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Operating & Maintenance Manual for
JRZA AccuLAB Pump
Dixon Sanitary
N25 W23040 Paul Road • Pewaukee, WI 53072 ph: 800.789.1718 • fx: 800.789.4046
dixonvalve.com
2
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 JRZA AccuLAB Pump.
READ THIS MANUAL carefully to learn how to service these pumps. Failure to do so could result in bodily injury or equipment damage.
Table of Contents
Safety ................................................................................................................................................................................................... 3
Care of Stainless Steel ......................................................................................................................................................................... 4
Technical Specifications ....................................................................................................................................................................... 5
Unpacking............................................................................................................................................................................................. 6
Installation & Start Up ......................................................................................................................................................................7-15
Tools needed ...................................................................................................................................................................................... 16
Maintenance ..................................................................................................................................................................................16-31
Pump Housing Disassembly ..................................................................................................................................................16-19
Inspection .................................................................................................................................................................................... 19
Seal Assembly............................................................................................................................................................................. 20
Pump Housing Assembly .......................................................................................................................................................21-22
Rotor Clearance .......................................................................................................................................................................... 23
Rotor Timing ................................................................................................................................................................................ 24
Gear Box Disassembly ...........................................................................................................................................................25-29
Gear Box Assembly..................................................................................................................................................................... 30
Scheduled Maintenance .............................................................................................................................................................. 31
Dimensions ......................................................................................................................................................................................... 31
Troubleshooting .............................................................................................................................................................................32-34
BOMs .................................................................................................................................................................................................. 35
Certificates .......................................................................................................................................................................................... 36
Warranty ............................................................................................................................................................................................. 37
800.789.1718
Rotary Lobe Pumps - JRZA AccuLAB Series
Safety Information
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 qualified 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 fluids 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 fluids 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.
Rotary Lobe Pumps - JRZA AccuLAB Series 800.789.1718
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4
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, fittings, wrenches, etc. in contact with stainless steel. Corrosion: Pitting or galvanic action. Objects retard complete drying, preventing air from reforming the protective oxide film. 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 specified 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 film destroyed. Chlorine and other halogen bactericides can destroy the protective film. 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 fitting 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 film cannot be restored and corrosion will continue at an accelerated rate.
800.789.1718
Rotary Lobe Pumps - JRZA AccuLAB Series
JRZA-Series Technical Specifications
Specifications:
• Maximum Inlet Pressure: 14.5 PSI
• Maximum Differential Pressure: 58 PSI
• Maximum Flow Rate: 4.4 GPM
• Temperature Range: 14°F to 212°F
• Viscosity Range: Up to 100,000 cPs
• Noise Level: 60 ~ 80 dB
Materials:
• Product contact parts: AISI 316L Stainless Steel (standard)
• Product contact elastomers: EPDM
• Optional seals: FKM
Shaft Seals:
• Seal types: Single and Double Mechanical Seal
• Maximum flushing water pressure: 7 PSI (0.5 bar)
• Flushing water consumption: 0.25~0.5 liter/min (30~60 cubic inches/min)
• Stationary seal ring material: Tungsten Carbide
• Rotating seal ring material: Tungsten Carbide
• O-ring material: EPDM (standard)
• Optional O-ring material: FKM
Rotor Information:
• Multi-lobe rotor (standard)
• Optional rotors: spur gear
Rotary Lobe Pumps - JRZA AccuLAB Series 800.789.1718
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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.
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Rotary Lobe Pumps - JRZA AccuLAB Series
Installation & Start Up
Mounting Configurations
Pump Mounting Adjustable:
• Adjustable leg base, commonly used for sanitary pumps for wash down under base. Can be easily moved or repositioned.
Pump Mounting Casters:
• Portable bases – for movement to different locations. Can also be mounted on a cart with handles.
Rotary Lobe Pumps - JRZA AccuLAB Series 800.789.1718
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Installation & Start Up
Proper Installation
Piping Support :
Weight of piping and fluid – support piping independently with hangers or pedestals. On rectangular inlet flange pumps, hopper should also be supported independently.
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Installation & Start Up
Proper Installation (continued)
Piping Slope:
• Inlet side – slope piping up to inlet to avoid air pocket.
Rotary Lobe Pumps - JRZA AccuLAB Series 800.789.1718
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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
• Overflow conditions
• Indication of flow
• Changes in pump condition
• Changes in system conditions
• Changes in fluid viscosity
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Installation & Start Up
Proper Installation (continued)
Inlet Check Valve:
• Inlet side – use check valves to keep inlet line full, particularly with low viscosity fluids, and in start-stop operation.
Outlet Check Valve:
• Inlet Vacuum Service – use check valve on outlet side.
• Prevents backflow (air or fluid)
• Facilitates initial start-up (minimizes differential pressure pump must supply to start flow)
Rotary Lobe Pumps - JRZA AccuLAB Series 800.789.1718
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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 flexible hose in system.
Isolation Valves:
• Isolation Valves – permit pump maintenance and removal safely without emptying entire system.
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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 fluid 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 will cause heating of the fluid circulating through the relief valve.
Rotary Lobe Pumps - JRZA AccuLAB Series 800.789.1718
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Installation & Start Up
At Start Up
Pump Flow:
All pumps are labeled with flow direction based on motor being wired for clockwise rotation. If motor is wired for counterclockwise rotation, flow direction will be opposite of what is indicated on pump head.
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Installation & Start Up
At Start Up
Pump Alignment:
A flexible 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.
Rotary Lobe Pumps - JRZA AccuLAB Series 800.789.1718
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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
Drain all product from the pump head prior to disassembly. The pump head may be isolated with inlet and outlet valves.
Disconnect the suction and discharge piping from the pump.
Note: Reference numbers are listed in part list refer to section view on page 35.
1.
Loosen and remove the four-cover bolts from the cover. Remove the cover. If it is stuck, tap on the cover with a soft hammer.
Remove the cover O-ring.
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Maintenance
Pump Housing Disassembly (continued)
2. Remove rotor-retaining bolts. Use the special tool supplied with pump. To remove rotor-retaining bolts, place the plastic dowel between the rotors. Turn the first rotor bolt counter-clockwise.
The rotors can be removed from the pump housing by pulling straight. If it is stuck tight, alternately use special rotor extraction tool supplied with pump. Handle the rotors with care to avoid damage. The shims behind rotors should be carefully maintained not to be lost or damaged in order to use when assembling. Shims must be placed back on the same shaft from which they were removed.
Rotary Lobe Pumps - JRZA AccuLAB Series 800.789.1718
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Maintenance
Pump Housing Disassembly (continued)
4 . In order to remove the stationary seals, both of the seal stopper/pins on the top and bottom should be loosened as shown.
5.
Rotary seal rings are being installed into rotors with rotary seal ring rubber cup.
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Maintenance
Pump Housing Disassembly (continued)
6. Remove seal bodies from housing. The seals can be easily moved forward by using standard flathead driver as shown.
Maintenance
Inspection
1.
Inspect O-rings and seals for wear and tear. Worn O-rings and seals should be replaced.
2.
Inspect seal faces for scoring or cracks. Replace any seal faces that are damaged.
3.
Inspect shafts, rotors and other metal parts for wear and tear.
4.
Inspect for signs of rotor galling within the rotor casing, on the front cover and on the rotors.
5.
Inspect for burrs in the rotor bolt grove. Burr must be removed or rotor bolt replaced.
Rotary Lobe Pumps - JRZA AccuLAB Series 800.789.1718
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Maintenance
Seal Assembly
Install Slinger O-Ring (4.9) onto the shaft ensuring the O-ring is all the way up the shaft and against the pump body bore face. This is also visible through the slots in the sides of the pump body.
• Install external O-rings (4.5) and internal Quad-ring (4.8) to the Seal body (4.5)
• Install the seal housing into the pump assembly. Aligning the flush holes with the tapping in the pump body.
• Install the flush locking adapter O-ring onto the adapter.
• Install the flush locking adapter (5.1) such that the end of the component is locking the seal body in position.
• Install the primary O-ring (4.6) onto the Static Seal (4.3)
• Install the static seal face (4.3) aligning the slots in the seal face with the anti-rotation pins in the seal body.
• Install the rotor and rotary seal face assembly.
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Rotary Lobe Pumps - JRZA AccuLAB Series
Maintenance
Pump Housing Assembly
1.
After replacing the old seals with new seals, place the shims onto the shafts.
2.
Assemble the rotors onto shafts. Make sure seal side of rotor is facing the back of the rotor casing before placing the rotors onto the shafts.
Rotary Lobe Pumps - JRZA AccuLAB Series 800.789.1718
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Maintenance
Pump Housing Assembly (continued)
3.
Tighten the first rotor bolt with a special tool to the recommended torque. To tighten the second rotor bolt with a special tool to the recommended torque.To tighten the second rotor place the plastic dowel on the opposite side of the rotor and tighten the second rotor bolt to the proper torque 34 ft lb. Excessive torque could make rotor bolts damaged or its surface produced burr. If a burr is raised, it should be removed by sand paper smoothly.
4.
Install the cover and tighten the front cover bolts.
Use feeler gauges and depth micrometer to verify the back and redial clearances between the rotors and the housing. A depth gauge should be used to verify the front clearance.
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Maintenance
Rotor Clearance
Rotor clearance must be precisely maintained to provide maximum pumping efficiency, yet prevent contact between rotors, rotor housing, and front cover during operation. If pumping efficiency is below expectations, or if parts contact has occurred during operation (within rated differential pressure), check rotor clearances and adjust if incorrect.
Front 'A'
0.1
Rear 'B'
0.1
Metric (mm)
Radials 'C'
0.1
Rear 'B'
0.0039
Imperial (inches)
Radials 'C'
0.0039
Mesh 'D'
0.1
Front 'A'
0.0039
Mesh 'D'
0.0039
There are two areas of rotor clearances as illustrated following:
Rotor tip clearance - not adjustable and set by manufacturer
Front and back face clearance - adjustable by shim
Rotor width and body depth are fixed at manufacture. Therefore, with the correct rotor (1.1) size selected, the only maintenance adjustment that can be made is the proportion of front and rear clearance. Measure the front clearance as follows:
1.
The rotor to rotor housing back face clearance is maintained by the shim plate ( ).
2.
Check the rotor bolts (3.5) are tight.
3.
Measure the clearance between the back face of the pump housing and the back of the rotor with a filler gauge. Check the reading with the recommended back face clearance.
4.
If incorrect, adjust by adding or removing shim plates from behind the rotors.
5.
Check each rotor and adjust as necessary.
Rotary Lobe Pumps - JRZA AccuLAB Series 800.789.1718
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Maintenance
Rotor Timing
Rotor timing must be precisely maintained to provide maximum pumping efficiency, yet prevent contact between rotors during operation. If pumping efficiency is below expectations or if rotors contact during operation (within rated differential pressure), check rotor timing and adjust if incorrect. Also check rotor timing after any gearbox dismantling when the gears are removed and/or replaced.
Check Rotor timing as follows:
1.
Assemble each rotor (1.1) in its normal location on the drive shaft and the idle shaft. Assemble each rotor bolt (3.5) and tighten hand tight.
2.
Rotate the shafts 30 degrees and measure gap as illustrated by arrows. Rotate the shafts 60 degrees the opposite direction and measure gap as illustrated.
3.
The rotors are correctly timed when the gap measured at both locations are equal. If the gap is unequal, adjust the timing as follows.
4.
Rotor timing is determined by the relative location of the two helical gears (3.2) on the shafts.
5.
Place the wooden dowel between the rotors.
6.
Bend away the tab of the lock washer (3.3) on one shaft. Loosen the lock nut and temporarily insert shim stock between the gear and gear spacer. Tighten the lock nut, reassemble the rotor in its correct location, and recheck rotor timing.
• If rotor timing is correct, remove the gear and replace added other spacer or add a shim equal in thickness to the shim stock temporarily added. Reassemble the gear and gear nut, tighten to the correct torque, and check rotor timing again to confirm that it is correct.
• If rotor timing is incorrect, but closer to equal than original measurement, repeat previous step adding additional shim stock.
• If rotor timing is incorrect and more unequal than original measurement, remove temporary shim stock from one shaft and add instead to the other shaft.
7.
Repeat above procedures until the timing gap is equal after gear spacers are in place and gear nuts are tightened to correct torque.
8. Reassemble pump.
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Maintenance
Gear Box Disassembly
The pump, when operating, can cause SEVERE INJURY to anyone in contact with the rotating parts. Turn off the energy source and
LOCK OUT before dismantling pump. Use a locking device for which only the person doing the dismantling has the key.
AccuLAB series has a single body combined pump housing with gear housing. Generally, gear housing is not needed for the maintenance for the gear. If gear housing is needed for the maintenance, experts with special care should do the work.
1.
Dismantle pump bracket by removing the four bracket bolts.
2.
Then, dismantle the gear box cover by removing four bolts.
Rotary Lobe Pumps - JRZA AccuLAB Series 800.789.1718
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Maintenance
Gear Box Disassembly (continued)
3.
Remove the lock nut and washer from the drive shaft and idle shaft.
4.
Pull the two gears off the pump shafts. Remove the gear keys.
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Maintenance
Gear Box Disassembly (continued)
5.
Remove two long bolts securing bearing cover.
6.
Bearing is firmly secured and so, after hitting the shaft from the front with soft hammer and bearing can be easily dismantled by using two long bolts as shown. Be careful not to damage the shaft with excessive hitting.
Rotary Lobe Pumps - JRZA AccuLAB Series 800.789.1718
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Maintenance
Gear Box Disassembly (continued)
7.
Bearings on drive and idle shaft can be dismantled.
8.
Shim should be carefully kept not to be lost for the assembly.
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Maintenance
Gear Box Disassembly (continued)
9.
Quad ring is protecting bearing when a leakage occurs.
Rotary Lobe Pumps - JRZA AccuLAB Series 800.789.1718
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Maintenance
Gearbox Assembly
Place the rotor (1.1) on a flat surface. Lubricate the front and rear bearing areas of the drive and idle shafts with grease. Insert the shafts into the rotor splines, for support. Heat the front bearing to 250°F. Place the bearing over the shaft, after the bearing cooled.
Place the gearbox over the shafts.
Position the gearbox with wet end up. Insert the front bearing with shaft perpendicular to the gearbox. There should be a tight sliding fit between the gearbox and the bearing outer rings. Press or soft hammer can be used.
Place the front bearing and tighten.
Rear bearing assemblies insert into the rear cover. There should be a tight sliding fit.
Heat the inner ring of the rear bearing to 250°F. Place the inner ring over the shafts with the flange end sliding over the shaft first.
Lubricate the gear area of the shaft and the face of the lock washer with grease.
Position both shaft gear keys to the 12:00 position.
Place the gear, lock washer (3.3) and lock nut (3.3) onto the shafts and hand tighten.
After the gears are installed, turn the shafts to make sure they turn freely and that the rotors (1.1) are timed correctly.
Use a spanner wrench to tighten the gear lock nut (3.3) on the drive shaft. You can install the rotors to hold the shafts in place while you tighten the nut.
Measure rolling torque with no load on bearing. Set the torque wrench to zero while rotating, this will remove the load caused by the lip seal.
The bearing locknut should be tightened until the rolling torque on the shaft measures the values in the following table.
Tighten the locknut (3.3) on the idle shaft, following the previous steps.
Measure the shaft endplay to be sure it is zero. If the endplay is not zero, repeat the tightening steps. To repeat these steps, the locknut (3.3) will have to be backed off and the bearing will have to be tapped to remove the loadings.
Install the liquid gasket to rear cover quad ring (4.12) and mount the rear cover (1.4) assembly over the drive shaft extension onto the gearbox.
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Maintenance
Scheduled Maintenance
• After initial startup – change oil after 4,000 hours.
• After, change oil annually based on 8 hrs a day, 5 days a week run time.
• Every two years, change oil seals
Recommended Spare Parts:
• 1 Year – (2) Seal sets and (1) O-ring set
• 2 Years – (4) Seal sets and (2) O-ring sets and (1) set rotors
Dimensions
Rotary Lobe Pumps - JRZA AccuLAB Series 800.789.1718
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Troubleshooting
32
Problem
No Flow, Pump Rotors Are
Not Turning
Possible Cause
Drive motor not running.
Suggested Action
Check resets, fuses, circuit breakers.
No Flow, Pump Rotors Are
Turning
Key sheared or missing.
Drive belts, power transmission components slipping or broken.
Pump shaft, keys or gears sheared.
Rotors turning in the wrong direction.
Replace.
Replace or adjust.
Inspect and replace parts as necessary.
Check motor hookup to reverse motor rotation.
No Flow, Pump Not Priming
Insufficient Flow
Insufficient Flow – Flow Being
Bypassed Somewhere
Relief valve not properly adjusted or held open by foreign material.
Suction port is blocked, not allowing flow to the pump.
Valve closed in inlet line.
Inlet line clogged or restricted.
Air leaks due to bad gaskets or pipe connections.
Pump speed too slow.
Pump speed to fast for high viscosity liquid.
Liquid drains or siphons from system during off periods.
"Air" lock caused by fluids which "gas off" or vaporize or allow gas to come out of material during off periods.
Extra clearance rotors, worn pump.
NPSHA too low.
Adjust or clear valve.
Check all inlet valves, strainers and tank outlet ports.
Open valve.
Clear line, clean filters, etc.
Replace gaskets, check lines for leakage (can be done by air pressure or by filing with liquid and pressurizing with air.
Increase pump speed.
Decrease pump speed.
Use foot valve or check valves. Filling inlet lines with material before startup may solve startup priming problems due to no material in system.
Install and use a manual or automatic air bleed from pump or lines near pump.
Increase pump speed within limits, use foot valve to improve priming.
Replace worn rotors.
Check net inlet pressure available against net inlet pressure required. Change inlet system as needed.
Install check valve in discharge line.
On "Vacuum" inlet system: On initial start-up, atmospheric "blow back" prevents pump from developing enough differential pressure to start flow.
Speed too low or too high to obtain desired flow.
Air leak due to bad seals, pipe connections or other equipment.
Flow diverted in branch line, open valve, etc.
Check curve and adjust as necessary.
Replace seals, check inlet fittings.
Check system and controls.
Insufficient Flow – High Slip
Relief valve not adjusted or jammed.
Hot (HC) or extra clearance rotors being used on "cold" fluid and/or low viscosity fluid.
Worn pump.
Clear or adjust valve.
Replace with standard clearance rotors.
High pressure.
Increase pump speed (within limits).
Replace rotors
Reduce pressure by adjusting system settings or hardware.
800.789.1718
Rotary Lobe Pumps - JRZA AccuLAB Series
Cavitation
Problem
Noisy Operation
Noisy Operation Caused By
Mechanical Problems
Troubleshooting
Possible Cause
Strainers, foot valves, inlet fittings or lines clogged.
Inlet line size too small, inlet line too long. Too many fittings or valves. Foot valve, strainers too small.
NPSHA too low.
Fluid viscosity greater than expected.
Fluid temperature higher than expected (vapor pressure higher).
Suggested Action
Clear lines. If problem continues, inlet system may require changing.
Increase inlet line size. Reduce length, minimize direction and size changes, reduce number of fittings.
Raise liquid level in source tank to increase net inlet pressure.
Increase net inlet pressure by raising or pressurizing source tank.
Select larger pump size with lower net inlet pressure required.
Reduce pump speed and accept lower flow or change system to reduce line losses.
Change temperature of product to reduce viscosity.
Reduce temperature, reduce speed and accept lower flow or change system to increase net inlet pressure available.
Cavitation
High fluid viscosity
High vapor pressure fluid
High temperature.
NPSHA less than NPSHR.
Air or gas in fluid .
Slow down pump, reduce temperature, change system setup.
Increase NPSHA or decrease NPSHR.
Leaks in the pump or piping.
Dissolved gas or naturally aerated products.
Fix leaks.
Minimize discharge pressure (also see
"Cavitation" above).
Rotor to Body Contact
Improper assembly of pump.
Distortion of pump due to improper piping installation.
Pressures required higher than the pump is rated for.
Worn bearings.
Check clearances and adjust shimming.
Change piping installation to eliminate piping stress and distortion on body.
Reduce discharge pressure required.
Rebuild with new bearings and lubricate regularly.
Rotor to Rotor Contact
Loose or incorrectly-timed gears.
Sheared keys.
Worn gear splines.
Drive noise caused by gear trains, chains, couplings or bearings.
Rebuild with new parts. Note: This will cause severe damage.
Rebuild with new parts. Note: This will cause severe damage.
Rebuild with new parts. Note: This will cause severe damage.
Repair or replace drive parts. Check bearings for damage and replace as necessary.
Rotary Lobe Pumps - JRZA AccuLAB Series 800.789.1718
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Troubleshooting
Problem
Pump Requires Excessive
Power (overheats, stalls, high current draw, breakers trip)
Possible Cause
Higher than expected viscosity losses.
Higher than expected pressures.
Fluid is colder with a higher viscosity than expected.
Fluid sets in line and pump during shutdown.
Short Pump Service Life
Any Other Issue
Fluid builds up on pump surfaces.
Pumping abrasives.
Speeds and pressures higher than rated.
Worn bearings and gears due to lack of lubrication.
Misalignment of drive and piping. (Excessive overhung load or misaligned couplings.)
Suggested Action
If within pump rating, increase drive size
Reduce pump speed. Increase line sizes.
Heat fluid, insulate lines or heat trace lines.
Increase line sizes.
Insulate lines or heat trace lines.
Install a "soft start" drive.
Install a recirculating bypass system.
Flush system with a nonsetting fluid.
Replace the pump with more running clearances.
Larger pumps at slower speeds.
Reduce speeds and pressures by making changes in the system.
Replace pump with a larger model with higher pressure ratings.
Check and replace bearing and gears as necessary. Adjust lubrications schedule to decrease time between lubrication.
Modify external wash down method to reduce water entering into gear case.
Check alignment of piping and drive. Adjust as necessary.
Contact: Dixon Sanitary 800-789-1718
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BOMs
Rotary Lobe Pumps - JRZA AccuLAB Series 800.789.1718
35
36
4.3
4.4
4.5
4.6
4.7
4.8
3.1
3.2
3.3
3.4
3.5
4.1
4.2
4.9
4.10
4.11
4.12
4.13
4.14
5.1
1.7
2.1
2.2
2.3
2.4
2.5
Item No.
1.1
1.2
1.3
1.4
1.5
1.6
Description
Rotor
Casing
Front Cover
Rear Cover
Bracket
Bearing Cover
Bearing Spacer
Bearing Cover Bolt
Rear Cover Bolt
Bracket Bolt
Front Cover Bolt
Bearing Cover Ass’y Pin
Drive Shaft
Helical Gear
Lock Nut/ Washer
Shaft Bearing
Rotor Bolt
Rotary Seal Ring L-cub
Rotating Seal Ring
Stationary Seal Ring
Wave Spring
Case O-ring
Rotor O-ring
Seal Body
Quad Ring for flushing
O-ring for flushing
Quad Ring for bearing
Rear Cover Quad-ring
Rear Cover O-ring
Rotor Bolt O-ring
Front Cover O-ring
Seal Stopper/Seal flush port
Bill of Materials
SUS304
S45C
S45C
32004XJ
SUS316
EPDM
TC or SiC
TC or SiC
SUS304
EPDM
EPDM
SUS304
EPDM
Materials
SUS316
SUS316
SUS316
SUS304
SUS316
SUS316
SUS304
SUS304
SUS304
SUS304
SUS304
SUS304
EPDM
EPDM
EPDM
EPDM
EPDM
EPDM
SUS304
Size
M6 x15
M6 x 50
M6 x 15
M6 x 15
Ø5 x 11.5
M20 x 1
AN210
AN210
AN210
AN114
AN042
AN019
AN235
M6 x 23
2
2
2
2
2
2
2
2
4
2
2
2
2
Qty per Pump
2
1
1
1
1
1
4
4
2
2
2
2
1
2
1
2
2
1
2
800.789.1718
Rotary Lobe Pumps - JRZA AccuLAB Series
Certificates
Rotary Lobe Pumps - JRZA AccuLAB Series 800.789.1718
37
Certificates
38 800.789.1718
Rotary Lobe Pumps - JRZA AccuLAB Series
Limited Warranty
DIXON VALVE AND COUPLING COMPANY (herein called "Dixon") warrants the products described herein, and manufactured by Dixon to be free from defects in material and workmanship for a period of one (1) year from date of shipment by Dixon under normal use and service. It's sole obligation under this warranty being limited to repairing or replacing, as hereinafter provided, at its option any product found to Dixon's satisfaction to be defective upon examination by it, provided that such product shall be returned for inspection to Dixon's factory within three (3) months after discovery of the defect. The repair or replacement of defective products will be made without charge for parts or labor. This warranty shall not apply to: (a) parts or products not manufactured by Dixon, the warranty of such items being limited to the actual warranty extended to Dixon by its supplier; (b) any product that has been subject to abuse, negligence, accident, or misapplication; (c) any product altered or repaired by others than Dixon; and (d) to normal maintenance services and the replacement of service items (such as washers, gaskets and lubricants) made in connection with such services. To the extent permitted by law, this limited warranty shall extend only to the buyer and any other person reasonably expected to use or consume the goods who is injured in person by any breach of the warranty. No action may be brought against Dixon for an alleged breach of warranty unless such action is instituted within one (1) year from the date the cause of action accrues. This limited warranty shall be construed and enforced to the fullest extent allowable by applicable law.
Other than the obligation of Dixon set forth herein, Dixon disclaims all warranties, express or implied, including but not limited to any implied warranties of merchantability or fitness for a particular purpose, and any other obligation or liability.
The foregoing constitutes Dixon's sole obligation with respect to damages, whether direct, incidental or consequential, resulting from the use or performance of the product.
Some products and sizes may be discontinued when stock is depleted, or may require a minimum quantity for ordering.
NOTE: Reasonable care has been taken in preparing this catalog. Dixon Sanitary, a division of Dixon Valve & Coupling Company, reserves the right to make corrections and any dimensional changes.
Rotary Lobe Pumps - JRZA AccuLAB Series 800.789.1718
39
Dixon ® , founded in 1916, is a premier manufacturer and supplier of hose couplings, valves, dry-disconnects, swivels, and other fluid transfer and control products. The company’s global reach includes a wide range of products for numerous industries including petroleum exploration, refining, transportation, chemical processing, food & beverage, steel, fire protection, construction, mining and manufacturing.
Dixon ® ’s strategic objective is to create solutions that make products safer, leak-free, longer lasting, and always available. dixonvalve.com •
Customer Service:
800.789.1718
®
Dixon Sanitary
N25 W23040 Paul Road • Pewaukee, WI 53072
Customer Service: 800.789.1718
Fax: 800.789.4046
Dixon
Customer Service
© 2017 DVCC Rotary Lobe Pumps - JRZA AccuLAB Series
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