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Dixon RZL-400, Operating And Maintenance Manual, Page: 7 / 78

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Dixon RZL-400 Operating And Maintenance Manual Download Page 7

7

Rotary Lobe Pumps - RZL-400 Series

800.789.1718

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.

Summary of Contents for RZL-400

Page 1: ...Operating Maintenance Manual for RZL 400 Series Rotary Lobe Pumps Dixon Sanitary N25 W23040 Paul Road Pewaukee WI 53072 ph 800 789 1718 fx 800 789 4046 dixonvalve com...

Page 2: ...Clearance 50 52 Shimming 52 Rotor Timing 53 Gear Box Disassembly 54 Gear Box Assembly 55 Scheduled Maintenance 55 Maximum RPM 56 Maximum Solids 56 Dimensions 57 Troubleshooting 58 60 BOM 61 73 Certif...

Page 3: ...el 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 p...

Page 4: ...g 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 pa...

Page 5: ...l Maximum flushing water pressure 7 PSI 0 5 bar Flushing water consumption 30 60 cubic inches min 0 25 0 5 liter min Stationary seal ring material Tungsten Carbide Rotating seal ring material Tungsten...

Page 6: ...6 Rotary Lobe Pumps RZL 400 Series 800 789 1718 Rotary Lobe Pump Composite Family of Curves...

Page 7: ...er 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 bas...

Page 8: ...Mounting Adjustable Adjustable leg base commonly used for sanitary pumps for wash down under base Can be easily moved or repositioned Mounting Configurations Pump Mounting Casters Portable bases for...

Page 9: ...s 800 789 1718 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 shoul...

Page 10: ...10 Rotary Lobe Pumps RZL 400 Series 800 789 1718 Installation Start Up Proper Installation continued Piping Slope Inlet side slope piping up to inlet to avoid air pocket...

Page 11: ...allation 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...

Page 12: ...ve 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 Prevent...

Page 13: ...n 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 a...

Page 14: ...xcessive 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 dis...

Page 15: ...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 w...

Page 16: ...he 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 coup...

Page 17: ...ump 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 o...

Page 18: ...Lobe Pumps RZL 400 Series 800 789 1718 Maintenance Pump Housing Disassembly Single Mechanical Seal continued 3 Remove the cover O ring 34 2 Remove the cover 32 If it is stuck tap the cover with a sof...

Page 19: ...Housing Disassembly Single Mechanical Seal continued 4 Remove the rotor retaining bolts 35 To remove the rotor retaining bolts place the dowel between the rotors Turn the first rotor bolt counter cloc...

Page 20: ...Remove the rotors 38 from the pump housing 31 by pulling straight 6a If the rotors 38 will not come out freely remove the stud bolt hex nuts 46 and then tap on the back of the inlet and outlet ports...

Page 21: ...21 Rotary Lobe Pumps RZL 400 Series 800 789 1718 Maintenance Pump Housing Disassembly Single Mechanical Seal continued 6a continued...

Page 22: ...Rotary Lobe Pumps RZL 400 Series 800 789 1718 Maintenance Pump Housing Disassembly Single Mechanical Seal continued 7 Remove the seal ring 52 from the back of the rotor 38 8 Remove the rotor O rings...

Page 23: ...23 Rotary Lobe Pumps RZL 400 Series 800 789 1718 Maintenance Pump Housing Disassembly Single Mechanical Seal continued 9 Remove the casing seal rings 52 10 Remove the stud bolt hex nuts 46...

Page 24: ...ps RZL 400 Series 800 789 1718 Maintenance Pump Housing Disassembly Single Mechanical Seal continued 11 Remove the rotor case 31 12 Remove the rotor case O ring 53 This can be done before you remove t...

Page 25: ...400 Series 800 789 1718 Maintenance Pump Housing Disassembly Single Mechanical Seal continued 13 On the back of the rotor case remove the four mechanical seal gland wrench bolts 42 43 14 Remove the s...

Page 26: ...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 flush option Power needs to be locked out to preven...

Page 27: ...Remove the cover O ring 34 4 Remove the rotor retaining bolts 35 To remove the rotor retaining bolts place the dowel between the rotors Turn the first rotor bolt counter clockwise Maintenance Pump Ho...

Page 28: ...L 400 Series 800 789 1718 5 Remove the rotor bolts 35 spring washers 36 and O ring 37 Maintenance Pump Housing Disassembly Double Mechanical Seal continued 6 Remove the rotors 38 from the pump housing...

Page 29: ...Double Mechanical Seal continued 6a If the rotors 38 will not come out freely remove the stud bolt hex nuts 46 and then tap on the back of the inlet and outlet ports with a soft hammer Once the rotors...

Page 30: ...30 Rotary Lobe Pumps RZL 400 Series 800 789 1718 6a continued Maintenance Pump Housing Disassembly Double Mechanical Seal continued 7 Remove the seal ring 52 from the back of the rotor 38...

Page 31: ...31 Rotary Lobe Pumps RZL 400 Series 800 789 1718 Maintenance Pump Housing Disassembly Double Mechanical Seal continued 8 Remove the rotor O rings 51 9 Remove the casing seal rings 52...

Page 32: ...32 Rotary Lobe Pumps RZL 400 Series 800 789 1718 10 Remove the stud bolt hex nuts 46 Maintenance Pump Housing Disassembly Double Mechanical Seal continued 11 Remove the rotor case 31...

Page 33: ...Series 800 789 1718 Maintenance Pump Housing Disassembly Double Mechanical Seal continued 12 Remove the rotor case O ring 53 This can be done before you remove the casing or after 13 Remove seal body...

Page 34: ...34 Rotary Lobe Pumps RZL 400 Series 800 789 1718 Maintenance Pump Housing Disassembly Double Mechanical Seal continued 14 Remove casing O ring 53 15 Remove shaft seal base 63...

Page 35: ...35 Rotary Lobe Pumps RZL 400 Series 800 789 1718 Maintenance Pump Housing Disassembly Double Mechanical Seal continued 16 Remove shaft O ring 64...

Page 36: ...rden crystallize or freeze in the pump it should be thoroughly drained and cleaned immediately after use Same attention applies if there is a seal flush option Power needs to be locked out to prevent...

Page 37: ...Maintenance Pump Housing Disassembly Single O ring Seal continued 3 Remove the cover O ring 34 4 Remove the rotor retaining bolts 35 To remove the rotor retaining bolts place the dowel between the ro...

Page 38: ...RZL 400 Series 800 789 1718 5 Remove the rotor bolts 35 spring washers 36 and O ring 37 Maintenance Pump Housing Disassembly Single O ring Seal continued 6 Remove the rotors 38 from the pump housing 3...

Page 39: ...y Single O ring Seal continued 6a If the rotors 38 will not come out freely remove the stud bolt hex nuts 46 and then tap on the back of the inlet and outlet ports with a soft hammer Once the rotors 3...

Page 40: ...40 Rotary Lobe Pumps RZL 400 Series 800 789 1718 6a continued Maintenance Pump Housing Disassembly Single O ring Seal continued 7 Remove O ring 51 from the rotor...

Page 41: ...1718 Maintenance Pump Housing Disassembly Single O ring Seal continued 8 Remove the rotor case O ring 53 This can be done before you remove the casing or after Note This is easier to do after you remo...

Page 42: ...den crystallize or freeze in the pump it should be thoroughly drained and cleaned immediately after use Same attention applies if there is a seal flush option Power needs to be locked out to prevent u...

Page 43: ...8 3 Remove the cover O ring 34 Maintenance Pump Housing Disassembly Triple Lip Seal continued 4 Remove the rotor retaining bolts 35 To remove the rotor retaining bolts place the dowel between the roto...

Page 44: ...RZL 400 Series 800 789 1718 Maintenance Pump Housing Disassembly Triple Lip Seal continued 5 Remove the rotor bolts 35 spring washers 36 and O ring 37 6 Remove the rotors 38 from the pump housing 31...

Page 45: ...bly Triple Lip Seal continued 6a If the rotors 38 will not come out freely remove the stud bolt hex nuts 46 and then tap on the back of the inlet and outlet ports with a soft hammer Once the rotors 38...

Page 46: ...46 Rotary Lobe Pumps RZL 400 Series 800 789 1718 Maintenance Pump Housing Disassembly Triple Lip Seal continued 6a continued 7 Remove O ring 51 from the rotor...

Page 47: ...47 Rotary Lobe Pumps RZL 400 Series 800 789 1718 Maintenance Pump Housing Disassembly Triple Lip Seal continued 8 Remove lip seal cover 56...

Page 48: ...48 Rotary Lobe Pumps RZL 400 Series 800 789 1718 Maintenance Pump Housing Disassembly Triple Lip Seal continued 9 Remove triple lip seal 55...

Page 49: ...m plate between pump housing and gear box Install the pump housing 31 onto the gear box 1A and secure the four housing set nuts 46 When installing the ceramic shaft sleeve onto the pump shaft align sl...

Page 50: ...RZL 105 0 05 0 002 0 05 0 002 0 07 0 003 0 07 0 003 0 1 0 004 RZL 110 0 05 0 002 0 05 0 002 0 07 0 003 0 07 0 003 0 1 0 004 RZL 115 0 15 0 006 0 15 0 006 0 27 0 011 0 12 0 005 0 15 0 006 RZL 120 0 15...

Page 51: ...de 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 45 2 Check that the rotor housing 31...

Page 52: ...Lobe Pumps RZL 400 Series 800 789 1718 Maintenance Rotor Clearance continued 4 If incorrect adjust by adding or removing shim plates 45 from behind the pump housing 5 Check each rotor and adjust as n...

Page 53: ...relative location of the two helical gears 14 on the shafts Gear spacers 16 are used to adjust the location and the timing When adjusting timing move only one of the two gears 5 Place the wooden dowel...

Page 54: ...tors 38 on the drive 8 and idle 9 shafts Lock the rotor with a plastic dowel Remove the lock nut 12 1 and lock nut washer from the drive shaft 8 and idle shaft 9 7 Pull the two helical gears 14 off th...

Page 55: ...t and the face of the lock washer with oil 11 Position both shaft gear keys 7 to the 12 00 position 12 Place the gear lock washer 12 and lock nut 12 1 onto the shafts and hand tighten 13 After the gea...

Page 56: ...ted and estimated within the ideal operational condition 2 Pressure solid particle operation hour and other operational conditions effect on this maximum rpm 3 High RPM is not recommended for pump dur...

Page 57: ...14 13 RZL 340 19 69 9 53 13 54 15 83 6 06 6 30 9 53 3 47 22 2 76 9 59 5 06 7 32 45 57 14 13 RZL 440 24 41 12 76 18 03 19 88 7 80 8 27 12 60 3 94 30 3 15 12 76 6 69 9 72 55 67 14 15 RZL 450 25 79 12 76...

Page 58: ...valves Filling inlet lines with material before startup may solve startup priming problems due to no material in system Air lock caused by fluids which gas off or vaporize or allow gas to come out of...

Page 59: ...ailable Noisy Operation Cavitation High fluid viscosity High vapor pressure fluid High temperature Slow down pump reduce temperature change system setup NPSHA less than NPSHR Increase NPSHA or decreas...

Page 60: ...ss system Flush system with a nonsetting fluid Fluid builds up on pump surfaces Replace the pump with more running clearances Short Pump Service Life Pumping abrasives Larger pumps at slower speeds Sp...

Page 61: ...61 Rotary Lobe Pumps RZL 400 Series 800 789 1718 Parts List for RZL 400 Series Pumps Basic Assembly Single M Seal...

Page 62: ...1 1 12 1 RZL 440B TGWSHD Lock Washer drive shaft S45C RZL400 1 2 12 2 RZL 440B TGNUTD Lock Nut drive shaft S45C 1 2 12 3 RZL 440B TGWSHI Lock Washer idle shaft S45C 1 2 12 4 RZ 440B TGNUTI Lock Nut i...

Page 63: ...Rotor Bolt AN228 NBR 1 2 RZL 440B RBORE O ring Rotor Bolt AN228 EPDM 1 2 RZL 440B RBORV O ring Rotor Bolt AN228 FKM 1 2 RZL 440B RBORP O ring Rotor Bolt AN228 Perfluoro 1 2 38 See page 64 Seal Pin Rot...

Page 64: ...r Case 5 SMS SUS316L 1 1 RZL 450 RCCLMP Rotor Case 5 TRICLAMP 5 TRICLAMP SUS316L 1 1 RZL 450 RCFLNG Rotor Case 5 FLANGE SUS316L 1 1 38 RZL 440 SWA Rotor Single Wing SUS316L RZL440 1 2 RZL 440 BWA Roto...

Page 65: ...440B MSGWB Wrench Bolt M Seal Gland M6x10L SUS304 RZL400 2 4 51 RZL 440B RTORB O ring Rotor AN151 NBR 1 2 RZL 440B RTORE O ring Rotor AN151 EPDM 1 2 RZL 440B RTORV O ring Rotor AN151 FKM 1 2 RZL 440B...

Page 66: ...NBR 1 2 RZL 440B RTORE O ring Rotor AN151 EPDM 1 2 RZL 440B RTORV O ring Rotor AN151 FKM 1 2 RZL 440B RTORP O ring Rotor AN151 Perfluoro 1 2 52 RZL 440B TCSEAL Seal Ring TC 2 4 RZL 440B SCSEAL Seal R...

Page 67: ...1 2 RZL 440B RCORV O ring Rotor Case AN234 FKM 1 2 RZL 440B RCORP O ring Rotor Case AN234 Perfluoro 1 2 61 RZL 440B CDSBTC Double Seal Body Case TC SUS304 1 2 RZL 440B CDSBSC Double Seal Body Case SiC...

Page 68: ...ir Kit FKM 1 2 51 RZL 440B RTORB O ring Rotor AN151 NBR RZL400 1 2 RZL 440B RTORE O ring Rotor AN151 EPDM 1 2 RZL 440B RTORV O ring Rotor AN151 FKM 1 2 RZL 440B RTORP O ring Rotor AN151 Perfluoro 1 2...

Page 69: ...Rotor AN151 EPDM 1 2 RZL 440B RTORV O ring Rotor AN151 FKM 1 2 RZL 440B RTORP O ring Rotor AN151 Perfluoro 1 2 53 RZL 440B RCORB O ring Rotor Case AN234 NBR 1 2 RZL 440B RCORE O ring Rotor Case AN234...

Page 70: ...AN234 NBR RZL400 1 2 RZL 440B RCORE O ring Rotor Case AN234 EPDM 1 2 RZL 440B RCORV O ring Rotor Case AN234 FKM 1 2 RZL 440B RCORP O ring Rotor Case AN234 Perfluoro 1 2 54 RZL 440B CSSB Seal Base Sin...

Page 71: ...1 1 RZL 440B OR1V O ring 1 stage plate AN252 FKM 1 1 RZL 440B OR1P O ring 1 stage plate AN252 Perfluoro 1 1 93 RZL 440B OR2B O ring 2 stage plate AN249 NBR 1 1 RZL 440B OR2E O ring 2 stage plate AN24...

Page 72: ...antity Per Assembly Per Pump 111 RZL 440B FCJ Front Cover Jacket SUS316 RZL400 1 1 112 RZL 440 CTJ Jacket Case Top SUS304 RZL440 1 1 RZL 440 CBJ Jacket Case Bottom SUS304 1 1 RZL 450 CTJ Jacket Case T...

Page 73: ...tor Case RECT 5 ISOMALE SUS316L 1 1 RZL 440B RRJT Rotor Case RECT 5 RJT SUS316L 1 1 RZL 440B RSMS Rotor Case RECT 5 SMS SUS316L 1 1 RZL 440 RCRI2C Rotor Case RECT 5 Tri clamp SUS316L 1 1 RZL 440B RFLG...

Page 74: ...74 Rotary Lobe Pumps RZL 400 Series 800 789 1718 Certificates...

Page 75: ...75 Rotary Lobe Pumps RZL 400 Series 800 789 1718 Certificates...

Page 76: ...to normal maintenance services and the replacement of service items such as gaskets and seats made in connection with such services To the extent permitted by State law this limited warranty shall ext...

Page 77: ...77 Rotary Lobe Pumps RZL 400 Series 800 789 1718 Notes...

Page 78: ...rer 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 inc...

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