Operating Manual for Haight Positive Displacement Rotary Gear Pumps Pre-Installation 1. Choose a location that is easily accessible for pump servicing. Ensure adequate electrical service is available. Locate the pump for direct piping. Special attention should be given to the suction piping which should be as large, or larger, than the pump intake port. For efficient operation, it is essential the suction side of a gear pump not be restricted. Avoid tees, elbows, valves, and other flow devices within 12 pipe diameters of the pipe inlet. Provide adequate support for the piping. The pump should not be used to support piping. Pumps are shipped with the suction port marked - IN; the discharge port marked - OUT. The suction port on pumps with relief valves is the port nearest to the relief valve adjusting screw. Pumps will operate in either direction. However, the relief valve will only function in one direction. Relief valve components are symmetrical and can be installed to operate with either clockwise or counter-clockwise shaft rotation. Have an electrician connect the motor using sound practice. Provide adequate overload protection. Note: When checking the direction of rotation, the pump must be full of liquid. Pumps fitted with mechanical seals must not run dry, not even momentarily. Determine the direction of rotation by watching the motor fan, which must turn clockwise. The motor selected meets the requirements of the specified operating conditions. Changed conditions, for example, higher viscosity, higher specific gravity, or lower head losses, can overload the motor. When changing operating conditions, or whenever there is any doubt, please contact your local distributor with the full details. 2. 3. 4. 5. 6. Installation 1. 2. Provide a solid foundation free from excessive vibration. Shim to prevent distortion of the pump mount base. Securely anchor the pump and motor to the foundation. All pipe connections on the suction side of the pump must be air tight. An air leak on the suction side of the pump will result in the loss of prime. Provide priming tee on the discharge line of the pump. If the media pumped contains solids, a suction strainer is recommended to exclude solid particles from the pump. Contact Haight Pump for a recommendation. Support the piping independent of the pump. Excessive strain on the pump casing can interfere with gear alignment. When the piping is complete, loosen the bracket set screws and allow the pump to align with the piping. Tighten the bracket set screws and re-check the shaft alignment. Make sure there is no metal to metal contact of the coupling halves. Do not over tighten the pipe/pump connections, as damage can result. A vacuum gauge can be installed in the pipe plug on the relief valve nearest the adjustment screw. A pressure gauge can be installed in the opposite pipe plug. Check the shaft rotation to ensure it is correct. Normal rotation is clockwise as viewed from the shaft side of the pump. Page 1 Operating Manual 3. 4. 5. 6. 7. 8. 9. Haight Pump (800) 871-9250 Precautionary Notes 1. Prior (a) (b) (c) to performing any service on the pump or motor: Disconnect and lockout the power source to the motor (refer to OSHA 1910.147.) Shut off any liquid heating source. If the unit operates at elevated temperatures, allow it to cool to room temperature before performing any service. 2. Drain the pump and piping of excess liquid. Caution: Handle and dispose of liquids in accordance to the manufacturers Material Safety Data Sheets. Disassembly for Inspection Purposes Only 1. 2. Remove the bolts from the drive plate. Carefully separate the drive cover and housing. Rotate the pump shaft by hand. It should turn freely. If resistance is present, check for built up residue. Use a soft marker to mark the rotor/pinion location. Remove the rotor from the housing. Inspect the housing, shaft/pinion, rotor, and drive plate for signs of wear or damage. Excessive wear will decrease pump performance. Inspect the O-rings, gaskets, and bearings for chipping, splitting, or missing sections. Inspection of the pump seal requires complete removal of the pump from the motor and bracket. 3. 4. 5. 6. Complete Disassembly for Repair or Replacement 1. 2. Complete precautionary steps 1 and 2. Loosen the support bracket screws that secure the pump to the bracket. (a) Size 1-8 pumps: 3 set screws (b) Size 10-40 pumps: 4 cap screws Remove the coupling and shaft key. Inspect the shaft end for burrs or other damage. Rotate the pump shaft by hand. It should rotate freely. Remove the bolts from the drive plate. Carefully separate the drive cover and housing. Use a soft marker to mark the rotor/pinion location. Remove the rotor from the housing. Remove the shaft/pinion assembly from the housing. Carefully pry the cover off the housing. Inspect, repair, or replace all damaged parts. Note: If significant damage is evident to the major pump components, it is best to replace the pump. If possible, determine the cause of the damage and correct the identified problem. 3. 4. 5. 6. 7. 8. 9. 10. Haight Pump (800) 871-9250 Page 2 Operating Manual Reassembly 1. Pump reassembly is the reverse of disassembly. However, care should be exercised in three areas: (a) It is good practice to replace elastomer sealing devices and gaskets every time the pump is reassembled. This is mandatory for Teflon O-rings and lip seals. Gently stretch the O-rings before placing them in the O-ring groove. (b) Place the rotor into position with your mark facing out. (c) Use a cross bolt tightening pattern to re-assemble the housing and covers. Periodically turn the pump shaft. Check for unusual noise. Improper tightening will cause the pump to bind. The pump will function best if primed first. Return the pump to service and check for leaking and loose connections. Air leaks on the suction side of the pump will reduce pump performance. 2. Relief Valve Components 1. 2. See precautionary notes. To change the relief valve for reverse rotation: (a) Loosen the locknut on the adjusting screw while holding the adjusting screw stationary. (b) Remove the bonnet and bonnet washer. (c) Remove the adjusting screw, spring, and poppet. (d) Remove the cap and cap washer. Reassemble in reverse order. Remember the spring and adjusting screw must be on the suction side of the pump for the relief valve to operate. 3. Special Seal Components 1. Standard 1 through 40 D/DR pumps use a lip seal as the main shaft seal, and two wiper seals function to keep the bearings clean. These seals are available in Buna-N or Viton synthetic materials. Packed pumps use 4 or 5 element V-cup Teflon shaft seals. Shaft seals are also available in Graphite rope, Graphfoil, and virgin Teflon. A gland is included to provide tension for the packing. Crane Type 9 and Type 21 mechanical seals are available. Contact Haight Pump for special drawings for pumps with mechanical seals. 2. 3. Maintenance Parts or Factory Repair 1. When ordering parts, locate the pump serial number stamped on the machined face of the cover or body of the pump housing. Haight Pump maintains a repair service shop that will rebuild, test, and return pumps promptly. Remove pipes, coupling, and mounting bracket before returning the pump to the factory. Contact Haight Pump for a Return Authorization number before sending the pump to the factory. 2. 3. 4. Haight Pump (800) 871-9250 Page 3 Operating Manual General Information The following is general information about Haight rotary gear pumps. Due to the variety of options and configurations available, it is not possible to provide detailed information in this manual. Detailed drawings and bill of materials will be provided upon request. Never operate a pump with the discharge line closed or plugged. Severe damage to the pump and/or system will result. Haight Pump does not accept responsibility or liability for damage or injury resulting from improper application and/or operation of the pump and/or system. Direction of Rotation. Haight pumps are designed to operate in either direction by simply changing the shaft rotation. Pumps supplied with relief valves are the exception to this rule. Failure to reverse the relief valve components will render the relief valve inoperable. The procedure for reversing the flow direction in the relief valve is covered in the Assembly and Disassembly instructions. Pump Alignment. Bedplate mounted pumps and motor combinations are aligned and tested at the factory. Vibration during shipment and/or poor bedplate mounting conditions can cause premature failure or unacceptable noise and vibration. Simple alignment checks can be performed by placing a straight edge on the top and side of the coupling. Improper alignment is indicated by a separation between the coupling and straight edge. Adjust the motor and pump location until any separation disappears in both planes. Bedplate Mounting. Install nuts on the foundation bolts to provide location adjustment. Loosely place the bedplate on the foundation bolts. Adjust the bedplate height and location to meet the inlet and outlet piping. Ensure the bedplate is level and true. Fasten in place with lock washers or lock nuts. Check coupling alignment. Piping. Improper suction piping is the leading cause of poor pump performance, including cavitation, noisy operation, inadequate performance, and premature pump failure. Particular care should be taken to avoid long, restricted pipe runs, the use of elbows, tees, valves, or other flow devices within twelve (12) pipe diameters of the pump inlet. Inlet piping should be at least equal to the pump inlet size. The discharge piping arrangement is somewhat less critical than the inlet side, however, good engineering practice, as defined by the Hydraulic Institute, should be followed. Pumps are not designed to be used as piping system support devices. Piping systems should have adequate, independent hangers to provide support. Again, the Hydraulic Institute offers guidelines for proper pipe support design. Seals. Haight Pump offers three standard type seals, each with specific operating characteristics. · Lip seals: Available in Buna-N, Viton, Teflon, Silicone, and Kalraz, and as either single or double seals. Lip seals are inexpensive, but have certain limitations, which include: · Expected operating life of 2,000 -3,000 hours · Should not be used with system pressures over 75 psig · Should not be used in vacuum applications over 3" Hg Haight Pump (800) 871-9250 Page 4 Operating Manual General Information: Seals (cont'd) · Packing gland: Available in Graphfoil, or Teflon, and other materials upon request. Packing glands are useful at high temperatures and pressures, resist shock and vibration, and can be adjusted to accommodate wear. However, packing glands must weep to function properly and require adjustment during the start-up operation. During start-up, or after repacking, run the pump to pressurize the stuffing box. Steady weepage should occur in less than ten (10) minutes. If steady weepage has not begun within ten (10) minutes, stop the pump and allow it to cool. Overheating the gland will damage the packing gland and shaft. Do not loosen the gland adjustment screws. Repeat this process until steady weepage is established. Adjust the packing gland screws 1/6th of a turn in a cross bolt tightening pattern. Allow to run ten (10) minutes. Continue this process until the weepage rate is approximately one (1) drop per minute. Periodic inspection and adjustment will be required. Do not over tighten the packing gland as damage to the gland and shaft will result. Bearings and Rotor/Pinion Shaft DU Bearings. Recommended for applications over 100 PSI and for thin fluids. Teflon Rotor. Do not use Teflon rotors in applications exceeding 100 PSI, and 200° F. The pump is provided with open tolerances. Increased slip will reduce efficiency with fluids below 200 SSU. Delrin Rotor. Do not use above 120° F and 80 PSI. Delrin rotors provide better abrasion resistance than Teflon rotors. The pump is provided with open tolerances. Increased slip will reduce efficiency with fluids below 200 SSU. Stainless Steel Rotor and Pinion. Manufactured with open tolerances as standard. Increased slip will reduce efficiency with fluids below 200 SSU. Note: For applications above 175 PSI, vent both shaft bearings to the suction side of pump. Spares and Repairs Haight Pump operates a repair service for all pumps for which records exist. To ensure the correct parts are supplied, the pump serial number is required. The serial number is stamped into the metal of the pump body or cover, in a prominent position on the top area of the pump. We advise customers whose pumps are custom fabricated to have spare pumps or parts on hand. Custom fabricated pumps and parts generally have long delivery times for replacement. Pumps That Perform. Pumps That Fit. Haight Pump (800) 871-9250 Page 5 Oper ...