ZJ系列安装使用说明书

1、CONTENTS USES AND SCOPE OF APPLICATION 1 PATTERN、STRUCTURAL FEATURE OF PUMPS 1 SLING、INSTALLATION、ADJUSTMENT AND TEST RUN OF PUMPS 6 COMMON FAILURE AND HANDING MEASURE 22 MAINTENANCE AND DISMOUNTING OF PUMPS 28 LIST OF QUICK-WEAR PARTS 36VII LIST OF SPECIAL TOOLS 38ATTENTION1. The direction of motor

2、 must keep consistent with arrow on the Front casing. Before testing running the motor, the motor must be separated from pump. The shafts of Motor and pump are strictly forbidden to rotate reversely; otherwise some parts will be damaged. 2. Before operating the pump, the packing must be installed.3.

3、Adopt mechanical seal of pump, must ensure that the shaft seal water supplies, it is strictly prohibited without running water, or mechanical seal will be damaged.4. Before operation we must add oil (N32 summer or N46 winter) according to the oil level of oil gauge. Pump is strictly forbidden to ope

4、rate without lube; otherwise bearings will be burned out. 5. When Install the coupling or pulley, must first into the pump coupling or pulley and then load the mechanical seal to protect the mechanical seal from the impact damage, 6. When equipping the belt wheel of motor, the shaft of motor should

5、manufactured in according to drawings if the shaft diameter is higher than 65mm so that the belt wheel operating safely.7. Please read this technical manual carefully before installation and operation. USES AND SCOPE OF APPLICATIONType ZJ series Slurry Pump is a new energy-saving centrifugal pump. T

6、hey are innovative in hydraulic designs, structural designs and materials of castings after integrating con-generic products throughout the world. They have many features: high efficiency, reasonable design, reliable operation, long in service time, easy maintenance, and low running costs and so on.

7、 The ZJ series pumps lead their domestic counterparts in various technical performances, with most of them approaching the advanced world level, and widely used for handling abrasive or corrosive slurries in power, metallurgical, mining, coal, as well as chemical industries. For example, flushing as

8、h in power plants and pumping coal slurry in coal preparation plants. They are suitable for handling abrasive and corrosive solids-bearing slurry with maximum concentrations of wt.45%(ash) and wt.60%(ore). PATTERN、STRUCTURAL FEATURE OF PUMPS The Type of ZJ series slurry pump is divided into two cate

9、gories, one type is ZJ , as single-stage single-suction horizontal axial suction centrifugal slurry pump; Another type is ZJL, as single-stage single-suction vertical axial inhalation centrifugal slurry pump. 1ZJ Structural feature and type of ZJ slurry pumps（1）ZJ Pump Structure Feature Pump Head It

10、 is a horizontal cantilevered slurry double-cases pump. The pump head includes cases, impeller, and shaft seal. Double-cases pump centrally split vertical split direction. Discharge port can be positioned at 8 different position at an interval of 45.The outside cases made by HT200 or HT500-7, connec

11、ting with bolts. The inside cases (volute case, front liner, back liner) made by high-chrome alloy or rubber materials.Impeller front and back cover plates with back vanes to reduce leakage and increase operating life, impeller and shaft is firmly connected by ladder-shaped with disassembly ring, ”O

12、” rubber ring is used between liner and volute casing and it is very convenient and reliable.There are three kinds of shaft seal type, expeller shaft seal, packing shaft seal and mechanical seal, see fig.1 Expeller shaft seal is made of stuffing box, expeller, lantern ring, packing, packing gland an

13、d shaft sleeve, see fig.1 5 Packing shaft seal is made of stuffing box, spacer sleeves,lantern ring, packing, packing gland and shaft sleeve, see fig.15a。 Mechanical seal is made of stuffing box, spacer sleeves, mechanical seal, gland and shaft sleeve, see fig1 5b. SupportThe horizontal split-case h

14、as oil lubrication and grease lubrication. Oil lubrication is mainly composed of the bracket body, the bracket cover, shaft, bearing box, bearing, bearing gland, spacer sleeve, nuts, oil seal, water retaining plate, stripping ring parts, see fig 1. The main difference between grease lubrication brac

15、ket and oil lubrication bracket is that increased the embedded through cover and oil cup, remove the water cooling device, see figure 1 16a. ZJ type pump structure as shown in figure 1.。（1）ZJ type Model and Meaning 200 ZJ I A 60 Impeller Dia.，cm The No.of impeller vane ，A is 5、B is 4、C is 3、 F is 6、

16、G is7、H is 8. The Pump Stage，as first stage，as second stage； ZJ type slurry pump Pump Outlet Dia.，mm 2ZJL Pump Structure Characteristics and Model（1）ZJL Pump Structure CharacteristicsZJL type slurry pump is mainly composed of the impeller and volute, back plate, shaft sleeve, support, support plate,

17、 shaft, bearing, bearing body parts, etc. The material of the impeller volute and back plate is high chrome alloy. The impeller and shaft connected by screw thread, the volute and support, bearing connected by bolted. Pump shaft and motor adopt coupling to direct drive or belt drive. The bearings ZJ

18、L pump adopt grease lubrication.This series of pump is no shaft seal. ZJL type pump structure as shown in figure 2. ZJL type Model and Meaning 80 ZJL 36 Impeller Dia.，cm； ZJL,Vertical Slurry Pump Pump Outlet Dia.，mm SLING、INSTALLATION、ADJUSTMENT AND TEST RUN OF PUMPS 1.SlingWhen slinging a packed pu

19、mp, we operate in accordance with marks on the packing case. The packing case shall avoid vibrating violently, over-inclining, landing on the body with pointed ends and being placed upside down.When slinging an unpacked pump, we operate according as the following requirement.(1) When lifting the hor

20、izontal pump without base or with singly base, the lift gravity is on the side of support square hole that near the pump head. Wire rope pass through this place to join with lift hook. In order to keep the balance of pump, the auxiliary wire rope should be added between inlet pipeline and lifting sc

21、rew. The lifting screws on support cover and casings are assembled to dismount support cover and casings. They cannot be used when lift the whole pump in case of accident.(2) When slinging the horizontal pump with motor and common base, the lift gravity is on the side of support square hole that nea

22、r couplings. Wire rope pass through this place to join with lift hook. In order to keep the balance of pump, the auxiliary wire rope should be installed among inlet pipeline, lifting screws on motor and lift hook.(3) The horizontal pump units with intermediate speed-transformation, such as coupled a

23、pparatus, should be lift separately.(4) Cushion should be added between wire rope and body of pump to prevent damaging appearance of pump and cutting off wire rope.Noted: With mechanical seal of pump installed the Spacer sleeve not expeller.2. Installation(1) Examination before installation The pump

24、s have been inspected and tested before ex-factory. Pumps should be set up correctly in order to possess good operating mode. We must check up types of pumps、parameters of pumps and components and parts in accordance with Packing List before installation. We ensure that technical data and quality ce

25、rtificate of pump is complete. Pump can be installed after reading correlation technical data carefully, especially such as THE INSTRUCTIONS OF INSTALLATION AND APPLICATION FOR TYPE ZJ SLURRY PUMPS and mastering related technical requirements.(2) Installation and capturing of pumpThe horizontal pump

26、 units should be equipped by making use of twice grouting. The central line of pumps is consistent with the central line of foundation. The deviation between center-height of pump and design value is smaller than 2 mm vertically and 0.1/1000 horizontally.We assure axis of pump units by adjusting cou

27、plings when pumps are drove by couplings. There are two methods. The first method is the use of knife ruler and plug gauge. We adjust outside diameter of couplings with knife ruler to guarantee alignment in every direction and the max tolerance () less than 0.1 mm See Figure3, (a). We examine the in

28、terval between coupling to guarantee the max tolerance (=1-2) smaller than 0.1mmSee Figure3, (b). The other method is the use of plug gauge and magnetic centigrade scale. We fix magnetic centigrade scale on outside diameter of one coupling and put measuring head on outside diameter of the other coup

29、ling. The pulsation of centigrade scale should be smaller than 0.15mm See Figure3, (c) when turn rotor. We check up the space between couplings with plug gauge to ensure the max tolerance less than 0.1mm See Figure3, (b) The shaft of pump and the motor should assured the parallelism when pumps are d

30、rove by belts, so we adjust direction on the basis of pulley. When central distance is small, we can align end faces of pulley with ruler; when central distance is big, and we can adjust them by aligning end faces through span wire system See Figure, (4). (a) (b) (c) Figure 3 Capturing of coupling F

31、igure 4 Capturing of belt wheels(3) Configuration and requirement of discharge pipeline and suction pipeline According to the applied condition and the cavitation performance of pump, the arrangement of pump can be classified into exalted setting See Figure5, (a) and low setting See Figure5, ( b).Fi

32、gure 5 Arrangement of suction pipeline and discharge pipeline Suction pipelineDiameter of suction pipeline: diameter of suction pipeline should be equal to pump inlet or larger than it so as to avoid cavitation and deposition of slurry in pipeline.Gate valve of suction pipeline: In order to maintain

33、 easily, we should install inlet gate valves whose diameter is equal to the diameter of suction pipeline. The expansion pipe should be set up between inlet of pump and suction pipeline so as to disassemble pump. Discharge pipelineDiameter of discharge pipeline: diameter of discharge pipeline is usua

34、lly bigger than outlet of pump because diameter of discharge pipeline is related to properties of slurries and sedimentation flow rate.Gate valve of discharge pipeline: Diameter of outlet gate valve is equal to diameter of discharge pipeline.Piezometer: The piezometer should be set up on the ascendi

35、ng pipe between outlet of pump and the first valve. Points for configuration of pipelineThe diameter of pipeline is related to system resistance, critical sedimentation velocity of slurry etc. Before inlet of pump, one-stage pipe longer than 3 times diameter of pipeline had better be installed. The

36、velocity of slurry is between 1.5 and 3.0 m/s, which is determined by critical sedimentation velocity of slurry. When we install suction pipe in suction arrangement we adopt pipe of varying diameter whose upper generating line is horizontal to avoid cavitation (See Figure, 6). Figure 6 Reducing pipe

37、 with horizontal upper generating line When we adjust the capacity of pump with throttle, throttle should be installed on the discharge pipeline. When throttle is fixed on suction pipeline, cavity will happen easily.(4) Pipelines of water-sealing and water-coolingPacking seal will be equipped with s

38、tubs and piezometer. We must install pressure gauge on shaft seal water pipeline to adjust the pressure of shaft seal water. The setting of shaft seal water pipeline and water-cooling pipeline are seen Figure7. The Shaft seal water Water-cooling Figure 7 Arrangement of shaft seal water pipelineThe p

39、ressure of shaft seal water should be computed according as the following formula.Table 1 Pressure and Capacity of shaft seal waterSealing TypeThe Pressure of shaft seal water Pi(Mpa)The flow of shaft seal water （m3/h）G1/4”G3/8”G1/2”G3/4”Expeller Seal （stage pump)Pi=0.5P11.51.522335Packing SealPi=(i

40、-1/3)PMechanical SealPi=P出+0.15MPa pump flow 0.1 1%, when the flow is large choose small values, flow is small choose big value , but the minimum shaft seal water quantity not less than 1 m3 / h Note: This Table is suitable to single stage pump. When the suction pressure of pump is 0 (Pin=0), the pr

41、essure of shaft seal water is equal to the half of the pressure of pump exit (P=1/2Pout). The pressure of water-cooling is between 0.050.2MPa, the capacity is between 13 m/h.The type of water-cooling see Table 2.Table 2 Type of Packing, water-sealing and water-cooling No.ModelPacking Specification(m

42、m) ssssSsSSpecificatioSpecificationpecification Specification （mm）(mm)Shaft Seal Pipe JointCooling Water Pipe Joint 1300ZJA1002222636G3/4G1/22300ZJA953300ZJA902222605G3/4G1/24300ZJA855300ZJA701919502G1/2G1/26300ZJA657300ZJA568250ZJA1032222605G3/4G1/29250ZJA9610250ZJA9011250ZJA8512250ZJA8313250ZJA801

43、4250ZJA7815250ZJA751919502G1/2G1/216250ZJA7317250ZJA7018250ZJA6819250ZJA6520250ZJA6321250ZJA6022200ZJA852222605G3/4G1/223200ZJA751919502G1/2G1/224200ZJA7325200ZJA701919455G1/2G1/226200ZJA6827200ZJA6528200ZJA6329200ZJA6030200ZJA5831150ZJA7032150ZJA6533150ZJA6334150ZJA6035150ZJA5836150ZJA5537150ZJC583

44、8150ZJA5739150ZJA501616364G1/2G3/840150ZJA4841150ZJC4242100ZJA5043100ZJA4644100ZJA421313308G1/2G3/845100ZJA3946100ZJGB4247100ZJA36G3/8G1/248100ZJA334980ZJA521616364G1/2G3/85080ZJA421313308G1/25180ZJA395280ZJA361313308G3/85380ZJA335465ZJA301010226G1/45565ZJA275650ZJA501616364G1/2G3/85750ZJA461313308G

45、1/2G3/85850ZJA331010226G1/45940ZJA1788163G1/4(5)Packing selectionpacking material and choose Asbestos packing with mica should be often used when the working pressure of pump is less than 0.5MPa and asbestos packing with ploytetrafluoroethylene should be used when the pressure is more than 0.5 MPa.

46、The type of packing see Table 2.Packing Requirement The packing standard should be accord with stuffing box size, and from the direction of shaft, joints of the adjacent packing rings included 120. (6) Mechanical seal Mechanical seal is a kind of end face seal, zero leakage, low power consumption, e

47、tc.Mechanical seal used in slurry pump special need to pay attention to the following questions:Our factory adopts the mechanical seal is generally balanced double end face for special purpose, equipped with cooling water pipe, pressure gauge.Professional mechanical seal factory made it for our fact

48、ory, and factory has good installation and debugging, the user can no longer for debugging. Mechanical seal parts, import and export of shaft seal water, respectively, among them with the pump outlet in the same side as an outlet, the other side of the inlet. Before use the equipped mechanical seal

49、pump must first turn on the shaft seal water, stop the pump 3 minutes rear can close the shaft seal water. Provide customers with mechanical seal of spare parts, according to a suite. Equipped with mechanical seal of pump and mechanical seal of spare parts when not in use for a long time, mechanical

50、 seal parts should include full N46 # machine oil, to prevent rust and internal rubber parts failure mechanical seal parts.(7) The Requirement of add Lubricating oil Thin oil lubrication carrier should be in according to the oil standard oil line before driving position and N32 by mechanical blendin

51、g (winter) or N46 oil (summer). Avoid by all means is oil-free drive!3. Adjustment of pumpWe examine and adjust pumps after assembly.(1) Adjustment of the interval between impeller and front liner (See Following)(2) Adjustment of rotation direction of motorMotors direction of rotation must be in acc

52、ordance with pumps direction of rotation. When pump operate in opposite direction, some parts will be damaged. After pumps are divorced from motors completely, we can regulate motor direction of rotation. When they are in the same direction, we attach pumps to motors. We must not start motor blindly

53、.(3) Adjustment of transmissionWhen pumps are drove by elastic pin coupling, protective cover and pins should be set up carefully. When pumps are drove by belt, we adjust sliding track so as that every belt has the same pretightening force and install protective cover attentively. When pumps are dro

54、ve by speed controllers, they are adjusted according to installation instructions.(4) All of fasteners must be reinforced again.(5) Put the tools and the lumbers aside to avoid accident, which was set on pump units4. Test run of pumpsPump sets can be tested run after adjustment. If possible, slurry can be transported after test run with clear water.(1) Starting of pump Before starting of pump we must turn the impeller around in the stated direction in order that whether