Donjoy JZ1 Series User manual

JZ1单级均质泵
使用运行、维护说明书
JZ1 series emulsifying homogenizing pump
Operation and maintenance manual
东正科技有限公司
DONJOYTECHNOLOGYCO.，LTD.
Rev.02-EN(2021-09)

JZ1 SERIES PUMP
CATALOGUE
1 Summarize 3
1.1 About the User Manual 3
1.2 Safety warning symbol 3
1.3 Delivery content 3
2 Security announcements 3
2.1 Basic security instructions 3
2.2 Application range 3
2.3 Common error operation 3
2.4 Safety instruction for pump 4
2.5 Nameplate 4
2.6 Warning sign 4
2.7 Waste treatment 4
3 Structural features and working principles 5
3.1 Basic structure 5
3.2 General configuration 5
3.3 Model 5
3.4 Model Description 6
4 Transportation 6
5 Storage 7
5.1 Storage environment of the pump 7
5.2 Restart to use 7
6 Installation and use procedures 7
6.1 Installation safety instructions 7
6.2 Precautions for pump installation 7
6.3 Reduce noise and vibration 8
6.4 Installation method 8
6.5 Pipeline installation 8
6.6 Electrical installation 9
6.7 Water flush pipeline connection 9
6.8 Cleaning 10
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JZ1 SERIES PUMP
7 Running Operation 10
7.1 Safety Instruction 10
7.2 Advance Preparation 10
7.3 Observe operation 10
7.4 Finish operation 10
8 Cleaning 11
8.1 CIP cleaning 11
8.2 SIP cleaning 11
9 Common Fault and Removal 11
10 Maintenance 11
10.1 Security instructions 11
10.2 Check rinse solution (double mechanical seal) 11
10.3 Replace mechanical seal 11
10.4 Disassembly of Pump 12
10.5 Centrifugal pump head assembly 15
11 Appendix 16
11.1 Torque table for bolts and nuts 16
11.2 Common operating problem and troubleshooting 17
11.3 Exploded view and parts list 18
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JZ1 SERIES PUMP
1 Summarize
1.1 About the User Manual
Manual is composed of two parts, the text part and the appendix. The text part of the manual contains the
general knowledge of the storage, installation, operation and maintenance of JZ1 Series pump. The appendix of
the manual includes the special debugging of this pump and the name of spare parts.
1.2 Safety warning symbol
Warning symbol Warning symbol
Warning you of personal danger Warning of electrical hazard
Warning symbol Warning symbol
Warning of falling objects Warning the danger of mechanical injury
Attention symbol Warning symbol
Ensure security responsibilities Warning risk of mechanical damage
1.3 Delivery content
• Package attached list
• Contain motor (Option to provide pump head only)
• Pump instruction
• Motor instruction
2 Safety precautions
2.1 Basic safety instructions
Before using the pump, please read this operation manual carefully and
save the manual in the pump working area for easy viewing.
All pump-related work require careful operation by experienced person
2.2 Application range
• JZ1 pumps are commonly used in food, pharmaceutical, biopharmaceutical, daily chemical.
• JZ1 pumps have different stator and rotor are selected, according to different media requirements.
(Contact DONJOY)
2.3 Common error operation
Improper media may cause damage to the pump
Impurities present in the media may cause the pump to get stuck or even be damaged
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JZ1 SERIES PUMP
2.4 Safety instruction for pump
• Running without medium
Pump is strictly prohibited to run without medium
If using double mechanical seal , it is allowed to run without medium for a short time.
If using single mechanical seal , short time dry rotation may also cause damage to the mechanical seal.
• Pump surface high temperature
It will couse high temperature after pump running , do not touch , it will hurt you
Check the surface temperature before touching pump
2.5 Name plate
2.6 Warning sign
Please set warning sign in the pump working area
2.7 Waste treatment
Please follow the relevant regulations to dispose of the disassembled waste.
!
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JZ1 SERIES PUMP
3 Structural feature and working principle
3.1 Basic structure
3.2 General configuration
•Single mechanical or double mechanical seal (double mechanical seal recommended)
•With discharge outlet (option)
3.3 Model
JZ1 Series
DJ-JZ1-130
DJ-JZ1-150
DJ-JZ1-170
DJ-JZ1-190
DJ-JZ1-210
DJ-JZ1-240
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JZ1 SERIES PUMP
3.4 Model Description
For example：DJ-JZ1-130-3T-10-3KW-380V-50HZ-M-1.5"/1.5"-S
4 Transportation
Trained person are required to transport the pump
The complete set pump can be handled by forklift or crane
4.1 Safety instructions
• Be careful to drop or unfixed parts that can cause severe abrasions.
• Do not remove the inlet and outlet end caps of the pump until the piping is connected.
4.2 Forklift transportation instructions
• Pay attention to parts falling, which may cause serious injury and bruises on your hands and feet.
To prevent rollover during transportation, use a conveyor belt or bolt to fix the plate
Connectionstandard
连接标准：DIN(D)SMS(S)3A(A)RJT(R)ISO/IDF(I)
Inlet/Outlet SIZE
进/出口规格
Connectionmethod:Thread(M)Clamp(C)Flange(F)
连接方式：螺纹（M）卡箍（C）法兰(F)
Motorfrequency
电机频率：50HZ；60HZ
Voltage:110V220V380V(seetable)
电压：110V220V380V(详见选型表)
Motorpower:1.1kw1.5kw2.2kw........
电机功率:1.1kw1.5kw2.2kw........
DJ-JZ1 130 3T 10 3.0kw 380V 50hz M1.5"/1.5"S
Pumphead(seetable)
泵扬程（详见选型表）
Pumpflow（seetable）
均质泵流量（详见选型表）
Pumpmodel
均质泵型号
Emulsifyinghomogenizingpumpcode:DJ-JZ1
单级均质泵代码：DJ-JZ1
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JZ1 SERIES PUMP
4.3 Crane transportation instructions
• "Warning", pay attention to parts falling, which may cause serious injury, bruises and even death.
To prevent falling during transportation, use a suitable lifting tool.
• Please make sure that the crane and the rope have enough bearing and strength.
• Make sure nobody stay under pump
5 Store
5.1 Storage environment of the pump
• The pump shall be stored according to the following procedures:
1. Drain the pump medium and keep it dry. Store it in a dry environment.
2. Storage temperature should not be too high or too low,
suitable for storing temperature is 20 ℃to 25 ℃(rnormal temperature).
3. The storage environment shall be ventilated and dust-free.
4. All parts of the pump are required to rotate regularly (three months)
5.3 Restart to use
• After storage, please check the mechanical seal before restart to use.
6 Installation and use procedures
6.1 Installation safety instructions
• Make sure that each part is fixed during installation,
falling parts may cause damage to the pump, as well as injury to personnel.
• please wear labor protection shoes when installing.
• Fix bolt according to the specified torque, please check 11.1 《Bolt Fixed Torque Table》
• Use a torque wrench
6.2 Precautions for pump installation
• Confirm the installation environment of the pump,
explosion-proof pump should be used in the explosion-proof environment.
• The environment must be dust-free.
• Working environment temperature at-20 ℃to 40 ℃.
•The installation platform must be strong enough to support the whole pump.
• The installation platform must be horizontal.
•Sufficient maintenance space must be guaranteed.
• Ensure the air circulation of the installation environment and promote the heat dissipation of the motor.
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JZ1 SERIES PUMP
6.3 Reduce noise and vibration
6.3.1 Main measures
• Operate in optimum working conditions to avoid cavitation.
• Avoid resonance of inlet and outlet pipeline.
• Fix inlet and outlet pipelines.
6.3.2 Auxiliary measures
• Isolation measures can be used to isolate noise, such as sound insulation coverage, space isolation, etc.
6.4 Installation method
• Use base mounting to install the pump ,and the pump is mounted on a fixed mounting platform.
• Use base mounting to install (with adjustable support foot), the height of the support foot can be adjusted
freely to ensure the stable installation of the pump.
6.5 Pipeline installation
• Reduce pipe resistance as much as possible and
avoid to use unnecessary elbows and valves.
• When designing piping connection, try to avoid
causing pressure loss and avoid cavitation caused by
inhalation end
• The inlet and outlet control valves should be as close
as possible to the inlet and outlet end.
• Inhalation end pipeline should be as short as
possible
• The inlet end pipeline should be installed horizontally
to reduce the possibility of residual air in the pipeline.
• Design pipeline reasonably according to pressure,
temperature and medium characteristics.
• Avoid stress from pipes to pumps (pipes must be
supported independently)
Wrong pipe type Right pipe type
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JZ1 SERIES PUMP
6.6 Electric Power Installation
• "Warning". Attention should be paid to using ground wire to connect pumps to eliminate static electricity
• Electrical connections need to be completed by qualified electrical engineers
1. Check motor nameplate to confirm rated power, rated voltage and wiring mode.
2. Follow the wiring diagram in the Motor junction box to connect the electricity.
3. Click start motor with less than 1 second and check motor rotation direction.
4.Rewiring is required if the rotation direction is wrong.
Attached image, correct rotation direction of motor
6.7 water flushing pipeline connection (double machine seal)
• pumps with double mechanical seals must be connected to water flushing lines and supplied with cooling
water.
OD of Hose
couping
connection
Inlet and outlet
thread connection
6mm G1/8
• It is recommended that the flushing water should be entered from below and discharged from the top.
Double Seal
shaft
Water outlet
Water inlet
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JZ1 SERIES PUMP
6.8 Cleaning
1. Before cleaning, make sure there is no impurities in the pump chamber and pipeline.
2. Confirm that the pump is in the stop state.
3. Connecting the pipeline.
4. Before the first use, please thoroughly clean the pump and pipeline.
7. Running Operation
7.1 Safety Instruction
• Please confirm outlet valve has been opened when turning on pump and in operation.
In order to avoid overhigh outlet pressure,
it could be added with bypass line or safety valve etc. protective measures.
• Please confirm inlet valve has been opened when turning on pump.
If inlet valve is closed, will be occured with idling, and mechanical seal will be damaged.
• Please confirm pump chamber has been full filled with liquid before turning on pump.
If without liquid in pump chamber, will be occured with idling, and mechanical seal will be damaged.
7.2 Advance Preparation
1. Double mechanical seal: to confirm cooling water has been connected .
Note: cooling water temperature＜70℃; to adjust the pressure of wash water＜1bar.
2. To open inlet valve.
3. To open outlet valve.
4. Waiting for a while, to confirm the pump chamber and inlet pipeline has been full filled with liquid.
5. Start motor.
7.3 Observe Operation
Safety Instruction in pump operation:
• Pump was stuck or damaged: there might be with impurity in your media.
• It's prohibited to close outlet valve in pump operation,
if not, will be caused with moment overhigh pressure and damage on pump.
•It's prohibited to close inlet valve in pump operation,
if not, will be caused with cavitation and idling and damage on mechanical seal.
7.4 Finish operation
1. To turn off motor.
2. To close inlet valve, to avoid idling in next operation.
3. To close outlet valve.
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JZ1 SERIES PUMP
8. Cleaning
8.1 CIP Cleaning
• JZ1 Series pump is supported with CIP cleaning.
8.2 SIP Cleaning
•Note: Do not turn on pump in SIP sterilization,
idling will be caused with damage on mechanical seal.
•Allow with max. steam temperature 145℃.
9. Common Fault and Removal
• See appendix 11.2 《Common Fault and Removal》.
10. Maintenance
10.1 Safety Instruction
• To confirm the motor has been turned off and powered off when touch pump.
• Please wear safety shoes, to avoid unnecessary damage.
• To close inlet and outlet valve.
• Double mechanical seal pump: to switch off wash water.
• To fully discharge liquid in pump chamber before separating pump.
10.2 To inspect wash water (double mechanical seal)
If choose double mechanical seal pump:
• To inspect wash water pressure＜1bar.
• To confirm wash water temperature＜70℃.
10.3 To replace mechanical seal
Need to replace mechanical seal in the following situation:
• When conveying media, with leakage.
• When conveying media, with leakage of wash water.
• When conveying media, wash water was into conveying liquid.
Please refer to the chapter of disassembly and installation of pump head -- mechanical seal, when to replace.
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JZ1 SERIES PUMP
10.4 JZ pump head disassembly
10.4.1 Disassemble pump head and impeller
1. Disassemble head cover bolts(part 1）8. Remove the bolts(part 9) from the pump cover
2. Disassemble pump cover(part 2) 9. Loosen the nut(part 11) counterclockwise
3. Disassemble side signs(part 7)、bolt(part 8) 10. Remove the bolts(part 10) clockwise,
4. Fixed the pump shaft with tools,rotate
counterclockwise, and remove the rotor nut(part 3)
and remove the stator(part 14)
11.Remove the O ring(13) from the stator(14)
5. Take down rotor nut O-ring (part 4) 12.Remove the O ring(12) from the pump cover(part 2)
6. Disassemble rotor(part 5)
7. Take down pump shaft on the flat key(part 6)
1
2
3
4
5
6
78
9
10
12
13
14
15
11
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JZ1 SERIES PUMP
10.4.2 Mechanical seal disassembly
Only double mechanical seal construction
Double mechanical seal disassemble procedure
1. Take out the inner sealing ring, static ring, as shown on the right(Part D2、D3)
2. Take down back cover(part 16)
3. Take down bolt(part D12),water seal(part D7), spring components(part D4)
4. Take down the external seal static ring (part D3), moving ring (part D9) and support (part D11) successively.
Attached pictures (structure sketch of double mechanical seal for JZ1-130 to JZ1-170)
Position Description Qty
D1 O-ring ID44.04X3.53 2
D2 Rotary Face 1
D3 Static Face 2
D4 Washer 2
D5 Coil Spring 1
D6 Pin φ3x6 2
D7 Hosing 1
D8 O-ring ID53.64x2.62 1
D9 Rotary Face 1
D10 O-ring ID32.92x3.53 1
D11 Drive ring 1
D2
D3
16
D4
D7
D3
D9
D11
D12
D1D2D3D1D4D5D4D1D3
D7D8
D9
D10
D11
D6
Double seal
Shaft
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JZ1 SERIES PUMP
Attached pictures (structure sketch of double mechanical seal for JZ1-190 to JZ1-240)
Position Description Qty
D1 O-ring ID53.64x2.62 1
D2 Rotary holder 1
D3 Pin φ4x9 2
D4 O-ring ID56.74x3.53 3
D5 Rotary face 1
D6 Static face 1
D7 Static face 1
D8 Rotary face 1
D9 O-ring ID45.69x2.62 1
D10 Spring 6
D11 Pin sleeve 2
D12 O-ring ID37.77x2.62 1
D13 Pin φ4 h8x8 1
D14 Pin φ4 h8x12 4
D15 O-ring ID75x2.5 1
D16 Seal holder 1
OUTLET(BSP 1/8)
INLET (BSP 1/8)
D1 D2 D3 D4 D5 D6 D4 D4
D8
D9D10
D11
D13
D7
D12
Shaft
D15 D16
D14
14
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JZ1 SERIES PUMP
10.5 Pump head assembly
Preparing before assembly
• Cleaning the component
• If there is some part to replace
• Please note that it should be assamble in an clean environment while the mechanical seal is easy to damaged
• Please use water or lubricating grease to clean the mechanical seal before assembly
• Please do not touch after cleaning
10.5.1 Adjust the clearance between rotor and back cover
1. Install the pump shaft assembly into the motor shaft, pretighten the sleeve screw,
but do not tighten it completely.
2. Mount the connecting bracket, back cover, impeller and impeller nut successively.
Adjust the distances "X" between impeller and back cover, usually controlled at 0.5mm
Use depth ruler to measure the distance "Z" between rotor and end face.
SIZE
distances（mm）
XYZ
JZ1-130
0.5 0.5
5.5
JZ1-150 5.0
JZ1-170 9.5
JZ1-190 5.5
JZ1-210 5.5
JZ1-240 5.5
3. Take down the rotor nut, rotor, back cover, connecting bracket, and lock the fastening screw.
4. Use dial indicator to check pump shaft circular runout, which should be controlled below 0.05mm.
XY
Z
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JZ1 SERIES PUMP
10.5.2 Install bracket and back cover
1. Install connection bracket
2. Machine seal press plate, machine seal spring into the back cover
3. Install back cover
10.5.3 Mechanical seal installation
Reverse assembly according to the disassembly steps of mechanical seal
(refer to the schematic diagram of mechanical seal structure for mechanical seal structure)
10.5.4 Install impeller
1.Put the flat key into the pump shaft
2.Insert the impeller into the pump shaft
3.Install O - ring on impeller nut and tighten with 120NM.
10.5.5 Install pump front cover and bolts
1. Put O - ring(part 12) into pump head(part 2) sealing groove.
2. Install O-rings(part 13,part 15) in the stator(part 14).
3. Instal the stator assembly into the pump head(part 2),and tight with bolts(part 9).
4. Tight the bolts(part 10),nut(part 11)
5. Install the pump head assembly.
6. Tighten the pump head fixing nut and install torque. See "bolt tightening torque" in chapter 11.
11 Appendix
11.1 Bolt tightening torque
Set bolt and nut torque ±15%
Materials grade A2-70
Nut/bolt M6 M8 M10 M12 M16 M20
Tightening torque NM 7 18 36 63 143 262
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JZ1 SERIES PUMP
11.2 Common fault and eliminating methods
work breakdown Common cause of failure Solution
pump chamber is not filled with liquid filling of liquid
No flow or unstable flow outlet valve is closed open outlet valve
inlet pipe is closed or blocked open inlet piping or wash
pump stuck
clean the pump chamber and check
if there is any foreign body entering
medium viscosity is too high to be inhaled
Increase inlet pipe diameter and
shorten pipe length
model of the pump is too small contact Donjoy
Flow and discharge too
small wrong direction of motor rotation Adjust motor steering
transport medium viscosity is too high, poor
liquidity
Increase inlet pipe diameter and
shorten pipe length
too low speed (wrong voltage)
check power supply voltage
according to motor nameplate
hard object in the pump chamber exclude foreign body
Noise and vibration Impeller scratches check impeller clearance and adjust
suction line resistance is too large
Increase inlet pipe diameter and
shorten pipe length
pipe weight and pressure act directly on the
pump
add pipeline support to eliminate
resonance
Sudden increase in shaft
power
too high viscosity of conveying medium contact Donjoy
bearing or motor damage check and repair
Damaged mechanical seal(wear) change mechanical seal
Mechanical seal leakage mechanical seal dry rotation, medium
temperature is too high
Double mechanical seals are
recommended
corrosion of mechanical seal material contact Donjoy
flushing circulation line is blocked cause dry
rotate check and repair
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JZ1 SERIES PUMP
11.3 Explosion diagram and parts list
Please refer to next pages.
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