Dixon Rotary Lobe Pumps - JRZL-400 Series User manual

Type
User manual

This manual is also suitable for

Operating & Maintenance Manual
for
JRZL-400 Series
Rotary Lobe Pumps
Dixon Sanitary
N25 W23040 Paul Road • Pewaukee, WI 53072
ph: 800.789.1718 • fx: 800.789.4046
dixonvalve.com
2 Rotary Lobe Pumps - JRZL-400 Series800.789.1718
Table of Contents
Thank you for purchasing a Dixon Sanitary Product!
This manual contains installation, operation, disassembly and assembly instructions, maintenance procedures, troubleshooting and a
complete parts list for all JRZL-Series positive displacement pumps.
READ THIS MANUAL carefully to learn how to service these pumps. Failure to do so could result in person injury or equipment
damage.
Safety ................................................................................................................................................................................................... 3
Care of Stainless Steel ......................................................................................................................................................................... 4
Technical Specications ....................................................................................................................................................................... 5
Curves ............................................................................................................................................................................................... 6-9
Unpacking Installation & Start Up .................................................................................................................................................. 10-19
Tools needed ...................................................................................................................................................................................... 20
Maintenance .................................................................................................................................................................................. 20-58
Pump Housing Disassembly ...................................................................................................................................................... 20-51
Single Mechanical Seal .......................................................................................................................................................... 20-28
Double Mechanical Seal......................................................................................................................................................... 29-38
Single O-ring Seal .................................................................................................................................................................. 39-44
Triple Lip Seal ........................................................................................................................................................................ 45-51
Inspection........................................................................................................................................................................................ 52
Pump Housing Assembly ................................................................................................................................................................ 52
Rotor Clearance ......................................................................................................................................................................... 53-55
Shimming ............................................................................................................................................................................... 54-55
Rotor Timing ................................................................................................................................................................................... 56
Gear Box Disassembly ................................................................................................................................................................... 57
Gear Box Assembly ........................................................................................................................................................................ 58
Scheduled Maintenance ................................................................................................................................................................. 58
Maximum RPM ................................................................................................................................................................................... 59
Maximum Solids ................................................................................................................................................................................. 59
Dimensions ......................................................................................................................................................................................... 60
Troubleshooting ............................................................................................................................................................................. 61-63
Repair Kits .......................................................................................................................................................................................... 64
BOM .............................................................................................................................................................................................. 65-76
Certicates..................................................................................................................................................................................... 77-78
Warranty ............................................................................................................................................................................................. 79
3Rotary Lobe Pumps - JRZL-400 Series 800.789.1718
DO’S & DON’TS
DO read and understand these instructions before installing or using the pump.
DO use Dixon spare parts when replacing a component of the pump.
DO NOT service the pump while it is running.
DO NOT place the pump in an application where the service ratings are exceeded.
DO NOT modify the pump. Modifying the pump creates unsafe conditions and voids all warranties.
SAFETY PRECAUTIONS WHEN INSTALLING PUMP
DO use an authorized electrician when connecting the pump.
DO observe the mechanical limits of the pump (refer to the pump performance sheet).
DO install a throttling valve in the discharge line.
DO NOT install a throttling valve in the suction line.
SAFETY PRECAUTIONS WHEN OPERATING PUMP
DO allow only qualied personnel to operate this pump.
DO NOT start the pump until all personnel are clear.
DO NOT touch the pump or the lines when pumping hot uids or when performing Clean In Place (CIP) procedures.
DO NOT run the pump with BOTH the suction inlet and discharge outlet blocked. Running the pump with the inlet
blocked will cause serious damage to the pump.
DO NOT check pump rotation with liquid in the pump.
DO NOT run the pump with the front cover removed. The rotors and rotor case could be damaged or may cause severe
injury.
DO NOT operate the pump with the safety guard removed.
SAFETY PRECAUTIONS WHEN SERVICING PUMP
DO ensure the pump is cool to touch before performing service.
DO relieve all pressure and drain all uids from pump and connected piping before performing service.
DO ENSURE POWER TO THE UNIT HAS BEEN DISCONNECTED PRIOR TO PERFORMING ANY PUMP
MAINTENANCE OR CLEANING.
DO exercise caution and wear protective clothing when using lye or acid for cleaning.
Safety Information
4 Rotary Lobe Pumps - JRZL-400 Series800.789.1718
Care of Stainless Steel
The stainless steel components in Dixon Sanitary equipment are machined, welded and assembled by skilled craftsmen using
manufacturing methods that preserve the corrosion-resistant quality of the stainless steel.
Retention of corrosion-resistant qualities under processing conditions requires regular attention to the precautions listed below.
1. Regularly check all electrical devices connected to the equipment for stray currents caused by improper grounding, damaged
insulation or other defects. Corrosion: Pitting often occurs when stray currents come in contact with moist stainless steel.
2. Never leave rubber mats, ttings, wrenches, etc. in contact with stainless steel. Corrosion: Pitting or galvanic action. Objects
retard complete drying, preventing air from reforming the protective oxide lm. Galvanic corrosion occurs when two dissimilar
metals touch when wet.
3. Immediately rinse equipment after use with warm water until the rinse water is clear. Clean the equipment (manual or CIP)
as soon as possible after rinsing. Corrosion: discoloration, deposits, pitting. Product deposits often cause pitting beneath the
particles.
4. Use only recommended cleaning compounds. Purchase chemicals from reputable and responsible chemical manufacturers
familiar with stainless steel processing equipment, they continuously check the effects of their products on stainless steel.
5. Use cleaning chemicals exactly as specied by the manufacturer. Do not use excessive concentrations, temperatures or exposure
times. Corrosion: Pitting, discoloration, stress cracks. Permanent damage often occurs from excessive chemical concentrations,
temperatures or exposure times.
6. For manual cleaning, use only soft non-metallic brushes, sponges or pads. Brush with the grain on polished surfaces, avoid
scratching the surface. Corrosion: Pitting, scratches. Metal brushes or sponges will scratch the surface and promote corrosion
over a period of time. Metal particles allowed to remain on a stainless steel surface will cause pitting.
7. Use chemical bactericides exactly as prescribed by the chemical manufacturer in concurrence with local health authority. Use
the lowest permissible concentration, temperature and exposure time possible. Flush immediately after bacterial treatment. In no
case should the solution be in contact with stainless steel more then 20 minutes. Corrosion: Protective lm destroyed. Chlorine
and other halogen bactericides can destroy the protective lm. A few degrees increase in temperature greatly increases chemical
activity and accelerates corrosion.
8. Regularly inspect the joints in pipelines. Be sure all connections are tight tting without binding. Corrosion: Crevice corrosion.
Small crevices caused by improperly seated gaskets will promote crevice corrosion. Stainless steel under stress will develop
stress cracking especially in the presence of bactericides containing chlorine.
9. Regularly inspect equipment for surface corrosion (i.e. pitting deposits, stress cracks, etc.). If deposit or color corrosion is
detected, remove it immediately using mild scouring powder and detergents. Rinse thoroughly and allow to air dry. Review
production and cleaning procedures to determine the cause. Note: If corrosion is not removed, the protective lm cannot be
restored and corrosion will continue at an accelerated rate.
5Rotary Lobe Pumps - JRZL-400 Series 800.789.1718
JRZL 400-Series Technical Data
Specications:
1
Up to 435 PSI (30 bar) is available with Front Bearing Cover
Materials:
Product wetted steel part: AISI 316L Stainless Steel (standard)
Product wetted elastomers: EPDM (standard)
Optional seals: Buna, FKM
Shaft Seals:
Seal options: Single and Double Mechanical, Single and Double O-Ring and Triple Lip-seal
Maximum ushing water pressure: 7 PSI (0.5 bar)
Flushing water consumption: 30~60 cubic inches/min (0.25~0.5 liter/min)
Flush inlet at lowest port on casing
Stationary seal ring material: Tungsten Carbide
Rotating seal ring material: Tungsten Carbide (standard) or Silicon Carbide (optional)
O-ring material: EPDM (standard)
Optional O-ring material: Buna, FKM
Triple lip seal material: PTFE(Polytetrauoroethylene)+Glass (standard) or PTFE+Copper (optional)
Rotor Information: Not all rotors available in all models.
Single/bi-wing and bi-lobe/tri-lobe/heli-lobe are interchangeable
Optional rotors: Multi-lobe, Hardened
Optional Information:
Ultra clean version
High pressure version up to 435 PSI (30 bar)
Heating jacket on rotor case and front cover
Rectangular inlet version
Pressure relief front cover (not 3A)
Surface hardening
Model
Maximum Differential
Pressure (PSI)
1
Maximum Flow Rate
(GPM)
Temperature
Range
Viscosity
Range
Noise
Level
440 174 299
14°F to 356°F (-10°C to 180°C)
above 248°F (120°C) may require
Hot Clearance Rotors
Up to
1,000,000 cPs
60 ~ 80 dB
450 116 441
6 Rotary Lobe Pumps - JRZL-400 Series800.789.1718
JRZL440 Curves
Rotary Lobe Pump JRZL440
APPLIES TO BI-WING, BI-LOBE, AND SINGLE WING* ROTORS
* SINGLE WING ROTOR MAX 100 RPM
PORT SIZE: 4 X 4



  


















Dixon Sanitary
N25 W23040 Paul Road • Pewaukee, WI 53072
Customer Service: 800.789.1718
Fax: 800.789.4046
dixonvalve.com
7Rotary Lobe Pumps - JRZL-400 Series 800.789.1718
JRZL 440 NPSHR Curves
Rotary Lobe Pump JRZL440
NET POSITIVE SUCTION HEAD REQUIRED
PORT SIZE: 4 X 4
Dixon Sanitary
N25 W23040 Paul Road • Pewaukee, WI 53072
Customer Service: 800.789.1718
Fax: 800.789.4046
dixonvalve.com
0
5
10
15
20
25
0 50 100 150 200 250 300 350 400 450 500
NPSHR (PSIA)
SPEED (RPM)
8 Rotary Lobe Pumps - JRZL-400 Series800.789.1718
JRZL450 Curves
Rotary Lobe Pump JRZL450
APPLIES TO BI-WING, BI-LOBE, AND SINGLE WING* ROTORS
* SINGLE WING ROTOR MAX 100 RPM
PORT SIZE: 5 X 5



  


















Dixon Sanitary
N25 W23040 Paul Road • Pewaukee, WI 53072
Customer Service: 800.789.1718
Fax: 800.789.4046
dixonvalve.com
9Rotary Lobe Pumps - JRZL-400 Series 800.789.1718
JRZL 450 NPSHR Curves
Rotary Lobe Pump JRZL450
NET POSITIVE SUCTION HEAD REQUIRED
PORT SIZE: 5 X 5
Dixon Sanitary
N25 W23040 Paul Road • Pewaukee, WI 53072
Customer Service: 800.789.1718
Fax: 800.789.4046
dixonvalve.com
0
5
10
15
20
25
0 50 100 150 200 250 300 350 400 450 500
NPSHR (PSIA)
SPEED (RPM)
10 Rotary Lobe Pumps - JRZL-400 Series800.789.1718
Unpacking
Carefully unpack all parts of the pump and inspect for damage that may have occurred during shipment. Report any damages to the
carrier immediately.
The ports on the pump are protected with a plastic cover. If any covers are missing or damaged, inspect the ports on the pump
thoroughly for any damage.
If you are receiving a complete base mounted unit, please check shaft alignment as it may have changed during shipment.
The drawing below shows how the pump should be lifted. Ensure that the lifting equipment is correctly rated.
11Rotary Lobe Pumps - JRZL-400 Series 800.789.1718
Installation & Start Up
Pump Mounting Adjustable:
Adjustable leg base, commonly used for sanitary pumps for wash down under base. Can be easily moved or repositioned.
Mounting Congurations
Pump Mounting Casters:
Portable bases – for movement to different locations. Can also be mounted on a cart with handles.
12 Rotary Lobe Pumps - JRZL-400 Series800.789.1718
Installation & Start Up
Proper Installation
Piping Support:
Weight of piping and uid – support piping independently with hangers or pedestals. On rectangular inlet ange pumps, hopper
should also be supported independently.
13Rotary Lobe Pumps - JRZL-400 Series 800.789.1718
Installation & Start Up
Proper Installation (continued)
Piping Slope:
Inlet side – slope piping up to inlet to avoid air pocket.
14 Rotary Lobe Pumps - JRZL-400 Series800.789.1718
Installation & Start Up
Proper Installation (continued)
Pressure Gauges:
Pressure and vacuum gauges provide the easiest way to tell you something about the pump operation.
Normal or abnormal pressures
Overow conditions
Indication of ow
Changes in pump condition
Changes in system conditions
Changes in uid viscosity
15Rotary Lobe Pumps - JRZL-400 Series 800.789.1718
Installation & Start Up
Proper Installation (continued)
Inlet Check Valve:
Inlet side – use check valves to keep inlet line full, particularly with low viscosity uids, and in start-stop operation.
Outlet Check Valve:
Inlet Vacuum Service – use check valve on outlet side.
Prevents backow (air or uid)
Facilitates initial start-up (minimizes differential pressure pump must supply to start ow)
16 Rotary Lobe Pumps - JRZL-400 Series800.789.1718
Installation & Start Up
Proper Installation (continued)
Thermal Expansion:
Thermal expansion of piping can cause tremendous forces. Use thermal expansion joints to minimize forces on pump. Flexible
joints can also be used to limit the transmission of mechanical vibration. Anchor free ends of any exible hose in system.
Isolation Valves:
Isolation Valves – permit pump maintenance and removal safely without emptying entire system.
17Rotary Lobe Pumps - JRZL-400 Series 800.789.1718
Installation & Start Up
Proper Installation (continued)
Relief Loop:
Relief Valve – To protect the pump and piping system against excessive pressure, a relief valve should be installed. An integral
relief valve, designed to bypass the uid internally from the pump outlet to the inlet, should not be used on applications where the
discharge must be closed for more than a few minutes. Prolonged operation of the pump with closed discharge with cause heating
of the uid circulating through the relief valve.
18 Rotary Lobe Pumps - JRZL-400 Series800.789.1718
Installation & Start Up
At Start Up
Pump Flow:
All pumps are labeled with ow direction based on motor being wired for clockwise rotation. If motor is wired for counterclockwise
rotation, ow direction will be opposite of what is indicated on pump head.
19Rotary Lobe Pumps - JRZL-400 Series 800.789.1718
Installation & Start Up
At Start Up
Pump Alignment:
A exible coupling is used to compensate for end play and small differences in alignment. The pump and drive shaft should be
aligned as closely as possible.
Check angular alignment using feeler or taper gauge.
Adjust to get equal dimension at all points – at the same time, set space between coupling halves to the coupling manufacturer’s
recommended distance.
Note: Pump is aligned prior to shipping, after installation verify alignment as misalignment may have occurred during shipment.
20 Rotary Lobe Pumps - JRZL-400 Series800.789.1718
Tools Needed
Rotor tool
Plastic dowel
Open ended wrench set
Rubber mallet
Flat head screw driver
Feeler gauges
Hex keys
O-ring pick
Spanner wrench
Rotor extraction tool (optional)
Additional tools needed when assembling or disassembling gear box
Spanner wrench
Arbor press or bearing puller
Maintenance
Pump Housing Disassembly - Single Mechanical Seal
Prior to removal of pump, the shut-off valves in the suction and discharge lines must be closed. If there is any risk that product
may harden, crystallize or freeze in the pump it should be thoroughly drained and cleaned immediately after use. Same
attention applies if there is a seal ush option. Power needs to be locked out to prevent unintended start of the pump.
Note: Reference numbers are listed in the sectional view located on pages 61-73.
1. Loosen and remove the four hex nuts (33) from the front cover.
  • Page 1 1
  • Page 2 2
  • Page 3 3
  • Page 4 4
  • Page 5 5
  • Page 6 6
  • Page 7 7
  • Page 8 8
  • Page 9 9
  • Page 10 10
  • Page 11 11
  • Page 12 12
  • Page 13 13
  • Page 14 14
  • Page 15 15
  • Page 16 16
  • Page 17 17
  • Page 18 18
  • Page 19 19
  • Page 20 20
  • Page 21 21
  • Page 22 22
  • Page 23 23
  • Page 24 24
  • Page 25 25
  • Page 26 26
  • Page 27 27
  • Page 28 28
  • Page 29 29
  • Page 30 30
  • Page 31 31
  • Page 32 32
  • Page 33 33
  • Page 34 34
  • Page 35 35
  • Page 36 36
  • Page 37 37
  • Page 38 38
  • Page 39 39
  • Page 40 40
  • Page 41 41
  • Page 42 42
  • Page 43 43
  • Page 44 44
  • Page 45 45
  • Page 46 46
  • Page 47 47
  • Page 48 48
  • Page 49 49
  • Page 50 50
  • Page 51 51
  • Page 52 52
  • Page 53 53
  • Page 54 54
  • Page 55 55
  • Page 56 56
  • Page 57 57
  • Page 58 58
  • Page 59 59
  • Page 60 60
  • Page 61 61
  • Page 62 62
  • Page 63 63
  • Page 64 64
  • Page 65 65
  • Page 66 66
  • Page 67 67
  • Page 68 68
  • Page 69 69
  • Page 70 70
  • Page 71 71
  • Page 72 72
  • Page 73 73
  • Page 74 74
  • Page 75 75
  • Page 76 76
  • Page 77 77
  • Page 78 78
  • Page 79 79
  • Page 80 80

Dixon Rotary Lobe Pumps - JRZL-400 Series User manual

Type
User manual
This manual is also suitable for

Ask a question and I''ll find the answer in the document

Finding information in a document is now easier with AI