Zenith® Pumps

Installation, Care And Maintenance

Zenith Finish Metering Applications

Spin Finish SeriesGear Pumps

For more than 70 years, Zenith®

Pumps has provided the syntheticfiber industry with precise, pulselessand repeatable gear metering pumps.From the earliest applications in vis-cose and hot-melt fiber spinning,through the more recent applicationsin high performance, specialty fiberspinning, Zenith has met the chal-lenges of the fiber industry withpumps of unmatched performanceand quality.

In virtually every stage of the syn-thetic manufacturing process, today’sfiber producers throughout the worldrely on Zenith pumps to accurately

meter polymer and fluid flows. In con-tinuous polymerization plants, Zenithpumps accurately transport pre-poly-mer fluids to and from reactor vessels.In melt polymer extrusion lines, Zenithpumps supply additives and boostpolymer pressures feeding spinbeams. In yarn, staple and nonwovenlines, Zenith spin pumps meter poly-mers to spinnerets for precise deniercontrol; and, prior to winding, Zenithspin finish pumps and systems accu-rately deliver yarn finishes to spunfibers to ensure optimum winding andtextile processability.

Zenith® Pumps

Benefits

Specifications

High AccuracyStable and repeatable flows are

assured even under varying condi-tions of temperature, viscosity, andpressure.

Minimum Pulsation

Unique design offers virtuallypulseless flow without valves or flexi-ble elements to hinder performance.

Precision Construction

Ground and lapped componentsallow for close control of operatingclearances.

High Volumetric Efficiency

Maximum efficiency is achievedwith minimal operating clearances.

Corrosion Resistance

400 series stainless steel providesgood bearing qualities and the neces-sary corrosion resistance for moststandard finishing chemicals.

Maximum Life

Only four moving parts per gearplate; components are through hard-ened to HRc 54 or better.

Pump Type: Rotary external spur gear, multiple stream.Rotation: Refer to pump drawing.Operating Speed: 5-120 rpm depending upon application conditions and fluid

viscosity (typically 10-60 rpm).Temperature: To 300° F (150° C) maximum. A heat jacket may be required

for above ambient temperatures.Viscosity: 1 to 100 cps.Pressure Rating: Flooded suction pressure required, 7 psi maximum.

Differential pressure should be near zero.

Thoroughly read and understand this entire manual before installationand operation of pump

2

Design

Operation

Zenith spin finish metering pumpsare constructed from high grade stain-less steels. The side, gear, and portplates are 420 modified and thegears, shafts, and arbors are 440-C.The pumps consist of three or moregears rotating in mesh within a closelyfitted housing. The center, or gearplate, fits closely around the outsidediameter of the metering gears. Thefront, rear, middle and/or intermediateplates sandwich the center plate andrestrict axial movement of the gears.

In the spin finish pump, the gearset is comprised of a driving gear andtwo driven gears per gear plate. In allseries, the driving gear is keyed to thedrive shaft while the driven gearsrotate on stationary arbors.

The standard spin finish pumpshave a lip seal design. A Buna-N lipseal with stainless steel spring ischemically inert to most chemicalsand is commonly used for generalpurpose metering in a variety of appli-cations.

Fluid enters the pump through aport located in the front side plate.The fluid fills the exposed gear toothcavities and is transported around theouter diameter of the gear pocket. Asthe gears mesh together, the fluid isdisplaced out through the dischargeports of the middle and/or intermedi-ate plates. Because the pumps aremanufactured with precision toler-ances and minimal gear clearances,extremely high volumetric efficienciescan be achieved.

Zenith gear pumps are not self-priming and therefore require a flood-ed suction at the pumps inlet port.However, when high viscosity fluidsare pumped, more time is required tofill the tooth cavities. As a result, theinlet pressure must be increased orthe gears must rotate at a slowerspeed to ensure complete volume fill-ing and to prevent cavitation.

Zenith pumps rely on the meteredfluid for lubrication of internal bearingareas. The pump should never beallowed to run dry or be allowed to runwith non-lubricating fluids such aswater or solvent. Because of verysmall bearing clearances, lack of suffi-cient lubrication can cause the pumpto seize and possibly experience cat-astrophic failure.

Slip can occur across the sides ofthe gears from the high-pressure sideto the low-pressure side of the pump.The amount of slip depends on fourfactors: fluid viscosity, speed, differen-tial pressure and pump clearances.Under reasonably stable operatingconditions, slip is repeatable and pre-dictable, and pump operation can beadjusted to compensate.

Zenith spin finish pumps aredesigned for low temperature opera-tion and low pressure applications.The maximum operating temperatureshould not exceed 300° F and differ-ential pressure should be kept nearzero. When operating at temperaturesabove ambient, heat jackets shouldbe used and pumps should be heatedslowly and uniformly.

The 400 series stainless steelsused in the construction of the spinfinish pumps provides sufficient corro-sion resistance for most standardchemical processes. The hardness ofthe pump materials (54 HRc) will provide a certain degree of wearresistance as well. However, process-es involving corrosive or abrasive fluids should always be verified withthe factory.

3

Installation

Cleaning, Inspection and Repair

Pumps should be carefullyunpacked to make sure shipment iscomplete. If any items were damagedduring shipment, the freight carrier andZenith Pumps should be notified imme-diately.

Zenith Pumps are shipped filledwith a rust preventative oil. If neces-sary, flush the pump thoroughly with acleaning solvent turning by hand. Itmay be necessary to disassemble theseal arrangement to remove all tracesof oil. Disassemble only if necessary.

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 brief “standard”installation procedure for Zenith spinfinish metering pumps. For any specialapplications, considerations, or techni-cal assistance, please contact ourApplications Engineering Group.

To prepare the pump for use:

1. Always flush the plumbing sys-tem prior to connecting the pump.

2. Filters should be installedupstream of the pump inlet port. The fil-ter should ideally be sized to one halfof the pump gear clearances.

3. Turn pumps by hand before run-ning. Pumps should turn freely.

4. Fixed mount pumps should beinstalled on an L-shaped saddle ormounting block and mounting screwsmust be secure. (Do not install withradial or axial loads on the pump driveshaft. This will adversely affect the lifeof the pump.)

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

6. Start the pump slowly and, ifpossible, break-in with a lubricatingfluid.

7. When satisfactory operation isachieved, the pump and system canbe gradually brought up to normaloperating speed.

8. If, at any time during operation,the pump does not appear to be run-ning smoothly, stop the pump immedi-ately to avoid serious internal damage.

Zenith spin finish metering pumpsare made for exacting duty. All partsare machined to extreme accuracy.Critical dimensions are held betweenone and two ten-thousandths of aninch (.0001”/.0002”). Accurate perfor-mance is dependent upon properhandling. Please handle the pumpswith extreme care, and if possible, setaside a separate clean area for pumpmaintenance and repair.

It is recommended that pumpusers institute a program for dimen-sional inspection of critical parts inorder to keep maintenance and oper-ating costs to a minimum. By notingthe performance of a pump immedi-ately before removing it from serviceand correlating the performance tomeasured component wear, the user

can establish maximum wear limits forthe pump’s critical components.Further, the service life of the pumpcan be predicted and downtime canbe scheduled accordingly.

As with any other Zenith pump,Spin Finish Series pumps may bereturned to Zenith for complete rehabil-itation. For a large number of pumps,Zenith offers a contract repair servicewhich helps to reduce repair costs anddelivery time. Zenith Pumps also offerspump maintenance seminars, repairvideo tapes, and installation, care, andmaintenance manuals. For more infor-mation concerning Zenith pump repairservices, please contact our customerservice department.

4

Lapping or Blocking

To remove nicks, burrs and scourmarks from pump parts, place two lay-ers of 400 Grit Emery Cloth on a lap-ping block or plate—a granite flat isalso suitable. Apply light pressure tothe part and turn it using a figure 8motion as shown in Figure 1 approxi-mately 10 times until a smooth finishappears. Components that are com-monly lapped are metering gearsides, and the inside faces of front,rear, center, middle and/or intermedi-ate plates. After lapping is completedthe parts are ready to be cleaned. Anultrasonic cleaner with a safe industrialsolvent (Nu solution) is preferred, buta large container filled with solvent toapproximately 4 inches deep can beused.

CAUTION: Never drop the compo-nents into a tank or container; placethem gently onto the bottom to avoiddamage.

Always use clean, lint free rags,and compressed air to clean compo-nents. Paper towels are not acceptablebecause they can leave small piecesof paper dust on the pump parts. Usechemical brushes to clean betweengear teeth, bores, and relief grooves.After all components are “hospitalclean”, the pump is ready for assembly.

New and replacement parts shouldalways be deburred and cleanedusing the above procedures.

Figure 1 Note: Part should be rotated by quarter turns as it moves through a “figure 8”pattern

5

Spin Finish SeriesDisassembly

Refer to Diagrams beginning on page8 (general reference only).

NOTE: As parts are disassembled,place them carefully on a clean sur-face such as a soft cloth. Do not allowthem to knock together. Pay closeattention to the order in which partsare removed. This will aide in theassembly of the pump.

1. Place the pump in a soft jawbench vise with the drive shaft facingupward.

2. Remove the binder screwswhich clamp the pump plates together.

3. Remove the front plate by liftingupwards sliding the plate over thedrive shaft until clear. It may be neces-sary to gently tap the plates with arubber mallet in order to separatethem from each other.

4. Gently remove the gear plate inthe same direction. Do not attempt toforce or pry the gear plate from thegears as possible damage may occur.

CAUTION: Do not allow the meteringgears to be lifted out with the gearplate. They may drop, causing dam-age to the gear teeth.

5. Remove the driven gears fromthe arbors.

6. Remove the driving gear bysliding it up and over the drive shaft.

7. Remove the drive shaft key.8. Remove the intermediate or

middle plate noting the orientation forreassembly.

9. Repeat procedures 4-8 until allgear, intermediate and or middleplates have been removed.

10. Remove the drive shaft fromrear plate.

11. Press arbors from the rear,intermediate and or middle platesusing the shortest path of resistance.

12. Remove the lip seal from thefront plate by gently placing a screw-driver in the ID of the seal and pry theseal from the plate.

6

Reassembly Considerable care should be takento prevent wedging or jamming. Neverforce the parts together. They will dropinto place if properly aligned.

1. Provide a can of clean oil,preferably SAE-50 motor oil or mineraloil.

2. Press Arbors into intermediate,middle and/or rear plates as requiredusing the driven metering gear as aguide for pressing the arbor uprightand perpendicular to the plate.

3. Press a new lip seal (by hand)into the counterbore of the front sideplate with the open area of the sealfacing the inside of the pump.

4. Clamp the rear plate in a softjaw bench vise with the inside surfacefacing upwards.

5. Lubricate the drive shaft bear-ing holes and arbors with a few dropsof oil.

6. Install the drive shaft into therear side plate.

7. Place the drive shaft key intothe keyway located along the driveshaft.

8. Install the driving gear by slid-ing it down the drive shaft and overthe key until it rests on the plate.

9. With a thin film of oil on your fin-gertips, lubricate the I.D. of the gearpockets in the gear plate. Place thegear plate over the driving gear andonto the plate. Be certain to install thegear plate in the same position as ithad been prior to disassembly.

10. Install the driven gears (insertover arbors in rear plate if equipped).Check for free rotation of the gear set.

11. Place a drop of oil into eachport location and rotate the drive shaftseveral times to ensure free rotation.

12. Place the intermediate plateonto the gear plate and locate thearbors with the I. D. of the drivengears. Be certain to install the platesin the same position as they were priorto disassembly.

13. Repeat steps 6-12 until allplates have been properly reinstalled.

Note: If the pump will not turn freelyafter each component is installed, thenthe last piece installed needs additionalattention or replacement.

14. Replace the front side plate bygently placing the I.D. of the lip sealover the O.D. of the drive shaft.Carefully slide the plate and sealdown the shaft until it touches the lastgear plate. The lip seal has no coverplate and may pop out during this pro-cedure. If this occurs, simply repeatthe same procedure.

15. Install binder screws andtorque to 50% of rated capacity usinga crossing pattern. Check for freerotation of the gears. If acceptable,continue to torque to full load of boltrating. Again, check for free rotation ofthe gears.

7

Spin Finish Series

Binder Screws

Front Plate

Bearing

Driven GearDrive Shaft

Key

Rear Plate

Retaining Ring

Driving Gear

Arbor

Center (Gear) Plate

Mounting ScrewsLip Seal

Zenith 2 StreamSpin Finish Pump

Binder Screws

Front Plate

Bearing

Intermediate Plate

Driven GearDrive Shaft

Key

Rear Plate

Retaining Ring

Driving Gear

Arbor

Center (Gear) Plate

Mounting ScrewsLip Seal

Zenith 4 StreamSpin Finish Pump

8

Diagram 1

Diagram 2

Spin Finish Series (cont.)

Binder Screws

Front Plate

Bearing

Intermediate Plate

Driven GearDrive Shaft

Key

Rear Plate

Retaining Ring

Driving Gear

Arbor (Long)

Center (Gear) Plate

Mounting ScrewsLip Seal

Zenith 6 StreamSpin Finish Pump Middle Plate

Arbor (Short)

Binder Screws

Front Plate

Bearing

Intermediate Plate

Driven Gear

Drive Shaft

Key

Rear Plate

Retaining Ring

Driving Gear

Arbor

Center (Gear) Plate

Mounting ScrewsLip Seal

Zenith 8 StreamSpin Finish Pump

Middle Plate

Intermediate Plate

9

Diagram 4

Diagram 3

Binder Screws

Front Plate

Bearing

Intermediate Plate

Driven Gear

Drive Shaft

Key

Rear Plate

Retaining Ring

Driving Gear

Arbor

Center (Gear) Plate

Mounting ScrewsLip Seal

Zenith 12 StreamSpin Finish Pump

Middle Plate

Intermediate Plate

Intermediate Plate

Middle Plate

Size ( UNC Alloy Steel )

M5

M6

Recommended Torque (lbs.-in.)(Based on lubricated threads)

56

96

Bolt Torque

10

Diagram 5

Spin Finish Series (cont.)

Troubleshooting

Trouble Probable Cause Remedy

Pump will not turn 1) Drive malfunction Verify power to drive. Check to assureall alarm circuits are clear. Check drivemotor current and speed settings.

2) Process conditions changed Check process conditions for propertemperature, pressures, viscosities andmaterials.

3) Entrained particle Disassemble and clean pump, replaceany damaged parts.

4) Possible internal damage Disassemble and clean pump, replaceany damaged parts.

Excessive seal leakage 1) Worn lip seal Replace lip seal.

2) Scored drive shaft Replace drive shaft if necessary

Reduced pump efficiency 1) Worn gears Replace worn gears

2) Worn bearings Replace worn bearings

3) Process conditions changed Consult factory for gear clearance recommendations for new process conditions.

11

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 1996 Zenith Pumps SF-C&M 10/04

Zenith® Pumps1710 Airport Road

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

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