ZJ系列安装使用说明书.docx

1、ZJ系列安装使用说明书CONTENTSUSES AND SCOPE OF APPLICATION (1PATTERN、STRUCTURAL FEATURE OF PUMPS (1SLING、INSTALLATION、ADJUSTMENT AND TEST RUN OF PUMPS (6COMMON FAILURE AND HANDING MEASURE (22MAINTENANCE AND DISMOUNTING OF PUMPS (28LIST OF QUICK-WEAR PARTS (36VII LIST OF SPECIAL TOOLS (38ATTENTION1. The direct

2、ion of motor 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 i

3、nstalled.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 forbid

4、den to operate 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

5、 should 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

6、 pump. They 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 an

7、d so on. 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, flu

8、shing ash 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 tw

9、o categories, 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.1.ZJ Structural feature and type of ZJ slurry pumps(1ZJ Pump Structure FeaturePump Hea

10、dIt 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, con

11、necting 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,

12、”O”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.1Expeller shaft seal is made of stuffing box, expeller, lantern ring, packing, packing gland an

13、d shaft sleeve, see fig.1 5Packing 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, glandand shaft sleeve, see fig1 5b.SupportThe horizontal split-case has o

14、il 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 bracket

15、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.。(1ZJ type Model and Meaning200 ZJ I A 60Impeller Dia.,cmThe No.of impeller vane ,A is 5、B is 4、C is 3、F is 6、G is7、H is

16、 8.The Pump Stage,as first stage,as second stage;ZJ type slurry pumpPump Outlet Dia.,mm2.ZJL Pump Structure Characteristics and Model(1ZJL Pump Structure CharacteristicsZJL type slurry pump is mainly composed of the impeller and volute, back plate, shaft sleeve, support, support plate, shaft, bearin

17、g, 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 ZJL pump adopt g

18、rease lubrication.This series of pump is no shaft seal.ZJL type pump structure as shown in figure 2.ZJL type Model and Meaning80 ZJL 36Impeller Dia.,cm;ZJL,Vertical Slurry PumpPump Outlet Dia.,mm SLING、INSTALLATION、ADJUSTMENT AND TEST RUN OF PUMPS1.SlingWhen slinging a packed pump, we operate in acc

19、ordance 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 horizontal pump without b

20、ase 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 screw. The lifting screw

21、s 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 near couplings. Wire rope

22、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 apparatus, should be lift

23、 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 installationThe pumps have been inspected and

24、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 certificate of pump is compl

25、ete. 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 technicalrequirements.(2 Installation and capturing of pumpThe horizontal pump units should be equipped by

26、 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 couplings when pumps are drove

27、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 interval between coupling to gua

28、rantee 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 coupling. The pulsation of centigrad

29、e 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, (bThe shaft of pump and the motor should assured the parallelism when pumps are drove by belts, so we adjust directi

30、on 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 (cFigure 3 Capturing of coupling Figure 4 Capturing of belt wheels(3 Confi

31、guration and requirement of discharge pipeline and suction pipelineAccording 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. Figure 5 Arrangement of suction pipeline and

32、discharge pipelineSuction 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 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 pipe