPERATURE  
PRESSURE  
Zenith Pumps can handle all your extrusion pumping applications including  
additive injection for on-line compounding of tackifiers, colorants, stabilizers, etc.  
The PEP-II pump is constructed of two  
gears rotating in mesh within a closely fit-  
ted housing that is comprised of three  
plates. The center, or gear plate, fits  
around the shaft, using both dynamic and  
static types of sealing mechanisms. A  
Rheoseal consists of a helical groove on  
the inner diameter, a cooling jacket and a  
Design  
closely around the outside diameter of the static, backup seal counter bore and  
metering gears and bearings. The front  
and rear, or cover plates, sandwich the  
center plate and restrict axial movement  
of the gears and bearings. In capacities  
of 5 cc/rev and larger, the driving gear is  
gland. These spiral grooves allow the  
Rheoseal to act as a screw-type pump.  
As the fluid attempts to leave the gear  
pump, the shaft's rotary motion forces the  
fluid into the grooves. This creates a pres-  
manufactured integral with the drive shaft, sure greater than the pressure forcing  
and the driven gear is machined integral  
with its shaft. In capacities of 3.0 cc/rev  
and below, the gears are keyed to their  
respective shafts. In all capacities the  
shafts are supported by “D” shaped  
bearings which fit into the center plate. In  
capacities of 40 cc/rev and above, these  
polymer out of the pump, thus returning  
the polymer back towards the pump.  
Since the rotary motion is required of the  
shaft, two other static types of seals are  
employed on the Rheoseal—a spring  
energized lip-seal or a packing seal  
secured by the gland. Also a flushing  
bearings are located by two screws which cooling jacket surrounds a portion of the  
pass through the cover plates. In capacities grooved seal. Use of the cooling jacket  
of 20 cc/rev and below, the bearings are  
keyed to each other for accurate location.  
Each cover plate is secured to the  
center plate by 10 screws (6 screws for  
below 5 cc/rev). Each side of the center  
plate has a circular port in the center of a  
bolt circle for the mounting of adapter  
may be required for effective sealing if the  
viscosity is below 1,000 poise at process  
conditions. If used, water passing through  
the housing cools the polymer, increasing  
the effectiveness of the seal's pumping  
action. A thermocouple well is provided  
in the seal housing to allow for measuring  
flanges that fit the pump to your equiment. the temperature close to the region where  
Threaded holes are provided on the top  
and bottom of the center plate for the  
mounting of heat plates and for the  
mounting of the pump to its stand.  
Thermocouple wells (1/8-27 NPT) are  
located on the body of the pump.  
sealing actually occurs.  
A complete line of accessories is  
available and includes heating plates  
(electric, oil and steam), adapter flanges,  
mounting blocks and pump drive systems  
complete with power package controls  
and process controls. Please contact  
Zenith or your local Zenith representative  
A Zenith Rheoseal assembly secured  
to each cover plate (front cover plate only  
on 3.0 cc/rev and below) prevents leakage for further information.  
3
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PEP-II Pump  
0.16-3 cc/rev  
Dimensional Diagram  
Diagram 1  
Dimensional Data Chart  
PUMP  
PUMP DIMENSIONS  
MAX  
APPROX  
CAPACITY  
A
B
C
D
E
F
G
H
I
J
TORQUE WEIGHT  
0.16  
0.3  
0.6  
1.2  
1.8  
3.0  
3.000  
3.000  
3.000  
3.000  
3.000  
3.000  
3.000  
3.000  
3.000  
3.000  
3.000  
3.000  
2.860  
2.860  
2.860  
3.650  
3.650  
3.650  
1.400  
1.400  
1.400  
1.400  
1.400  
1.400  
2.400  
2.400  
2.400  
2.400  
2.400  
2.400  
1.960  
1.960  
1.960  
1.960  
1.960  
1.960  
0.750  
0.750  
0.750  
0.750  
0.750  
0.750  
1/4  
1/4  
1/4  
5/16  
5/16  
5/16  
1.500  
1.500  
1.500  
2.500  
2.500  
2.500  
0.125  
0.125  
0.250  
0.750  
0.750  
1.000  
80  
80  
195  
410  
410  
600  
9
9
9
9
9
9
CC/REV  
PUMP DIMENSIONS ARE IN INCHES  
IN-LBS  
LBS  
Chart 1  
Materials Of Construction Diagram And Chart  
ITEM QTY  
PART  
MATERIAL  
1
2
3
4
5
6
8
9
10  
11  
13  
14  
15  
16  
17  
18  
19  
20  
1
1
1
1
1
2
2
2
2
1
1
1
6
4
4
2
2
1
FRONT PLATE  
CENTER PLATE  
REAR PLATE  
DRIVE SHAFT  
ARBOR  
METERING GEAR  
KEY, GEAR  
BEARING  
TOOL STEEL  
TOOL STEEL  
TOOL STEEL  
TOOL STEEL  
TOOL STEEL  
TOOL STEEL  
TOOL STEEL  
TOOL STEEL  
STAINLESS  
STAINLESS  
FILLED PTFE  
ALLOY  
BEARING  
RHEOSEAL  
SEAL PLATE  
LIP SEAL  
SOCKET HEAD BOLT  
SOCKET HEAD BOLT  
SOCKET HEAD BOLT  
METAL C-RING, PORTS  
KEY, D-BEARING  
ALLOY  
ALLOY  
KEY, EXTERNAL  
Diagram 2  
4
Chart 2  
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PEP-II Pump  
5-750 cc/rev  
Dimensional Diagram  
Diagram 3  
Dimensional Data Chart  
PUMP  
PUMP DIMENSIONS  
MAX  
APPROX  
CAPACITY  
A
B
C
D
E
F
G
H
I
J
TORQUE WEIGHT  
5
10  
20  
40  
100  
175  
3.250  
4.000  
4.750  
5.750  
8.000  
9.500  
3.250  
4.000  
5.000  
6.000  
8.250  
9.750  
3.250  
4.000  
5.000  
6.250  
8.250  
9.880  
1.125  
1.188  
1.188  
1.188  
1.750  
1.813  
2.375  
2.875  
3.375  
3.750  
4.438  
5.438  
6.375  
8.063  
2.125  
2.615  
3.300  
4.000  
5.458  
6.475  
8.000  
0.500  
0.625  
0.750  
1.000  
1.250  
1.500  
2.000  
2.500  
1/4  
5/16  
3/8  
7/16  
5/8  
3/4  
7/8  
1 1/8  
1.875 0.750  
2.344 1.000  
2.813 1.250  
3.531 1.500  
4.688 2.188  
5.750 2.625  
7.063 3.000  
9.688 4.250  
1225  
2085  
3250  
10  
18  
34  
6750  
61  
12100  
22400  
50600  
150  
260  
480  
300 11.250 12.000 12.500  
750 14.750 15.750 16.500  
3.000 10.000 10.542  
116600 1100  
CC/REV  
PUMP DIMENSIONS ARE IN INCHES  
IN-LBS LBS  
Chart 3  
Materials Of Construction Diagram And Chart  
ITEM QTY  
PART  
MATERIAL  
1
2
3
4
6
1
1
1
2
2
2
2
2
20  
8
DRIVING GEAR SHAFT  
DRIVEN GEAR SHAFT  
CENTER PLATE  
COVER PLATE  
BEARING  
BEARING  
SEAL PLATE  
LIP SEAL  
SOCKET HEAD BOLT  
SOCKET HEAD BOLT  
RHEOSEAL  
SOCKET HEAD CAP SCREW ALLOY  
METAL C-RING, SEALS  
TOOL STEEL  
TOOL STEEL  
TOOL STEEL  
4140  
TOOL STEEL  
TOOL STEEL  
STAINLESS  
FILLED PTFE  
ALLOY  
7
14  
16  
17  
18  
20  
21  
22  
23  
ALLOY  
STAINLESS  
2
8
2
2
METAL C-RING, PORTS  
NOT SHOWN  
Diagram 4  
Chart 4  
5
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Polymer enters the PEP-II pump on the  
suction side where shaft rotation exposes  
gear tooth volumes between the gear  
teeth. Polymer fills these spaces and is  
transported to the discharge side where  
the gear teeth mesh together, decreasing  
fluids such as water or solvent. When  
high-viscosity fluids are used, more time  
is required to fill the tooth volumes. As a  
result, the inlet pressure must be  
increased or the gears must rotate at a  
slower speed to ensure complete volume  
Operation  
the gear tooth volumes and displacing the filling. Proper speed and inlet pressure  
polymer. Due to the precision tolerances  
and close clearances within the rotating  
spaces, very high pressures can be  
achieved at the pump discharge with  
extremely high volumetric efficiencies.  
As PEP-II pumps rely on the metered  
polymer for lubrication of internal bearing  
must always be maintained to prevent  
cavitation and to ensure proper lubrication.  
Slip can occur across the sides  
of the gears from the high-pressure side  
to the low-pressure side. The amount of  
slip depends on four factors: polymer  
viscosity, speed, differential pressure  
surfaces, the operating speed is designed and pump clearances. Under reasonably  
to be from 10 to 90 rpm on most extrusion stable operating conditions, slip is repeat-  
processes depending on process parame- able and predictable, and pump operation  
ters. Do not allow the pump to run dry  
can be adjusted to compensate.  
or attempt to pump poor lubricating  
Pumps should be carefully unpacked to  
make sure that the shipment is complete.  
If any items are missing or damaged, the  
freight carrier and Zenith should be noti-  
fied immediately.  
certain that their mating faces are flat,  
with no pilots that protrude into the pump.  
Check that the pump rotates freely by  
turning the shaft with your hand.  
5) The pump drive shaft should be  
connected to the motor drive assembly  
with a flexible coupling, a double universal  
joint shaft or an appropriate Zenith SJMC  
coupling. Side loading on the pump shaft  
is to be avoided at all costs.  
6) If water is used for sealing, connect  
either 1/8-27 or 1/4-18 NPT fittings to the  
Rheoseal and turn on the water. Be sure  
to avoid excessive cooling, or damage to  
the pump may occur.  
Installation  
To prepare the pump for use:  
1) Where required, install the heat  
plates as follows. Zenith-supplied heat  
plates are machined to tolerances that  
eliminate the need for heat transfer cement.  
All bolts used should be lubricated with  
high-temperature thread lubricant such  
as DAG Dispersion 154, Felpro C-100 or  
equivalent.  
2) Place the top heat plate on the  
pump, then place the insulation jacket on  
top of the heat plate. Install and tighten  
the bolts, taking care not to crack the  
insulation block.  
3) Repeat for the bottom plate, noting  
that bottom heat plate mounting bolts are  
typically used to mount the pump to its  
mounting block.  
7) Turn on the pump heaters. A 250° F  
temperature rise per hour is recommended  
for cold starts. No attempt should be  
made to start the pump until the entire  
pump is at operating temperature. Cold  
starts are the most common cause of  
pump failure.  
On start-up, a small amount of molten  
polymer should be introduced into the  
pump by slowly rotating (less than 5 rpm)  
the pump by hand to ensure that the  
4) Place the supplied metal O-rings  
into the counterbores in the pump ports,  
and attach the inlet and discharge porting pump is free turning and well lubricated.  
flanges with lubricated screws. Replace  
the O-rings after each use. Torque down  
the screws in a crisscross pattern, taking  
them first to 1/4 the recommended torque  
value, then to 1/2, to 3/4 and finally to  
their full recommended torque value as  
shown on the table on page 10. If the  
flanges are not supplied by Zenith, make  
With sufficient inlet pressure, the pump  
can then be started at a very slow speed,  
with discharge pressure low enough to  
maintain low loading. When operating  
satisfactorily, the pump and system may  
now be gradually brought up to normal  
process speeds and pressures.  
6
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After removal from the system, the assem- all parts should be carefully inspected for  
Cleaning,  
Inspection,  
Repair and  
Service  
bled pump can be cleaned by placing it  
in a suitable furnace (i.e. vacuum oven,  
fluidized bed, etc.) and slowly increasing  
the temperature to 800-850° F in no less  
than two hours. Special care should be  
taken to avoid flashing of the polymer.  
Control of temperature is essential as it is  
possible to draw back the hardness of the  
nicks, burrs, scoring or other signs of  
wear. The side plates, D-bearings (and  
sides of the gears on the 3.0 cc/rev and  
smaller pumps) can be hand blocked on  
600 grit paper, and any nick or burrs and  
other sharp edges very lightly touched  
with an Arkansas stone.  
Note: After cleaning, all seals, O-rings  
steel and affect dimensional stability if the and fasteners must be discarded.  
pump is overheated. The time to com-  
pletely carbonize the polymer is three to  
twelve hours, depending on the polymer,  
CAUTION: As the thickness relation-  
ship between metering gears, center  
plate and D-bearings is critical to metering  
temperature, pump size and furnace load. performance, care should be taken that  
The pump must be gradually cooled  
to room temperature (no forced cooling  
or quenching), then disassembled and  
cleaned as instructed in the following  
section. Close adherence to these instruc-  
tions should be maintained for maximum  
pump life and performance.  
these parts are only polished and that  
no metal is removed. Lapping of these  
components should not be done under  
any circumstances.  
As with any other Zenith pumps, PEP-II  
pumps may be returned to Zenith for  
complete rehabilitation as necessary. This  
procedure may be desirable if only a few  
It is recommended that pump users  
institute a program of dimensional inspec- pumps are involved. If a large number of  
tion of critical parts in order to keep main- pumps are to be maintained at the user’s  
tenance and operating costs at a minimum. plant, it may be worthwhile to have key  
By noting the performance of a pump  
maintenance personnel attend a mainte-  
immediately before removing it from service nance seminar at the Zenith factory to view  
and correlating the performance to meas-  
ured component wear, the user can  
the manufacturing, gauging and assembly  
techniques involved in producing the  
PEP-II pump. In addition, Zenith also  
offers a contract service program. Please  
contact Zenith for further information on  
these services.  
establish the maximum wear limits for the  
pump’s critical components. Further, he  
can predict the service life of the pump,  
and schedule his downtime accordingly.  
After a pump has been disassembled,  
These instructions should be thoroughly  
read and understood before starting dis-  
assembly.  
General instructions that should be  
observed to ensure correct disassembly  
of the pump are as follows:  
• If the pump is to be disassembled  
on a regular basis, set up a room with a  
separate clean area with all the tools  
required for disassembly, reassembly and  
storage.  
• During disassembly, note the loca-  
tion and orientation of all parts to ensure  
proper reassembly.  
1) Clearly mark which side of the  
pump is the inlet port and drive input side.  
2) Remove the screws securing the  
Rheoseal seal plate cover to the seal  
housing and remove the cover.  
3) Remove the screws securing the  
Rheoseal seal housing to the cover plate  
and withdraw the housing from the cover  
plate and shaft, taking care not to dam-  
age the drive shaft. After removal of the  
seal housing, disassemble and clean the  
Rheoseal housings either mechanically or  
chemically (always replace the O-rings).  
4) Carefully pry out and discard the  
lipseals at this time, taking care not to  
damage the seal countersink in the hous-  
ing, as damage here could cause polymer  
Disassembly  
• Use a soft-jawed vise to hold the  
pump during disassembly.  
When maintenance is required, refer  
to the exploded view and disassemble the leakage at start-up.  
pump as follows:  
5) Loosen and remove the D-bearing  
CAUTION: Careful handling of the parts retainer screws (40 cc/rev and above  
is imperative. Do not drop or allow parts  
to strike each other. The slightest nick or  
only).  
6) Loosen all cover plate screws one  
burr can cause difficulty in reassembly and turn, then back them out and remove  
may cause further damage to the pump. them from the pump. Remove each cover  
7
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plate and set aside in a safe place to pre-  
vent damage. At this point, make certain  
to note the orientation of the groove on the out separately as the gear teeth will not  
rear of each bearing with respect to the  
inlet port. They MUST be reassembled in  
the same way as disassembled; that is,  
they must point toward the inlet port, or  
severe pump damage may result when  
the pump is started.  
7) Slide the gear shafts and bearings  
out of the center plate. They will not come  
Disassembly  
continued  
clear the bearings. Take extreme care not  
to nick or ding the gear teeth or the edges  
of the bearings. If they will not slide out  
easily, use a hammer with a plastic or soft  
brass head to gently tap them out. DO  
NOT use a steel-headed hammer.  
WARNING: (Read before steps 7 & 8)  
Extreme caution must be exercised when  
Alternate taps on the shafts until the parts  
slide clear. Separate the two shaft/bearing  
removing the gear shafts and bearing. For assemblies, taking care not to lose the  
the 40 cc/rev and above capacity pumps, keys in the 10 cc/rev and smaller pumps.  
which have two (2) tapped holes in the D- There are no keys in the 20 cc/rev and  
bearing faces, an optional disassembly  
method is possible. If the gear shaft and  
two D-bearings will not slide out as a  
complete assembly after tapping with a  
soft-faced hammer, it is recommended  
that a gear puller tool be used to extract  
the individual D-bearings from each side  
of the gear shafts. If these still exhibit  
force, soaking in a lubricating (penetrat-  
ing) oil will help the disassembly.  
larger pumps.  
8) Slide the bearings from the shafts,  
again taking extreme care not to damage  
the gear teeth, bearing edges or the  
shafts. If the bearings will not slide easily  
from the shaft (due to residual polymer),  
use a plastic or soft brass-headed ham-  
mer and a soft drift (NOT steel) to gently  
tap the bearings free. Do not pry them off  
with a screwdriver or other tool as this  
may damage the gear teeth. Identify  
which shaft the bearings came from, and  
set them aside in a safe place.  
For 20 cc/rev and smaller capa-  
cities, there are no tapped holes in the  
D-bearing faces to be utilized. The gear  
shaft and D-bearings must be removed  
as a complete assembly. Again, soaking  
the parts in lubricating (penetrating) oil  
or other non-damaging solution will help  
ease the disassembly. Do not force the  
parts out one side with a hammer or  
arbor press.  
9) On the 3 cc/rev and smaller, slide  
the gears from their shafts and remove  
the keys from the shaft.  
D-Bearing  
Orientation  
Schematic  
8
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These instructions should be thoroughly  
read and understood before starting  
reassembly.  
General instructions that should be  
observed to ensure correct reassembly  
of the pump are as follows:  
configuration. Set the flats on the circum-  
ference of the bearings against each  
other, and gently slide the bearings and  
shafts into the center plate. Slide them far  
enough through the center plate to allow  
the drive shaft to protrude out on the front  
side and allow the front bearings to be  
installed. See D-bearing orientation  
schematic on page 8.  
Reassembly  
• Using a solvent such as  
trichloroethane or chloroethene Nu,  
clean all parts that are to be used in the  
reassembled pump.  
5) Install the front bearings in the  
WARNING: Use extreme care when using same manner as the rear bearings, and  
any solvent. Prolonged contact with the slide the bearings and shafts back into  
liquid or inhalation of the vapor can cause the center plate so that the gears are  
serious health problems.  
roughly in the center of the center plate.  
6) For the 20 cc/rev and smaller  
pumps, the bearings should be allowed to  
protrude very slightly above the face of  
• During and between each of the  
assembly steps, manually turn the  
metering gears to ensure that they are  
free turning. If binding occurs at any time the center plate before the cover plates  
during assembly, determine the cause  
and correct it before proceeding further.  
A tiny nick, burr or foreign particle can  
extensively damage a valuable part if  
allowed to remain. Never use excessive  
force in assembling or turning a pump. If  
properly aligned, the pieces will fit easily  
into the plate, and the drive shaft will turn  
freely. All seals, O-rings and fasteners  
must be replaced with new parts prior  
to assembly.  
• Use a soft-jawed vise to hold the  
pump during reassembly.  
• Before installing screws, lubricate  
their threads with DAG Dispersion 154,  
Felpro C-100, or similar heat-resistant  
are installed. This will allow the bearings  
to fit flush against the cover plates as  
there are no bearing screws on these  
smaller pumps. For 20 cc/rev and smaller  
pumps, insert the bearing locating keys  
on each side.  
7) At this point make certain again  
that there is no foreign matter on the faces  
of the cover plates or on the faces of the  
center plate. An accidental smudge of  
thread lubricant can cause the small  
pumps to bind.  
8) Place the front cover plate on the  
pump (and center on pump), checking  
one more time that the configuration of the  
bearing grooves is correctly oriented for  
lubricant, and torque to prescribed values the inlet and discharge ports of the pump.  
as shown on the table on page 10.  
Insert the lubricated cover plate screws  
into the pump and tighten them finger  
tight only. Repeat for the rear cover plate.  
9) On the 40 cc/rev and larger pumps,  
1) On 3.0 cc/rev and smaller pumps,  
place a gear key on each shaft and slide  
each gear onto its shaft, engaging the key.  
2) Slide the gear shafts into the center insert the bearing retainer screws and  
plate, taking care not to damage the gear  
teeth. On 3.0 cc/rev and smaller pumps,  
tighten them finger tight at this time.  
10 Torque down the cover plate  
note that each shaft has a larger diameter screws in a crisscross pattern, taking  
end. These larger ends must be on oppo- them first to 1/4 the recommended torque  
site sides of the pump for the bearing  
grooves to align properly.  
value, then to 1/2, to 3/4 and finally to  
their full recommended torque value.  
11) Torque down the bearing retainer  
screws in the same manner as the cover  
plate screws. (Install C-Rings if applicable.)  
12) Fit the Rheoseal seal housing to  
the shaft. Loosely install but do not torque  
down the seal housing screws, as this will  
3) Gently slide the gear shafts so that  
the rear ends of the shafts protrude from  
the rear of the center plate. On the 3.0  
cc/rev and smaller pumps, take care not  
to slide the shafts out of the gears and  
allow the keys to drop out of the shafts.  
4) Slide a bearing onto the drive shaft, allow the lip seal to properly center the  
taking special care to select a bearing  
with the proper groove configuration (and  
with the proper ID on the 3.0 cc/rev and  
smaller pumps). Slide the matching bear-  
ing onto the driven shaft, taking care to  
select a bearing with the proper groove  
housing.  
13) Install the lip seals, using the  
special Zenith installation tools as follows  
to prevent damaging the seal. Install the  
lip seals with the open face toward the  
body of the pump. Slide the installation  
9
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ring on the shaft with the ID tapering  
toward the pump. On the drive shaft ends, until it rests on the protruding lip seal.  
fit the bullnose on the end of the shaft.  
Work the seal gently over the end of the  
bullnose and down the shaft, as any dam- screws. Tighten them evenly in a criss-  
14) Slide the seal cover over the shaft  
Reassembly  
continued  
Align the screw holes in the cover with  
those in the housing and insert the  
age could cause polymer leakage after  
start-up. Ease the seal into the wide end  
of the installation ring and, using the  
cross pattern so that the seal is slowly  
pressed into the seal housing. When the  
cover is touching the housing all the way  
pressing tool, gently press the lip seal into around, remove the seal cover and torque  
the Rheoseal housing. Do not attempt to  
press on the lip seal with screwdriver or  
other pointed object, as this will damage  
the seal. Do not press the lip seal all the  
way into its cavity. Instead, allow it to  
protrude slightly so that it will be correctly  
seated by the seal cover. Carefully  
the seal housing bolts down. Reinstall the  
seal cover on the shaft and torque it  
down. In reinstalling the pump, be certain  
to follow the instructions given in the  
Installation section of this manual.  
remove the special Zenith tools.  
Bolt Torque  
Size (UNC  
Alloy Steel)  
Recommended  
Torque (in-lbs)  
Size (UNC  
Alloy Steel)  
Recommended  
Torque (in-lbs)  
1/2-13  
9/16-12  
5/8-11  
3/4-10  
7/8-9  
922  
1,331  
1,836  
3,257  
5,800  
8,000  
12,000  
#8-32  
30  
#10-24  
#10-32  
1/4-20  
5/16-18  
3/8-18  
7/16-14  
43  
49 (UNF thread)  
103  
213  
378  
605  
1-8  
1 1/8-7  
PEP-II  
ISO View  
Clockwise rotation, pressure building pump shown (standard).  
10  
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When ordering replacement parts, please be sure to include the following information:  
1) Pump model number  
2) Part number (12-digit) and description  
3) Quantity  
Parts  
Replacement  
4) Shipping instructions  
Order parts from your local Zenith representative or direct from Zenith.  
Troubleshooting  
Trouble  
Probable Cause Remedy  
Pump will not turn  
1) Low pump  
temperature  
Check thermocouple and control  
loop for proper setting/operation.  
Allow sufficient heat-up time.  
2) Drive malfunction  
Verify drive is powered. Check to  
assure all alarm circuits are clear.  
Check drive motor current and  
speed settings. Check all drive  
couplings.  
3) Process  
conditions changed  
Check process conditions for  
proper melt temperature, pres-  
sures, viscosities and materials.  
4) Entrained particle  
Disassemble and clean pump;  
replace any damaged parts.  
5) Possible  
internal damages  
Disassemble and clean pump;  
replace damaged parts.  
Consult factory.  
Excessive seal  
assembly leakage  
1) Worn lip seal  
Replace lip seals.  
2) Incorrect water flow  
Monitor and adjust water flow  
to provide correct sealing  
temperature.  
3) Clogged Rheoseal  
channel  
Disassemble two-piece seal  
housing and inspect.  
Reduced pump  
efficiency  
1) Worn gear(s)  
2) Worn bearings  
Replace worn gear.  
Replace worn bearings.  
3) Process conditions  
changed  
Consult factory for clearance  
recommendations on new  
process conditions.  
11  
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FAILURE, IMPROPER SELECTION OR IMPROPER USE  
OF THE PRODUCTS AND/OR SYSTEMS DESCRIBED  
HEREIN OR RELATED ITEMS CAN CAUSE DEATH,  
PERSONAL INJURY AND PROPERTY DAMAGE.  
WARNING  
This document and other information from Zenith Pumps, its  
subsidiaries and authorized distributors provide product and/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 ꢀnal 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, speciꢀcations, designs, availability and pricing,  
are subject to change by Zenith Pumps and its subsidiaries at  
any time without notice.  
ISO 9001: 2000 Registered  
Zenith® Pumps  
1710 Airport Road  
Monroe, NC 28110  
Phone: 704-289-6511 • Fax: 704-289-9273  
A Colfax Buisiness Unit  
© Copyright 1992 Zenith Pumps PEP C&M 10/04  
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