DVZ-SERVICES GmbH
Boschstrasse 9 • D-28857 Syke
Germany
Phone: +49 4242 169 38-0
Fax: +49 4242 169 38-99
E-Mail: info@dvz-services.de
www.dvz-group.de
INSTRUCTION MANUAL
FOR
BIOLOGICAL SEWAGE TREATMENT PLANT
DVZ-JZR-50 "BIOMASTER"®
Order:
Astinave
Hull-No.:
PGO ISLA SAN SALVADOR
Order-No.:
REGNE-ASTEP-081-21
Project-No.:
995021
Issue: 08.02.2017
Kläranlage-JZR
Operating Manual
DVZ-JZR-„BIOMASTER®“
Document No. JZRY01001_EN
Volume I/I / Rev.01_20200527
Subject to technical modification without notice
Responsible for the content:
DVZ-SERVICES GmbH
Boschstraße 9
D-28857 Syke
Germany
FON +49 (0) 4242 16 93 8 0
FAX +49 (0) 4242 16 93 8 99
WEB www.dvz-services.de
MAIL info@dvz-services.de
JZR-„BIOMASTER®“
Manual de instrucciones
Tabla de contenidos
I/I
TOC
2
MAY 20
Tabla
de contenidos ........................................................................................................................... 2
Parte A
Introducción, información general ........................................................................................... 1-12
Parte B
Almacenamiento, transporte, instalación ................................................................................. 1-21
Parte C
Puesta en marcha, operación (MECH) .................................................................................... 1-23
Parte D
Puesta en marcha, operación (ELEC) ..................................................................................... 1-29
Mantenimiento de la Parte E
.........................................................................................................................................1-123
OM_2020051900_DVZ-JZR-BIOMASTER-JZRY01001_EN - Subject to technical modification without notice
DVZ-SERVICES GmbH | Boschstraße 9 | D-28857 Syke | Germany | FON +49 (0) 4242 16 93 8 0 | FAX +49 (0) 4242 16 93 8 99 | WEB www.dvz-services.de | MAIL info@dvz-services.de
JZR-„BIOMASTER®“
A-TOC
1.
Manual de instrucciones
Parte A: Introducción, información
general Tabla de contenidos
I/I
A-TOC
1
MAY 20
Tabla de contenidos ................................................................................................................... 1
Introducción, información general ........................................................................................................... 3
A-1.1
Prefacio ................................................................................................................................... 3
A-1.2
Notas de peligro y seguridad, notas generales, definiciones ............................................................ 3
A-1.3
Sistema de indexación y paginación ............................................................................................. 4
A-1.4
Cambiar sistema ...................................................................................................................... 4
A-1.5
Contenido y estructura volumen I/I ............................................................................................... 5
A-1.6
Abreviaturas e iniciales ............................................................................................................... 6
2.
Índice de cambios I/I ............................................................................................................................. 7
3.
Índice preliminar de cambios I/I .............................................................................................................. 9
4.
Lista de páginas válidas .................................................................................................................... 11
OM_2020051900_DVZ-JZR-BIOMASTER-JZRY01001_EN - Subject to technical modification without notice
DVZ-SERVICES GmbH | Boschstraße 9 | D-28857 Syke | Germany | FON +49 (0) 4242 16 93 8 0 | FAX +49 (0) 4242 16 93 8 99 | WEB www.dvz-services.de | MAIL info@dvz-services.de
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JZR-„BIOMASTER®“
1.
Operating Manual
Part A: Introduction, general information
Introduction, general information
I/I
A-1
3
MAY 20
Introducción, información
general A-1.1 Prefacio
Este manual de instrucciones es parte del producto. Con este manual de operación, usted, como
cliente, operador de la planta de tratamiento de aguas residuales y como instalador u
operador de la planta de tratamiento de aguas residuales designado e instruido por la
empresa operadora, recibe toda la información necesaria para el funcionamiento seguro de la
planta de tratamiento de aguas residuales. Por favor, lea atentamente la parte A para poder utilizar
la información ofrecida en el manual de instrucciones de forma óptima. Después de eso, lea
atentamente todas las partes de este manual de operación. El propósito de este manual de
operación es:
1.
Explicar la función de la planta de tratamiento de aguas residuales
2.
indicar los datos técnicos y los límites de funcionamiento
3.
Ofrecer notas de peligro y notas de seguridad
4.
proporcionar toda la información necesaria para el manejo de la planta de
tratamiento de aguas residuales;
Este manual de instrucciones está destinado exclusivamente a personal especializado cualificado.
El personal especializado cualificado es una persona que tiene una cualificación que refleja su
actividad, por ejemplo:
A-1.2
1. Capacitación o instrucción como trabajador calificado en las áreas de tecnología de
motores de barcos, sistemas eléctricos a bordo o tratamiento de aguas residuales para
buques de navegación marítima e instalaciones en alta mar.
2. Capacitación o instrucción con respecto al uso de equipos de protección personal de
acuerdo con las reglas reconocidas de ingeniería de seguridad.
3. Formación e instrucción en materia de protección del trabajo y de la salud, así como en
relación con el Reglamento de Prevención de Accidentes y el Reglamento de Prevención de
Accidentes para las Empresas de la Navegación Marítima.
4. Formación e instrucción con respecto al Código Internacional de Gestión de la Seguridad
Operacional de la OMI (código IGS ).
Notas de peligro y seguridad, notas generales, definiciones
En todos los lugares donde los textos del manual de instrucciones estén marcados con pictogramas
y las palabras de advertencia "Peligro", "Precaución" o "Nota", estos tienen los siguientes
significados.
Danger - general danger
Danger - danger due to electrical current
Danger - danger due to biomass (bacteria, viruses, fungi)
Danger - danger due to explosive atmosphere (methane gas)
Danger - danger due to circumstances which could cause hand injury
Caution - prohibitions, requirements, warnings with respect to damage or destruction
Note - general notes, useful hints for the entire product life cycle
OM_2020051900_DVZ-JZR-BIOMASTER-JZRY01001_EN - Subject to technical modification without notice
DVZ-SERVICES GmbH | Boschstraße 9 | D-28857 Syke | Germany | FON +49 (0) 4242 16 93 8 0 | FAX +49 (0) 4242 16 93 8 99 | WEB www.dvz-services.de | MAIL info@dvz-services.de
JZR-„BIOMASTER®“
Operating Manual
Part A: Introduction, general information
Introduction, general information
A-1
Introduction, general information (continued)
A-1.3
Sistema de indexación y paginación
I/I
A-1
4
MAY 20
El manual de instrucciones se divide en las partes A (Alfa) a J (Julieta). Cada parte se divide
en capítulos, cada capítulo se divide en secciones y subsecciones. Esta estructura permite
modificaciones más pequeñas cuando sea necesario sin necesidad de reemplazar todo el
capítulo o el manual de operación por completo.
Las páginas del manual de instrucciones tienen un encabezado que muestra el tipo de planta, el
número de fábrica de la planta de tratamiento de aguas residuales, el contenido, el volumen, el
índice, el número de página, la fecha de emisión y la fecha de cambio (en la medida en que sea
necesario).
Si es necesario, el manual de instrucciones se divide en varios volúmenes. I/I - volumen I en un volumen, I/II
- volumen I de dos volúmenes, II/II - volumen II de dos volúmenes
El índice se compone de partes, capítulos, secciones y
subsecciones. Ejemplo: C-TOC - parte C, tabla de contenido
(designación abreviada: TOC) Ejemplo: C-1.3.5 - parte C, capítulo
1, sección 3, subsección 5.
Algunas partes del manual de instrucciones se separan en una parte mecánica (designación
abreviada: MECH) y una parte eléctrica (designación abreviada: ELEC).
Ejemplo: Parte C: Puesta en marcha, operación (MECH)
Los cambios en los documentos se marcan en cada página. La fecha exacta del cambio se
documenta en el índice de revisión A-2 o en el índice de revisión preliminar A-3.
Ejemplo: REV 01 - cambio 1 de 99 cambios posibles.
Plant type
Factory number (optional)
Contents
Volume Index Page number
Year and moth of issue
Change, change index
Empty pages are not numbered. Empty pages will be marked with the text “This page has been
left blank intentionally.” This means that empty pages will be integrated into the operating manual
without giving the impression of a misprint.
A-1.4
Change system
Changes to this operating manual will be issued as considered necessary. Changed parts of this
operating manual will be provided to you as a customer and/or operating company, either as a printout or electronically. If you are not also the operating company of the wastewater treatment plant,
you must inform the operating company of the wastewater treatment plant of the changes.
|
|
Changes to the chapters, parts, sections and subsections are marked with a vertical black line.
Example: This line has been marked as a change at the left side of this page.
This change is further documented in the change index A-2.
(continued)
OM_2020051900_DVZ-JZR-BIOMASTER-JZRY01001_EN - Subject to technical modification without notice
DVZ-SERVICES GmbH | Boschstraße 9 | D-28857 Syke | Germany | FON +49 (0) 4242 16 93 8 0 | FAX +49 (0) 4242 16 93 8 99 | WEB www.dvz-services.de | MAIL info@dvz-services.de
JZR-„BIOMASTER®“
Operating Manual
Part A: Introduction, general information
Introduction, general information
A-1
Introduction, general information (continued)
A-1.4
Change system (continued)
I/I
A-1
5
MAY 20
Changes will not be marked with a vertical line if entire parts and chapters have been changed. As a
customer and/or the operating company of the wastewater treatment plant you additionally have the
possibility of documenting changes in the preliminary change index A-3 by hand at the request of
the manufacturer. Your handwritten entry is valid until the operating manual is amended by the
manufacturer. As a customer or operating entity you must insert the changed pages provided by the
manufacturer into the operating manual immediately.
After having inserted the changed pages you must delete (cross out) the hand-written entries in the
preliminary change index.
A-1.5
Contents and structure volume I/I
Part A Introduction, general information
This part explains how the operating manual is structured and how the change system is organised.
It explains how graphic symbols and signal words are used to warn you about hazards which might
cause death, severe injuries or diseases. It explains how graphic symbols and signal words are used
to warn you against actions which might result in the destruction of or damage to the wastewater
treatment plant, or in an impairment of the functioning of the wastewater treatment plant. It explains
the graphic symbol for useful hints.
Part B: Storage, transport, installation
This part explains how the wastewater treatment plant must be handled during transport. It explains
how the wastewater treatment plant must be stored. It provides advice about the environmental
conditions at the installation site and the required connections. You will receive instructions for
correct installation so that the wastewater treatment plant can be commissioned safely. This part
also provides a note with respect to the intended use of the wastewater treatment plant.
Part C: Commissioning, operation (MECH)
This part explains how to perform a safe commissioning of the mechanical components of the waste
water treatment plant. It includes information about the safe operation of the mechanical
components. It also includes a note with respect to the intended use of the wastewater treatment
plant. The commissioning of the mechanical components is always performed along with the
commissioning of the electrical components (part D).
Part D: Commissioning, operation (ELEC)
This part explains how to perform a safe commissioning of the electrical components of the wastewater treatment plant. It includes information about the safe operation of the electrical components.
It also includes a note with respect to the intended use of the wastewater treatment plant. The
commissioning of the electrical components is always performed along with the commissioning of
the mechanical components (Part C).
Part E: Maintenance
This part explains what should be maintained regularly at the wastewater treatment plant. It
includes information about the different pumps and blowers and how to dissemble and remount
them.
(continued)
OM_2020051900_DVZ-JZR-BIOMASTER-JZRY01001_EN - Subject to technical modification without notice
DVZ-SERVICES GmbH | Boschstraße 9 | D-28857 Syke | Germany | FON +49 (0) 4242 16 93 8 0 | FAX +49 (0) 4242 16 93 8 99 | WEB www.dvz-services.de | MAIL info@dvz-services.de
Operating Manual
JZR-„BIOMASTER®“
Part A: Introduction, general information
Introduction, general information
A-1
Introduction, general information (continued)
A-1.5
Contents and structure volume I/I (continued)
I/I
A-1
6
MAY 20
Part A to part J: Appendix APX
The appendix (short designation: APX) includes additional documents; it will be added as necessary.
A-1.6
Abbreviations and initials
JAN
January
AUG
August
REV
Revision
FEB
February
SEP
September
APX
Appendix
MAR
March
OCT
October
VOL
APR
April
NOV
November
MECH
Volume
Mechanical
MAY
May
DEC
December
ELEC
Electrical
OM
Operating Manual
DE
German
TOC
Table of contents
EN
English
JUN
JUL
June
July
OM_2020051900_DVZ-JZR-BIOMASTER-JZRY01001_EN - Subject to technical modification without notice
DVZ-SERVICES GmbH | Boschstraße 9 | D-28857 Syke | Germany | FON +49 (0) 4242 16 93 8 0 | FAX +49 (0) 4242 16 93 8 99 | WEB www.dvz-services.de | MAIL info@dvz-services.de
JZR-„BIOMASTER®“
A-2
Operating Manual
Part A: Introduction, general information
Change index I/I
I/I
A-2
7
MAY 20
Change index I/I
The change index includes the following information:
Consecutive number and date of the change, name of the person who entered the changes and the
date of the insertion of the change.
Nr.
Change date
Inserted on / by
Nr.
1
41
2
42
3
43
4
44
5
45
6
46
7
47
8
48
9
49
10
50
11
51
12
52
13
53
14
54
15
55
16
56
17
57
18
58
19
59
20
60
21
61
22
62
23
63
24
64
25
65
26
66
27
67
28
68
29
69
30
70
31
71
32
72
33
73
34
74
35
75
36
76
37
77
38
78
39
79
40
80
Change date
Inserted on / by
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DVZ-SERVICES GmbH | Boschstraße 9 | D-28857 Syke | Germany | FON +49 (0) 4242 16 93 8 0 | FAX +49 (0) 4242 16 93 8 99 | WEB www.dvz-services.de | MAIL info@dvz-services.de
This page has been left blank intentionally.
JZR-„BIOMASTER®“
A-3
Operating Manual
Part A: Introduction, general information
Preliminary Change Index I/I
I/I
A-3
9
MAY 20
Preliminary Change Index I/I
The Preliminary Change Index includes the following information:
Consecutive number and date of the change, page and index, name of the person who entered the
changes and the date of the insertion of the change.
Nr.
Date
Page / index
Inserted on / by
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
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DVZ-SERVICES GmbH | Boschstraße 9 | D-28857 Syke | Germany | FON +49 (0) 4242 16 93 8 0 | FAX +49 (0) 4242 16 93 8 99 | WEB www.dvz-services.de | MAIL info@dvz-services.de
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JZR-„BIOMASTER®“
A-4
Operating Manual
Part A: Introduction, general information
List of valid pages
I/I
A-4
11
MAY 20
List of valid pages
Page / index
Date / change
Page / index
Date / change
Page / index
Date / change
1 / A-TOC
MAY 20
12 / C-1
MAY 20
3 / E-TOC
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13 / C-2
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4 / E-TOC
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3 / A-1
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DVZ-SERVICES GmbH | Boschstraße 9 | D-28857 Syke | Germany | FON +49 (0) 4242 16 93 8 0 | FAX +49 (0) 4242 16 93 8 99 | WEB www.dvz-services.de | MAIL info@dvz-services.de
JZR-„BIOMASTER®“
A-4
Operating Manual
Part A: Introduction, general information
List of valid pages
I/I
A-4
12
MAY 20
List of valid pages (continued)
Page / index
Date / change
Page / index
Date / change
48 / E-2
MAY 20
94 / E-2
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49 / E-2
MAY 20
95 / E-2
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50 / E-2
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Page / index
Date / change
OM_2020051900_DVZ-JZR-BIOMASTER-JZRY01001_EN - Subject to technical modification without notice
DVZ-SERVICES GmbH | Boschstraße 9 | D-28857 Syke | Germany | FON +49 (0) 4242 16 93 8 0 | FAX +49 (0) 4242 16 93 8 99 | WEB www.dvz-services.de | MAIL info@dvz-services.de
JZR-„BIOMASTER®“
Operating Manual
Part B: Storage, transport, installation
Table of contents
I/I
B-TOC
1
MAY 20
B-TOC
Table of contents ....................................................................................................................... 1
B-1
Important notes ........................................................................................................................3
B-1.1
Intended use ............................................................................................................................3
B-1.2
Safety note ............................................................................................................................... 3
B-1.3
Caution ................................................................................................................................... 3
B-1.4
Note ........................................................................................................................................3
B-1.5
Caution ................................................................................................................................... 4
B-2
Storage ..................................................................................................................................5
B-2.1
Environment conditions ............................................................................................................5
B-2.2
Secondary packaging...............................................................................................................5
B-3
Transport ...............................................................................................................................7
B-3.1
Wastewater treatment plant with secondary packaging .................................................................7
B-3.2
Wastewater treatment plant without secondary packaging ............................................................7
B-3.3
Note ........................................................................................................................................7
B-4
Installation .............................................................................................................................9
B-4.1
Explanations ........................................................................................................................... 9
B-4.2
System description ...................................................................................................................9
B-4.3
Technical data ........................................................................................................................11
B-4.3.1
Power ...................................................................................................................................11
B-4.3.2
Dimensions and weights ...........................................................................................................11
B-4.3.3
Electric connections ..............................................................................................................12
B-4.3.4
Pneumatic connection ...........................................................................................................12
B-4.3.5
Mechanic connection: Flanges ..................................................................................................13
B-4.3.6
Mechanic connection: Threaded spouts / threaded sleeves2 .......................................................13
B-4.4
Erection of the wastewater treatment plant ................................................................................14
B-4.4.1
Caution ..................................................................................................................................14
B-4.4.2
Note ......................................................................................................................................14
B-4.4.2
Note (continued)....................................................................................................................15
B-4.4.3
Fixing points ..........................................................................................................................15
B-4.4.4
Connection dimensions ...........................................................................................................15
B-4.4.5
Connecting the connections ......................................................................................................15
B-4.5
Glossary ................................................................................................................................16
B-APX1
Assembly drawing documentation..............................................................................................17
B-APX2
R&I flow diagram documentation ...............................................................................................19
B-APX3
Certificate of Type Approval for Sewage Treatment Plants ..........................................................21
OM_2020051900_DVZ-JZR-BIOMASTER-JZRY01001_EN - Subject to technical modification without notice
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JZR-„BIOMASTER “
®
B-1
Important notes
B-1.1
Intended use
Operating Manual
Part B: Storage, transport, installation
Important notes
I/I
B-1
3
MAY 20
The DVZ-JZR “BIOMASTER®” wastewater treatment plant is solely suitable for the biological
cleaning of grey and black water according to IMO MEPC 159 (55) and IMO MEPC 227 (64) on e.g.
seagoing vessels, riverboats, yachts, naval vessels and offshore constructions.
The Equipment conforms to the requirements of “Technical Regulations on the Safety of Sea
Transport Items” (it is approved as the resolution of the Government of the Russian Federation of
August 12, 2010 No. 620). All-Production Classification Code of Products 64 1600. The product is
labelled with conformity mark (RF Government Order No.696 dated 19.11.2003).
B-1.2
The DVZ-JZR “BIOMASTER®” wastewater treatment plant is unsuitable for the treatment of
catering waste as well as wastewater containing acids, lyes and oil, or ballast water.
The wastewater treatment plant must not be operated with sea water, brackish water or
condensate. The rating of the DVZ-JZR “BIOMASTER®” wastewater treatment plant presupposes a
proportion of at least 80 litres of grey water per day and person as an operating condition. A buffer
tank or a wastewater collection tank must be upstream of the DVZ-JZR “BIOMASTER®” wastewater
treatment plant.
Safety note
B-1.3
The wastewater treatment plant may only be stored, transported, assembled, operated,
maintained and disposed of by qualified specialist staff. Qualified specialist staff are persons who
have a qualification reflecting their activity, e.g.:
1. Training or instruction as a skilled worker in the areas of ship engine technology, shipboard
electrical systems or wastewater treatment for vessels and offshore constructions.
2. Training or instruction with respect to the use of personal protection equipment according
to the acknowledged rules of safety engineering.
3. Training and instruction with respect to work and health protection as well as with respect to
the Accident Prevention Regulations and the Accident Prevention Regulations for Enterprises
engaged in Seafaring.
4. Training and instruction according to the IMO International Safety Management Code (ISM
code).
Caution
B-1.4
The wastewater treatment plant has special sling points for transport purposes.
If lifting accessories are fixed to other points than the provided sling points, the wastewater
treatment plant or individual parts of the wastewater treatment plant will be seriously damaged or
become inoperable. The wastewater treatment plant may only be lifted and transported using the
sling points provided for this purpose and with appropriate lifting accessories.
The weights of the different installation types are stated in the Technical Data.
Note
We recommend round using slings according to EN 1492-2 or round sling harnesses to lift the
waste- water treatment plant. We recommend that the round slings or round sling harnesses be
attached to an appropriate spreader and that this be used to move the wastewater treatment plant
to the storage or installation site.
JZR-„BIOMASTER “
®
Operating Manual
Part B: Storage, transport, installation
Important notes
I/I
B-1
4
MAY 20
B-1 Important notes (continued)
B-1.5
Caution
All flange and threaded connections of the wastewater treatment plant are fitted with plugs and
caps in order to protect against contamination and foreign objects.
If the plugs or caps are removed during storage or transport, contamination and foreign objects may
penetrate the wastewater treatment plant. Only remove plugs and caps from flanges and threaded
connections during installation.
Only remove plugs and caps from flanges and threaded connections during installation.
JZR-„BIOMASTER “
®
Operating Manual
Part B: Storage, transport, installation
Storage
I/I
B-2
5
MAY 20
B-2
Storage
B-2.1
Environment conditions
B-2.2
The wastewater treatment plant must be stored in a dry place and on a level surface free from
vibrations. The storage place must not be contaminated with dust, solvent-containing gases or oils.
Dripping water or splash water must not come into contact with the wastewater treatment plant. The
ambient temperature must be in the range of 5°C / 41°F to 40°C / 104°F.
Secondary packaging
The wastewater treatment plant is normally delivered in wooden secondary packaging (wooden
crate or wooden shed).
The secondary packaging corresponds to the standard ISPM No. 15 of the “International Plant
Protection Convention” (IPPC). The packaging wood is not gassed with methyl bromide.
All necessary markings must be permanently applied to the packaging by means of a branding iron
or a colour template with black colour.
The markings have the following meanings:
IPPC marking according to ISPM No. 15 (example)
DE= ISO country code for Germany
NI= marking of the approving authority
(NI= Chamber of Agriculture of Lower Saxony, Germany)
49XXXXX= Registration number of the company which manufactured the wooden packaging
HT= Heat-treated wood
This side up
Overall weight of the secondary packaging in kg (example)
Marking of the sling points on the secondary packaging
Manufacturer of the packaging contents with complete address
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JZR-„BIOMASTER “
®
Operating Manual
Part B: Storage, transport, installation
Transport
B-3
Transport
B-3.1
Wastewater treatment plant with secondary packaging
I/I
B-3
7
MAY 20
The wastewater treatment plant may only be lifted and transported using the sling points provided
for this purpose and with appropriate lifting accessories. The sling points are marked with a symbol
on the secondary packaging:
Marking of the sling points on the secondary packaging
B-3.2
Wastewater treatment plant without secondary packaging
The wastewater treatment plant has special sling points for transport purposes.
The wastewater treatment plant may only be lifted and transported using the sling points provided
for this purpose and with appropriate lifting accessories.
The weights of the different installation types are stated in the Technical Data.
Sling points on the wastewater treatment plant; the rear sling point cannot be seen here.
B-3.3
Note
We recommend using round slings according to EN 1492-2 or round sling harnesses to lift the
wastewater treatment plant. We recommend that the round slings or round sling harnesses be
attached to an appropriate spreader and that this be used to move the wastewater treatment plant to
the storage or installation site.
OM_2020051900_DVZ-JZR-BIOMASTER-JZRY01001_EN - Subject to technical modification without notice
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This page has been left blank intentionally.
JZR-„BIOMASTER®“
B-4
Installation
B-4.1
Explanations
Operating Manual
Part B: Storage, transport, installation
Installation
I/I
B-4
9
MAY 20
The wastewater treatment plant is manufactured according to the acknowledged rules of
technology, the state of the art and on the basis of the DVZ Quality Management System according
to EN ISO 9001 et seq. All components built into the wastewater treatment plant are subject to the
strictest quality standards. All functions of the wastewater treatment plant are tested prior to
delivery. The wastewater treatment plant is designed so that it works flawlessly under the operating
and environmental conditions defined by DVZ.
The customer and/or operating entity must create an environmental and installation situation which
corresponds to the state of the art for biological wastewater treatment plants. The installation of the
wastewater treatment plant must be performed according to the acknowledged rules of technology
by the customer.
B-4.2
System description
The DVZ-JZR “BIOMASTER” is a biological wastewater treatment plant for seagoing vessels,
riverboats, yachts, naval vessels and offshore constructions. The DVZ-JZR “BIOMASTER” complies
with all current requirements and limit values for the treatment of grey and black water (wastewater)
of the Marine Environment Protection Committee (MEPC.159 (55)), the International Maritime
Organization (IMO) as well as the International Standard ISO 15749 et seq. - Drainage systems on
ships and marine structures.
The DVZ-JZR “BIOMASTER” is designed as a compact installation, consisting of a three-zone
bioreactor, filters, membranes, fans, pumps, tubing, measuring equipment, shut-off devices and a
switching cabinet with integrated control electronics and operating elements. All assemblies are
installed to a steel frame with high packing density. The size of the wastewater treatment plant is
rated against the amount of wastewater per person.
The wastewater is supplied to the DVZ-JZR “BIOMASTER” from the (customer-provided) wastewater
tank with a transfer pump, pre-cleaned with a filter and fed into the bioreactor.
The three-zone-bioreactor consists of a primary reactor, a secondary reactor and a calming
chamber.
The primary reactor works according to the patented principle of the Jet Zone Loop Reactor. This
permits the fast and intensive mixing of wastewater enriched with varying levels of microorganisms
(bio- mass) and atmospheric oxygen. The biochemical degradation of the wastewater contents is
performed in an aerobic way, i.e. in the presence of air oxygen. A pump recirculates wastewater
from the secondary reactor to the primary reactor. During this process it is continuously enriched
with atmospheric oxygen (primary air) via a binary fuel nozzle. The high proportion of active biomass
(activated sludge), due to the principles involved, allows a high cleaning performance with low
space requirements. Due to the high metabolic activities of the micro-organisms, minimal surplus
sludge is generated.
|
The secondary reactor collects the wastewater treated in the primary reactor. Untreated
wastewater from the wastewater collection tank is added continuously. It thereby first comes
contact with active biomass. A fan supplies the secondary reactor with additional atmospheric
oxygen (secondary air) in or- der to support the biochemical degradation of the substances.
Furthermore, explosive and toxic gases such as methane or hydrogen sulphide are extracted via the
ventilation spouts. After the contents of the secondary reactor have mixed, they are once again
transferred to the primary rector with a pump.
(continued)
OM_2020051900_DVZ-JZR-BIOMASTER-JZRY01001_EN - Subject to technical modification without notice
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JZR-„BIOMASTER®“
Operating Manual
I/I
Part B: Storage, transport, installation
Installation
B-4
Installation (continued)
B-4.2
System description (continued)
B-4
10
MAY 20
Due to thickening with surplus sludge, the sludge must be evacuated to a sludge collection tank (to
be provided by the customer) at varying load-dependent intervals (approximately once per week).
The calming chamber collects the treated wastewater from the secondary reactor.
It is fed into this part, which has a special geometric shape, passing over a weir and a calming
section. The sludge precipitates, accumulates at the bottom and must be evacuated to a sludge
collection tank (to be provided by the customer) in varying load-dependent intervals (approximately
once per week) (DESLUDGE MODE). The pre-cleaned wastewater in the upper part contains biomass
(micro-organisms), suspended solids and a small amount of sludge. A pump transfers this
wastewater to a special membrane, the DVZ Biomass Separation Unit (BMSU).
The Biomass Separation Unit (BMSU) is a semipermeable membrane.
The BMSU works according to the principle of the pressure-driven membrane filter procedure.
The pre-cleaned wastewater is continuously recirculated in the membrane (BSMU) with a pump. A
pressure-sustaining valve which can be regulated manually creates a sliding working pressure in the
membrane so that clear water (permeate) passes the membrane in cross-flow. The backflow sludge
with the micro-organisms stays on the other side of the membrane. A part of the pre-cleaned wastewater is fed back to the secondary rector via the pressure-sustaining valve.
This prevents thickening and sludge precipitation and micro-organisms are fed back to the
secondary reactor. The inflow direction of the pre-cleaned wastewater in the membrane (BMSU) is
changed at fixed intervals using the control electronics so that accumulations of solid matter can be
flushed back to the primary reactor (SIDE CLEANING).
SIDE CLEANING is an automatic cleaning program for the membrane (BMSU).
SIDE CLEANING, also called “head-to-tail flushing”, inverts the flow direction of the pre-cleaned
wastewater in the membrane at fixed intervals. The change of the flow direction effectively removes
coarse organic solid matter and paper fibres from the membrane. SIDE CLEANING is a physical
cleaning program which can also be activated manually via the control electronics outside of the defined intervals when necessary. SIDE CLEANING is activated manually prior to the chemical cleaning
process of the membrane(s) (CLEANING-IN-PLACE).
CLEANING-IN-PLACE (CIP) is a manual cleaning program for the membrane (BMSU).After the
membrane has been in operation for a longer period of time, the passage of clear water in crossflow is increasingly blocked by fine contamination, so that the quantity of clear water (permeate) is
significantly reduced and the working pressure in the membrane necessary for the filtration process
rises up to a limit value. The manual CLEANING-IN-PLACE MODE regenerates the membrane until
the full clear water performance is possible again. CLEANING-IN-PLACE is a chemical cleaning
program. The chemical cleaning process is performed using membrane cleaning agents Osmotech
2691® or Osmotech 2610® or similar, which are dispensed into a holding tank.
During the temperature and time-limited CLEANING-IN-PLACE process, the membrane (BMSU) is
unable to separate clear water from pre-cleaned wastewater. In wastewater treatment plants with
more than one membrane (BMSU) the CLEANING-IN-PLACE process is performed selectively
depending on the degree of contamination so that the remaining membranes remain available for
waste- water treatment.
Osmotech® is a registered trademark of BK Giulini GmbH, BKG Water Solutions, Düsseldorf, Germany
OM_2020051900_DVZ-JZR-BIOMASTER-JZRY01001_EN - Subject to technical modification without notice
DVZ-SERVICES GmbH | Boschstraße 9 | D-28857 Syke | Germany | FON +49 (0) 4242 16 93 8 0 | FAX +49 (0) 4242 16 93 8 99 | WEB www.dvz-services.de | MAIL info@dvz-services.de
JZR-„BIOMASTER®“
B-4
Installation (continued)
B-4.3
Technical data
Operating Manual
I/I
B-4
Part B: Storage, transport, installation
Installation
11
MAY 20
B-4.3.1 Power
Type
Quantity of Quantity of primary
filters
reactors
Quantity of
membranes (BMSU)
maximum wastewater load
[m³/d] / [ft³/d]
maximum organic load1
[kg BSB5/d] / [lbs BOD5/d]
1,70 / 3,75
JZR 10-1-1
1
1
1
1,85 / 65,32
JZR 25-1-1
1
1
1
4,625 / 163.30
4,25 / 9.37
JZR 50-1-1
2
1
1
9,250 / 326.60
8,49 / 18.72
JZR 100-1-2
2
1
2
18,50 / 653.20
16,98 / 37.43
JZR 150-1-2
2
1
2
27,75 / 979.81
25,47 / 56.15
JZR 200-2-4
2
2
4
37,00 / 1306.41
33,96 / 74.87
JZR 250-2-4
2
2
4
46,25 / 1633.10
42,45 / 93.58
JZR 300-2-4
2
2
4
55,50 / 1959.61
50,94 / 112.30
JZR 400-2-6
2
2
6
74,00 / 2612.82
67,92 / 149.74
JZR 500-3-6
2
3
6
92,50 / 3266.20
84,09 / 187.17
JZR 600-4-8
2
4
8
111,00 / 3919.93
101,88 / 224.61
JZR 800-4-12
JZR 1000-6-12
2
2
4
6
12
12
148,00 / 5226.57
185,00 / 6533.21
135,84 / 299,48
169,80 / 374,34
1 BSB5 : Biochemical oxygen demand of bacteria in a water sample over a period of 5 days at a temperature of 20°C / 68°F
B-4.3.2 Dimensions and weights
Type
Length
[mm] / [inch]
Width
[mm] / [inch]
Height
[mm] / [inch]
Service dimension²
[mm] / [inch]
Dry weight
[kg] / [lbs]
Wet weight
[kg] / [lbs]
JZR 10-1-1
1182 / 46,5
1026 / 40,4
1236 / 48,7
1200 / 47,3
450 / 992
700 / 1543
JZR 25-1-1
1420 / 55.9
1210/ 47.6
1650 / 65.0
1200 / 47.3
1100 / 2425
1600 / 3527
JZR 50-1-1
1672 / 65.8
1203 / 47.4
2257 / 88.9
1200 / 47.3
1360 / 2998
1960 / 4321
JZR 100-1-2
1774 / 69.8
1836 / 72.3
2257 / 88.9
1200 / 47.3
1580 / 3483
3080 / 6790
JZR 150-1-2
1174 / 46.2
1836 / 72.3
2257 / 88.9
1200 / 47.3
1650 / 3638
3150 / 6944
JZR 200-2-4
2552 / 100.5
2200 / 86.6
2257 / 88.9
1200 / 47.3
2500 / 5512
4730 / 10428
JZR 250-2-4
2959 / 116.5
2339 / 92.1
2257 / 88.9
1200 / 47.3
3000 / 6614
5260 / 11596
JZR 300-2-4
3512 / 138.3
2339 / 92.1
2257 / 88.9
1200 / 47.3
3200 / 7055
5460 / 12037
JZR 400-2-6
3600 / 141.7
2359 / 92,9
2305 / 90.8
1200 / 47.3
4050 / 8929
7150 / 15763
JZR 500-3-6
4078 / 160.6
2400 / 94.5
2871 / 113.0
1200 / 47.3
4500 / 9921
8800 / 19400
JZR 600-4-8
3149 / 124.0
2785 / 109.6
2450 / 96.5
2242 / 88.3
2377 / 93.6
1200 / 47.3
4996 / 11014
9516 / 20979
3849 / 151.5
3826 / 150.6
4580 / 180.3
3826 / 150.6
2450 / 96.5
2242 / 88.3
2569 / 101.1
2242 / 88.3
2377 / 93.6
1200 / 47.3
6513 / 14359
12713 / 28027
2871 / 113.0
1200 / 47.3
7366 / 16239
24066 / 53056
JZR 800-4-12
JZR 1000-6-12
2 Necessary dimensions for the free space from the upper border in order to be able to feed the bioreactor from above
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Operating Manual
JZR-„BIOMASTER®“
I/I
B-4
Part B: Storage, transport, installation
Installation
B-4
Installation (continued)
B-4.3
Technical data (continued)
12
MAY 20
B-4.3.3 Electric connections
Type
Voltage
Fusage
[A]
Power consumption
[kW]
Voltage
Fusage
[A]
Power consumption
[kW]
JZR 10-1-1
3AC, 440V, 60Hz
12
7
3AC, 400V, 50Hz
12
6
JZR 25-1-1
3AC, 440V, 60Hz
21
10
3AC, 400V, 50Hz
19
8
JZR 50-1-1
3AC, 440V, 60Hz
24
11
3AC, 400V, 50Hz
20
9
JZR 100-1-2
3AC, 440V, 60Hz
30
15
3AC, 400V, 50Hz
29
13
JZR 150-1-2
3AC, 440V, 60Hz
32
16
3AC, 400V, 50Hz
31
13
JZR 200-2-4
3AC, 440V, 60Hz
44
23
3AC, 400V, 50Hz
43
19
JZR 250-2-4
3AC, 440V, 60Hz
44
23
3AC, 400V, 50Hz
43
19
JZR 300-2-4
JZR 400-2-6
3AC, 440V, 60Hz
3AC, 440V, 60Hz
45
60
24
32
3AC, 400V, 50Hz
3AC, 400V, 50Hz
45
59
20
27
JZR 500-3-6
3AC, 440V, 60Hz
63
34
3AC, 400V, 50Hz
62
29
JZR 600-4-8
3AC, 440V, 60Hz
90
48
3AC, 400V, 50Hz
90
40
JZR 800-4-12
3AC, 440V, 60Hz
120
64
3AC, 400V, 50Hz
118
54
JZR 1000-6-12
3AC, 440V, 60Hz
126
68
3AC, 400V, 50Hz
124
58
B-4.3.4 Pneumatic connection
Pressure MIN
[bar] / [psi]
Pressure MAX
[bar] / [psi]
Pressurised air demand
[l/min] / [GPM]
JZR 25-1-1
4,0 / 58.0
6,0 / 87.0
0,016 / 0.004
JZR 50-1-1
4,0 / 58.0
6,0 / 87.0
0,016 / 0.004
JZR 100-1-2
4,0 / 58.0
6,0 / 87.0
0,05 / 0.013
JZR 150-1-2
4,0 / 58.0
6,0 / 87.0
0,1 / 0.026
JZR 200-2-4
4,0 / 58.0
6,0 / 87.0
0,05 / 0.013
JZR 250-2-4
4,0 / 58.0
6,0 / 87.0
0,2 / 0.053
JZR 300-2-4
JZR 400-2-6
4,0 / 58.0
4,0 / 58.0
6,0 / 87.0
6,0 / 87.0
0,2 / 0.053
0,3 / 0.079
JZR 500-3-6
4,0 / 58.0
6,0 / 87.0
0,3 / 0.079
JZR 600-4-8
4,0 / 58.0
6,0 / 87.0
0,4 / 0.105
JZR 800-4-12
4,0 / 58.0
6,0 / 87.0
0,6 / 0.158
JZR 1000-6-12
4,0 / 58.0
6,0 / 87.0
0,6 / 0.158
Type
JZR 10-1-1
OM_2020051900_DVZ-JZR-BIOMASTER-JZRY01001_EN - Subject to technical modification without notice
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Operating Manual
JZR-„BIOMASTER®“
I/I
Part B: Storage, transport, installation
Installation
B-4
Installation (continued)
B-4.3
Technical data (continued)
B-4
13
MAY 20
B-4.3.5 Mechanic connection: Flanges
Nominal width DN [mm], flanges according to DIN EN 1092, connections see R&I flow diagram
Type
A1
A 2.1
A 2.2
A 13
A 14
JZR 10-1-1
40
80
G11
40
32
JZR 25-1-1
40
80
80
40
32
JZR 50-1-1
40
80
80
40
32
JZR 100-1-2
40
100
100
40
32
JZR 150-1-2
40
100
100
40
32
JZR 200-2-4
40
100
100
40
32
JZR 250-2-4
65
100
100
40
32
JZR 300-2-4
65
100
100
40
32
JZR 400-2-6
65
100
100
40
32
JZR 500-3-6
80
100
100
40
32
JZR 600-4-8
80
100
100
40
32
JZR 800-4-12
80
100
100
40
32
JZR 1000-6-12
80
100
100
40
32
1 Threaded sleeve
B-4.3.6 Mechanic connection: Threaded spouts / threaded sleeves2
Nominal width DN [inch], pipe thread DIN ISO 228-1, connections see R&I flow diagrams
Type
A 3.1 A 72 A 151 A 163 A 17 A 18
A
A
A
A
A
A 21 A 22 A 232 A 24 A 25 A 26 A 27
A 29
19.1 19.2 20.1 20.2
282
JZR 10-1-1
G1½ G1
G½
G1
G¼
G1
G¼ G½
G2
G¼
G¼
G1
JZR 25-1-1
G1½ G1½ G1
8
G½
G1
G¼ G¼
G1
G1
G¼ G½
G2
G¼ G¼ G¼
G1
G1
G1
JZR 50-1-1
G1½ G1½ G1
8
G½
G1
G¼ G¼
G1
G1
G¼ G½
G2
G¼ G¼ G¼
G1
G1
G1
JZR 100-1-2 G1½ G1½ G1
8
G½
G1
G¼ G¼
G1
G1
G¼ G½
G2
G¼ G¼ G¼
G1
G1
G1
JZR 150-1-2 G1½ G1½ G1
8
G½
G1
G¼ G¼
G1
G1
G¼ G½
G2
G¼ G¼ G¼
G1
G1
G1
JZR 200-2-4 G1½ G1½ G1
8
G½
G1
G¼ G¼
G1
G1
G¼ G½
G2
G¼ G¼ G¼
G1
G1
G1
JZR 250-2-4 G1½ G1½ G1
8
G½
G1
G¼ G¼
G1
G1
G¼ G½
G2
G¼ G¼ G¼
G1
G1
G1
JZR 300-2-4 G1½ G1½ G1
8
G½
G1
G¼ G¼
G1
G1
G¼ G½
G2
G¼ G¼ G¼
G1
G1
G1
JZR 400-2-6 G1½ G1½ G1
8
G½
G1
G¼ G¼
G1
G1
G¼ G½
G2
G¼ G¼ G¼
G1
G1
G1
JZR 500-3-6 G1½ G1½ G1
8
G½
G1
G¼ G¼
G1
G1
G¼ G½
G2
G¼ G¼ G¼
G1
G1
G1
JZR 600-4-8 G1½ G1½ G1
8
G½
G1
G¼ G¼
G1
G1
G¼ G½
G2
G¼ G¼ G¼
G1
G1
G1
JZR 800-4-12 G1½ G1½ G1
8
G½
G1
G¼ G¼
G1
G1
G¼ G½
G2
G¼ G¼ G¼
G1
G1
G1
JZR 1000-6-12 G1½ G1½ G1
8
G½
G1
G¼ G¼
G1
G1
G¼ G½
G2
G¼ G¼ G¼
G1
G1
G1
1 Quick coupling, 2 threaded spouts 3 connection spout [mm]
OM_2020051900_DVZ-JZR-BIOMASTER-JZRY01001_EN - Subject to technical modification without notice
DVZ-SERVICES GmbH | Boschstraße 9 | D-28857 Syke | Germany | FON +49 (0) 4242 16 93 8 0 | FAX +49 (0) 4242 16 93 8 99 | WEB www.dvz-services.de | MAIL info@dvz-services.de
Operating Manual
JZR-„BIOMASTER®“
Part B: Storage, transport, installation
Installation
B-4
Installation (continued)
B-4.4
Erection of the wastewater treatment plant
I/I
B-4
14
MAY 20
The wastewater treatment plant must be erected in a place where the ambient temperature is a
minimum of 5 °C / 41 °F and a maximum of 40 °C / 104 °F. The wastewater treatment plant must
be erected on a level foundation. Compensate unevenness with spacers on site. If the heat radiation
of the foundation on site is more than 40 °C / 104 °F, the foundation must be effectively protected
against heat radiation prior to erecting the wastewater treatment plant. The wastewater treatment
plant is connected to the foundation at defined fixing points. This is performed on site with
appropriate screwed connections. The wastewater treatment plant must be installed on the
foundation free from tensions and decoupled from vibrations. There is an option to install machine
feet on the wastewater treatment plant in the factory in order to decouple it from vibrations and
sound.
B-4.4.1 Caution
In case of temperatures of more than 40 °C / 104 °F at the installation site, the biological cleaning
ability of the wastewater treatment plant is strongly impaired, or even becomes impossible.
The wastewater treatment plant must be erected at an appropriate and well ventilated site.
The nominal width of the bleeder tubes of the wastewater treatment plant must not be reduced on
site. A decrease of the nominal width of the ventilation tubes leads to increased back pressure.
Increased back pressure can lead to a breakdown of the wastewater treatment plant.
The bleeder lines must be laid on site in a way that no water pockets can be formed due to
condensate. Water pockets impair the breathing function and lead to a breakdown of the wastewater
treatment plant.
If any foreign objects, corrosive or toxic substances enter the wastewater treatment plant, the
waste- water treatment plant or individual components of the wastewater treatment plant will suffer
severe damage or become inoperable. The biological cleaning ability becomes heavily reduced or
even impossible for a long time. Do not use corrosive or toxic substances during installation and take
care that no foreign objects enter the wastewater treatment plant.
The bolt and screw connections could be loosened during the transportation. Before starting the
sewage treatment plant the screw connection must be checked and re-tighten, if necessary.
The back pressure must not exceed 0.5 bar / 7.25 psi at flange connection A13. If the back pressure
exceeds 0.5 bar / 7.25 psi, the clear water (permeate) cannot be discharged in a sufficient amount,
or not at all. The customer must ensure that the back pressure does not exceed 0.5 bar / 7.25 psi or
provide the DVZ-PL lifting station.
B-4.4.2 Note
Practice shows that people tend to throw objects into the on-board toilet which
damage the waste- water treatment plant or impair its function. We therefore
recommend that appropriate information or prohibition signs be posted in the
immediate vicinity of the on-board toilet.
Small amounts of blood, e.g. from nosebleed, female menstruation and a juicy
piece of meat, will have no impact to the waste water treatment plant. Large
amounts of blood, e.g. from the slaughter of animals, have to be avoided.
(continued)
OM_2020051900_DVZ-JZR-BIOMASTER-JZRY01001_EN - Subject to technical modification without notice
DVZ-SERVICES GmbH | Boschstraße 9 | D-28857 Syke | Germany | FON +49 (0) 4242 16 93 8 0 | FAX +49 (0) 4242 16 93 8 99 | WEB www.dvz-services.de | MAIL info@dvz-services.de
JZR-„BIOMASTER®“
B-4
Operating Manual
Part B: Storage, transport, installation
Installation
I/I
B-4
15
MAY 20
Installation (continued)
B-4.4 Erection of the wastewater treatment plant (continued)
B-4.4.2 Note (continued)
The selection of cleaning agents influences the function of the wastewater treatment plant. We
therefore recommend that a selection be made, prior to commissioning, of biologically degradable
cleaning agents which are free from damaging ingredients such as phosphates, silicates, borates,
formaldehyde, silicones, waxes or halogenated organic compounds.
B-4.4.3
Fixing points
The wastewater treatment plant is fixed to the foundation at the fixing points marked with arrows:
1. Screw fixing with appropriate, customer-provided fixing equipment
2. Screw fixing with factory-mounted machine feet (optional)
The weights necessary for the strength determination of screws are documented in
Bottom fixing points, JZR 25 and JZR 50 are shown
B-4.4.4 Connection dimensions
The connecting dimensions of the wastewater treatment plant depend on its size and type.
All mechanical and electrical connections of the wastewater treatment plant are documented in an
assembly drawing. The assembly drawing can be found in Appendix B-APX 2.
B-4.4.5 Connecting the connections
Attach the connection of the wastewater treatment plant according to the customer-provided
connections according to the Standard-R&I flow diagrams and according to the acknowledged rules
of technology. Plant and customer-specific R&I flow diagrams deviate from the standard R&I flow
diagrams and are given in Appendix B-APX-3.
OM_2020051900_DVZ-JZR-BIOMASTER-JZRY01001_EN - Subject to technical modification without notice
DVZ-SERVICES GmbH | Boschstraße 9 | D-28857 Syke | Germany | FON +49 (0) 4242 16 93 8 0 | FAX +49 (0) 4242 16 93 8 99 | WEB www.dvz-services.de | MAIL info@dvz-services.de
JZR-„BIOMASTER®“
B-4
Installation (continued)
B-4.5
Glossary
Operating Manual
Part B: Storage, transport, installation
Installation
I/I
B-4
16
MAY 20
Term
Definition
acknowledged rules of technology
Technical determination considered as the reflection of the
state of the art by a majority of representative specialists. 1
1
quotation from DIN EN 45020
State of the art
1
Quotation from DIN EN 45020
Developed status of technical possibilities at a certain point of
time, as far as products, processes and services are concerned,
on the basis of correspondingly secure knowledge in science,
technology and experience.1
Micro-organisms
Micro-organisms are all cellular or non-cellular micro-biological units which are capable of reproducing or transferring
genetic material.
Biomass, activated sludge
The concentration of micro-organisms which degrade organic
substances including inorganic and organic components during
the aerobic cleaning of wastewater.
biological wastewater treatment
plant
Installation for the cleaning of wastewater with the addition of
atmospheric oxygen without the admixture of chemical
additives.
Grey water
Faeces-free wastewater from sinks and showers, but not from
galleys.
Black water
Wastewater containing faeces with toilet paper
Clear water (permeate)
Wastewater cleaned by the DVZ-BMSU with a value
according to IMO MEPC.159 (55) specifications.
DVZ-BMSU
The DVZ Biomass Separation Unit (BMSU) is a semi-permeable
membrane with special technical characteristics.
DVZ-PL
The DVZ Permeat Lift is a lifting station for clear water
(permeate). The DVZ-PL is optionally available as a separate
installation.
Buffer tank,
wastewater collection tank
(customer-provided)
Collection tank for black and grey water. In the event of a
constructional separation of the substance flows, separate
wastewater collection tanks must be provided for grey and
black water.
Sludge collection tank
(customer-provided)
Collection tank for surplus sludge from the three-zone
bioreactor and for solid matter flushed out of the DVZ- BMSU
(SIDE CLEANING).
ships waste water tank
(customer-provided)
Collection tank into which treated clear water (permeate)
flows from time to time because, according to national regulations, clear water (permeate) must not be discharged into
the sea (“No Discharge Zone”) in harbours and special areas.
OM_2020051900_DVZ-JZR-BIOMASTER-JZRY01001_EN - Subject to technical modification without notice
DVZ-SERVICES GmbH | Boschstraße 9 | D-28857 Syke | Germany | FON +49 (0) 4242 16 93 8 0 | FAX +49 (0) 4242 16 93 8 99 | WEB www.dvz-services.de | MAIL info@dvz-services.de
JZR-„BIOMASTER®“
Operating Manual
Part B: Storage, transport, installation
Installation
I/I
B-APX
17
MAY 20
B-APX1 Assembly drawing documentation
OM_2020051900_DVZ-JZR-BIOMASTER-JZRY01001_EN - Subject to technical modification without notice
DVZ-SERVICES GmbH | Boschstraße 9 | D-28857 Syke | Germany | FON +49 (0) 4242 16 93 8 0 | FAX +49 (0) 4242 16 93 8 99 | WEB www.dvz-services.de | MAIL info@dvz-services.de
This page has been left blank intentionally.
8
7
6
5
4
3
2
1
1365
A16
A2
A2
A2.1
937
D3
A17
960
Ø13,5
1026
1522
A15
D1
555
493
D5
20
118
20
A2
135
D2
20
164
E
D3
189
366
730
555
637
730
A13
A1
A17
D4
A1
1341
1361
1461
20
A5
A3.1
D5
E
F
560
525
D1
D4
A15
A17
914
725
915
1026
1078
1076
1132
D
118
141
189
A5
900
135
110
1328
A2
118
131
F
D
1510
The hose must be mounted so that
it has a downward slope
and the sinter filter looks upwards.
793
135
As an example
A17
A1
A14
Dimension DIN
Position Flange PN10/16
A15
A16
A1
A2
A3.1
A5
A13
A14
A15
A16
A17
D1
D2
D3
D4
D5
110
730,5
1026
~1057
~600
D3
B
A5
900
860
560
A13
1365
~1506
C
Dimension for pipe connections
A2
~600
maintenance space
(recommended)
.
Description
C
Inlet Sewage
R 1" female
Vent
R 3" male
R 1 1/2" female to sludge tank / ships tank
R 1 1/2" male
Overflow
R 3/4" female
Outlet Permeate
R 1" female
Outlet Sludge
1"GEKA
Inlet Fresh Water
Inlet Compressed Air
8mmø
to buffer/ mixing tank
R 1" female
Drain Bioreactor
R 1" female
Drain Control Tank
R 1" female
R 1" female
Drain Membrane
R 1" famale
Drain Automatic filter
R 1" female
Drain CIP Tank
from P5
to mast
to sludge tank
to overboard
to sludge tank
max.3bar
max.16bar
to buffer/ mixing tank
approx. 420 Liter
approx. 100 Liter B
approx. 60 Liter
approx. 140 Liter
approx. 10 Liter
Project/Projekt
DVZ-Project No.: 995021; Astinave - Salvadore
Design/Bearb.
TK
Checked/Prüfer
TK
Issue Date/Ausgabedatum
29.06.2021
as built
A
Alle Anschlüsse mit ±10mm Toleranz
All connections with ±10mm tolerance
8
7
Lose supply:
Transfer Pump P5
Switch Box 600x600x250
©DVZ-SERVICES GmbH Refer to protection notice ISO 16016.
The reproduction, distribution and utilization of this document as well as the
communication of its contents to others without explicid authorization is prohibited.
Offenders will be held liable for the payment of damages. All rights reserved
in the event of the grant of a patent, utility model or design.
Weitergabe sowie Vervielfältigung dieses Dokuments, Verwertung und Mitteilung
seines Inhalts sind verboten, soweit nicht ausdrücklich gestattet.
Zuwiderhandlungen verpflichten zu Schadenersatz. Alle Rechte für den Fall
der Patent-, Gebrauchsmuster- oder Geschmacksmustereintragung vorbehalten.
Document type/Dokumententype
Customer Drawing
DVZ-JZR-50
"BIOMASTER"
6
5
Quantity/Anzahl
1 : 20
PART-023113
2
A
-
Document status/Dokumentenstatus
Freigegeben
ENG-084862.idw
3
Scale/Maßstab
Mass/Masse
Part No./Artikel Nr.
DVZ-SERVICES GmbH - Boschstraße 9 - 28857 Syke
info@dvz-services.de - www.dvz-services.de
Projection/Projektion
Material/Material-Werkstoff
Drawing No./Zeichnungsnummer
Dry weight approx.: 650kg
Wet weight approx. : 1250kg
4
Allowance/Toleranz
ISO 2768-m
ISO 9013-1
DIN 3141-3
ISO 13920-B
Title, Additional title/Titel, Zusatzbezeichnung
Rev.
G
Sheet size/Blattgröße
A2
1
Sheet/Blatt
1 /2
6
5
15
4
485
2
1
27
D
15
95
15 50 15
15
D
3
G 1 1/4" SUCTION SIDE
C
G 1 1/4" PRESSURE SIDE
C
B
100
160
242
G 1/2" DRY RUNNING PROTECTION
40
27
472
170
55
B
891,5
Project/Projekt
DVZ-Project No.: 995021; Astinave - Salvadore
Design/Bearb.
Checked/Prüfer
TK
RKL
Issue Date/Ausgabedatum
29.06.2021
©DVZ-SERVICES GmbH Refer to protection notice ISO 16016.
The reproduction, distribution and utilization of this document as well as the
communication of its contents to others without explicid authorization is prohibited.
Offenders will be held liable for the payment of damages. All rights reserved
in the event of the grant of a patent, utility model or design.
Weitergabe sowie Vervielfältigung dieses Dokuments, Verwertung und Mitteilung
seines Inhalts sind verboten, soweit nicht ausdrücklich gestattet.
Zuwiderhandlungen verpflichten zu Schadenersatz. Alle Rechte für den Fall
der Patent-, Gebrauchsmuster- oder Geschmacksmustereintragung vorbehalten.
404
A
Document type/Dokumententype
Allowance/Toleranz
customer drawing
ISO 2768-m
ISO 9013-1
DIN 3141-3
ISO 13920-B
Title, Additional title/Titel, Zusatzbezeichnung
DVZ-0813-1
Tranfer
Pump P5
Scale/Maßstab
1:5
Mass/Masse
Drawing No./Zeichnungsnummer
Document status/Dokumentenstatus
Part No./Artikel Nr.
Rev.
6
5
4
3
ENG-084866
2
Quantity/Anzahl
Material/Material-Werkstoff
A
-
Freigegeben
ENG-084866.idw
DVZ-SERVICES GmbH - Boschstraße 9 - 28857 Syke
info@dvz-services.de - www.dvz-services.de
Projection/Projektion
-
Sheet size/Blattgröße
A3
Sheet/Blatt
1
1 /1
6
5
4
3
2
1
Straight pipe as outlet
20
550
20
D
~510
~720
1008
20 170 20
min. 1000mm
D
C
C
~625
590
838
135
320
Outlet DN50
B
B
171
75
Inlet DN50
Project/Projekt
DVZ-Project No.: 995021; Astinave - Salvadore
Design/Bearb.
Checked/Prüfer
TK
JobUser
Issue Date/Ausgabedatum
29.06.2021
135
A
Allowance/Toleranz
Document type/Dokumententype
ISO 2768-c
ISO 9013-1
DIN 3141-3
ISO 13920-C
Title, Additional title/Titel, Zusatzbezeichnung
DVZ-Vacuumstation
Scale/Maßstab
6
5
4
3
-
Material/Material-Werkstoff
Mass/Masse
Drawing No./Zeichnungsnummer
Document status/Dokumentenstatus
Part No./Artikel Nr.
Rev.
PART-023114
2
A
-
Freigegeben
ENG-084864.idw
DVZ-SERVICES GmbH - Boschstraße 9 - 28857 Syke
info@dvz-services.de - www.dvz-services.de
Quantity/Anzahl
1 : 20
©DVZ-SERVICES GmbH Refer to protection notice ISO 16016.
The reproduction, distribution and utilization of this document as well as the
communication of its contents to others without explicid authorization is prohibited.
Offenders will be held liable for the payment of damages. All rights reserved
in the event of the grant of a patent, utility model or design.
Weitergabe sowie Vervielfältigung dieses Dokuments, Verwertung und Mitteilung
seines Inhalts sind verboten, soweit nicht ausdrücklich gestattet.
Zuwiderhandlungen verpflichten zu Schadenersatz. Alle Rechte für den Fall
der Patent-, Gebrauchsmuster- oder Geschmacksmustereintragung vorbehalten.
320
Projection/Projektion
A
Sheet size/Blattgröße
A3
Sheet/Blatt
1
1 /1
6
5
4
800
D
3
2
1
300
D
755
800
755
C
C
Back View
B
B
Project/Projekt
DVZ-Project No.: 995021; Astinave - Salvadore
Design/Bearb.
Checked/Prüfer
RKL
JG
Issue Date/Ausgabedatum
29.06.2021
©DVZ-SERVICES GmbH Refer to protection notice ISO 16016.
The reproduction, distribution and utilization of this document as well as the
communication of its contents to others without explicid authorization is prohibited.
Offenders will be held liable for the payment of damages. All rights reserved
in the event of the grant of a patent, utility model or design.
Weitergabe sowie Vervielfältigung dieses Dokuments, Verwertung und Mitteilung
seines Inhalts sind verboten, soweit nicht ausdrücklich gestattet.
Zuwiderhandlungen verpflichten zu Schadenersatz. Alle Rechte für den Fall
der Patent-, Gebrauchsmuster- oder Geschmacksmustereintragung vorbehalten.
ALL TERMINATION POINTS WITH ±10MM TOLERANCE
A
The indicated data are based on our current knowledge.
Subject to normal manufacturing tolerances if not stated,
Subject to change without notice.
6
5
Document type/Dokumententype
Allowance/Toleranz
detail drawing
ISO 2768-c
ISO 9013-1
DIN 3141-3
ISO 13920-C
Title, Additional title/Titel, Zusatzbezeichnung
Switch box
800x800x300 SPS
Scale/Maßstab
4
3
Quantity/Anzahl
-
Material/Material-Werkstoff
A
Mass/Masse
65,00 kg
Freigegeben
Drawing No./Zeichnungsnummer
Document status/Dokumentenstatus
Part No./Artikel Nr.
Rev.
ENG-084868.idw
DVZ-SERVICES GmbH - Boschstraße 9 - 28857 Syke
info@dvz-services.de - www.dvz-services.de
Projection/Projektion
ENG-084868
2
-
Sheet size/Blattgröße
A3
Sheet/Blatt
1
1 /1
JZR-„BIOMASTER®“
Operating Manual
Part B: Storage, transport, installation
Installation
I/I
B-APX
19
MAY 20
B-APX2 R&I flow diagram documentation
OM_2020051900_DVZ-JZR-BIOMASTER-JZRY01001_EN - Subject to technical modification without notice
DVZ-SERVICES GmbH | Boschstraße 9 | D-28857 Syke | Germany | FON +49 (0) 4242 16 93 8 0 | FAX +49 (0) 4242 16 93 8 99 | WEB www.dvz-services.de | MAIL info@dvz-services.de
This page has been left blank intentionally.
8
7
6
5
4
3
2
1
F
F
Dimension
Description
Position DIN ISO 228
.
female
A1
female 1"
Inlet Sewage
from P5
A2
R 3"
Vent
to mast
A3.1
R 1 1/2"
to sludge tank / ships tank to sludge tank
A5
R 1 1/2"
Overflow
A13
R 3/4"
Outlet Permeate
to overboard
A14
R 1"
Outlet Sludge
to sludge tank
A15
1" GEKA
Inlet fresh water
max. 3bar
A16
8mm
Inlet compressed Air
max. 6bar
A17
R 1"
to buffer/ mixing tank
to buffer/ mixing tank
D1
R 1"
Drain Bioreactor
approx. 420 Liter
D2
R 1"
Drain Control tank
approx. 100 Liter
D3
R 1"
Drain Membrane
approx. 60 Liter
D4
R 1"
Drain Automatic filter
approx. 140 Liter
D5
R 1"
Drain CIP-Tank
approx. 10 Liter
E
E
D
D
C
C
B
B
Design/Bearb.
TK
Checked/Prüfer
TK
Issue Date/Ausgabedatum
Document type/Dokumententype
Allowance/Toleranz
----
07.07.2021
©DVZ-SERVICES GmbH Refer to protection notice ISO 16016.
The reproduction, distribution and utilization of this document as well as the
communication of its contents to others without explicid authorization is prohibited.
Offenders will be held liable for the payment of damages. All rights reserved
in the event of the grant of a patent, utility model or design.
Weitergabe sowie Vervielfältigung dieses Dokuments, Verwertung und Mitteilung
seines Inhalts sind verboten, soweit nicht ausdrücklich gestattet.
Zuwiderhandlungen verpflichten zu Schadenersatz. Alle Rechte für den Fall
A
der Patent-, Gebrauchsmuster- oder Geschmacksmustereintragung vorbehalten.
8
7
6
5
4
3
Scale/Maßstab
P&ID simple
Quantity/Anzahl
---Material/Material-Werkstoff
----
DVZ-JZR-50
Document status/Dokumentenstatus
Part No./Artikel Nr.
Rev.
----
2
A
Mass/Masse
Drawing No./Zeichnungsnummer
ENG-085063
DVZ-SERVICES GmbH - Boschstraße 9 - 28857 Syke
info@dvz-services.de - www.dvz-services.de
Projection/Projektion
ISO 2768-m
ISO 9013-1
DIN 3141-3
ISO 13920-B
Title, Additional title/Titel, Zusatzbezeichnung
Freigegeben
####
Sheet size/Blattgröße
A2
1
Sheet/Blatt
8
7
6
5
4
3
2
1
F
F
E
E
BIO REACTOR
D
D
C
C
Position
A2
A3.1
A5
A13
A14
A15
A16
A17
D1
D2
D3
D4
D5
B
Dimension
DIN ISO 228
A1 R 1"female
R 3"
R 1 1/2"
R 1 1/2"
R 3/4"
R 1"
1" GEKA
8mm
R 1"
R 1"
R 1"
R 1"
R 1"
R 1"
Description
.
from P5
Vent
to mast
to sludge tank / ships tank to sludge tank
Overflow
Outlet Permeate
to overboard
Outlet Sludge
to sludge tank
Inlet fresh water
max. 3bar
Inlet compressed Air
max. 6bar
to buffer/ mixing tank
to buffer/ mixing tank
Drain Bioreactor
approx. 420 Liter
Drain Control tank
approx. 100 Liter
Drain Membrane
approx. 60 Liter
approx. 140 Liter
Drain Automatic filter
Drain CIP-Tank
approx. 10 Liter
Inlet Sewage
B
DVZ-Project No.: 995021 Astinave - Salvadore
Design/Bearb.
TK
Checked/Prüfer
NST
Issue Date/Ausgabedatum
Document type/Dokumententype
Allowance/Toleranz
Flow Diagram (P&ID)
28.10.2019
©DVZ-SERVICES GmbH Refer to protection notice ISO 16016.
The reproduction, distribution and utilization of this document as well as the
communication of its contents to others without explicid authorization is prohibited.
Offenders will be held liable for the payment of damages. All rights reserved
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Weitergabe sowie Vervielfältigung dieses Dokuments, Verwertung und Mitteilung
seines Inhalts sind verboten, soweit nicht ausdrücklich gestattet.
Zuwiderhandlungen verpflichten zu Schadenersatz. Alle Rechte für den Fall
A
der Patent-, Gebrauchsmuster- oder Geschmacksmustereintragung vorbehalten.
8
7
6
5
4
3
Scale/Maßstab
DVZ-JZR-50
Quantity/Anzahl
---Material/Material-Werkstoff
----
"BIOMASTETR" P&ID
Document status/Dokumentenstatus
Part No./Artikel Nr.
Rev.
----
2
A
Mass/Masse
Drawing No./Zeichnungsnummer
ENG-084863
DVZ-SERVICES GmbH - Boschstraße 9 - 28857 Syke
info@dvz-services.de - www.dvz-services.de
Projection/Projektion
ISO 2768-m
ISO 9013-1
DIN 3141-3
ISO 13920-B
Title, Additional title/Titel, Zusatzbezeichnung
Freigegeben
B
Sheet size/Blattgröße
A2
Sheet/Blatt
1
JZR-„BIOMASTER®“
Operating Manual
Part B: Storage, transport, installation
Installation
I/I
B-APX
21
MAY 20
B-APX3 Certificate of Type Approval for Sewage Treatment Plants
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JZR-„BIOMASTER “
®
Operating Manual
Part C: Commissioning, operation (MECH)
Table of contents
I/I
C-TOC
1
MAY 20
C-TOC
Table of contents ....................................................................................................................... 1
C-1
Commissioning .....................................................................................................................5
C-1.1
Provision of readiness for operation .............................................................................................5
C-1.1.1
Caution ................................................................................................................................... 5
C-1.2
Functional test ..........................................................................................................................5
C-1.2.1
Checking the valve position (starting position) ..............................................................................5
C-1.2.2
Check the filling level in the ships waste water tank .....................................................................5
C-1.2.3
Notes ......................................................................................................................................6
C-1.2.4
Note ........................................................................................................................................6
C-1.2.5
Connect to clear water tube ........................................................................................................6
C-1.2.6
Fill wastewater treatment plant with clear water ..........................................................................6
C-1.2.7
Bleed tubes, pumps, filters and membrane(s) ...............................................................................6
C-1.2.8
Caution ................................................................................................................................... 6
C-1.2.9
Performing a direction of rotation check for pumps and fans .........................................................7
C-1.2.10
Activate the compressed air supply .............................................................................................7
C-1.2.11
Starting the waste water treatment plant in AUTOMATIC-MODE ....................................................7
C-1.2.12
Membrane (BMSU) conditioning ................................................................................................... 7
C-1.2.13
Setting the pressure-sustaining valve ..........................................................................................7
C-1.2.14
Setting the amount of clear water (permeate)...............................................................................7
C-1.2.15
Checking the tightness ............................................................................................................... 8
C-1.2.16
Checking the SIDE CLEANING MODE ........................................................................................... 8
C-1.2.17
Checking the CLOG-ALARM .......................................................................................................8
C-1.2.18
Checking the BMSU-PRESSURE-ALARM ......................................................................................8
C-1.2.19
Checking the FLOW-LOW-ALARM ...............................................................................................9
C-1.2.20
Checking the CLEANING-IN-PLACE (CIP) mode .............................................................................. 9
C-1.2.21
Checking the HIGH-LEVEL ALARM ............................................................................................... 9
C-1.2.23
Checking the DESLUDGE MODE .................................................................................................. 9
C-1.2.24
Observe the temperature in the bioreactor .................................................................................10
C-1.2.25
Separate the clear water tube ...................................................................................................10
C-1.3
Start-up..................................................................................................................................10
C-1.3.1
Set the valves ..........................................................................................................................10
C-1.3.2
Open the shut-off valve to the ships waste water tank ................................................................10
C-1.3.3
Start the AUTOMATIC-MODE ..................................................................................................... 10
C-1.3.4
Membrane (BMSU) conditioning .................................................................................................10
C-1.3.5
Set the amount of clear water (permeate) ..................................................................................10
OM_2020051900_DVZ-JZR-BIOMASTER-JZRY01001_EN - Subject to technical modification without notice
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JZR-„BIOMASTER “
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Operating Manual
Part C: Commissioning, operation (MECH)
Table of contents
I/I
C-TOC
2
MAY 20
C-1.3.6
Note ..................................................................................................................................... 11
C-1.3.7
Finishing the commissioning ..................................................................................................... 11
C-1.4
Glossary ............................................................................................................................... 12
C-2
Operation ............................................................................................................................ 13
C-2.1
Intended use.......................................................................................................................... 13
C-2.2
Safety note ............................................................................................................................ 13
C-2.3
Danger ................................................................................................................................. 13
C-2.4
Operation of the wastewater treatment plant ............................................................................. 13
C-2.4.1
Note ..................................................................................................................................... 14
C-2.4.2
Valve position for operation ...................................................................................................... 14
C-2.4.3
Checking the temperature (operating range, operating limits) ..................................................... 14
C-2.4.4
Caution ................................................................................................................................ 14
C-2.4.5
Cooling or heating the bioreactor .............................................................................................. 15
C-2.4.6
Checking the bleeder tubes (bioreactor) .................................................................................... 15
C-2.4.7
Organic load .......................................................................................................................... 15
C-2.4.8
Membrane (BMSU) conditioning ................................................................................................ 15
C-2.4.9
Checking the pressure-sustaining valve.................................................................................... 15
C-2.4.10
Checking the clear water volume.............................................................................................. 15
C-2.4.11
Note ..................................................................................................................................... 16
C-2.4.12
BMSU-PRESSURE-ALARM .........................................................................................................16
C-2.4.13
FLOW-LOW-ALARM ................................................................................................................. 17
C-2.4.14
High-Level-Alarm..................................................................................................................... 17
C-2.4.15
Note ..................................................................................................................................... 17
C-2.4.16
CLOG-ALARM ....................................................................................................................... 17
C-2.4.17
Membrane (BMSU) conditioning ................................................................................................ 17
C-2.4.18
Start SIDE CLEANING MODE manually .........................................................................................18
C-2.4.19
CLEANING-IN-PLACE (CIP) ........................................................................................................18
C-2.4.19.1 Danger .................................................................................................................................. 18
C-2.4.19.2 Caution .................................................................................................................................. 18
C-2.4.19.3 Perform a CLEANING-IN-PLACE (CIP) ....................................................................................... 18
C-2.4.20
DESLUDGE MODE, removal of sludge in bioreactor...................................................................... 20
C-2.4.20.1 DESLUDGE MODE, manual removal of sludge in bioreactor ......................................................... 20
C-2.4.20.2 Automatic De-Sludge Valve ..................................................................................................... 21
C-2.4.20.3 Water Counter (optional) .......................................................................................................... 21
C-2.4.21
Holding Tank Function (optional)............................................................................................... 22
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JZR-„BIOMASTER “
®
C-2.5
Operating Manual
Part C: Commissioning, operation (MECH)
Table of contents
I/I
C-TOC
3
MAY 20
Glossary ................................................................................................................................23
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I/I
Operating Manual
JZR-„BIOMASTER®“
Part C: Commissioning, operation (MECH)
Commissioning
C-1
Commissioning
C-1.1
Provision of readiness for operation
C-1
5
MAY 20
The wastewater treatment plant can only be put into service after all mechanical connections
according to part B, Storage, Transport, Installation have been installed correctly and after the
electrical connections according to part D, Commissioning, Operation (ELEC) have been
established correctly.
C-1.1.1 Caution
Never use grey water, black water, sea water or brackish water for the first filling of the wastewater
treatment plant. It is impossible to perform a reliable functional test of the wastewater treatment
plant with grey and/or black water, sea water or brackish water.
Prior to initial start, a functional test is necessary with a water run.
The wastewater treatment plant, the buffer tank(s) (customer-provided) and/or wastewater
collection tank(s) (customer-provided) must be filled with clear water. The shut-off valves between
the waste- water treatment plant and the buffer tank(s) and/or wastewater collection tank(s) must
be open. Valves HM1 must be open.
If the wastewater treatment plant is put into operation with valves HM1, HM6, HM9 and HM13
closed, parts of the wastewater treatment plant are damaged or destroyed.
For the water run, fill the wastewater treatment plant with clear water.
C-1.2
Functional test
Perform the following steps consecutively:
C-1.2.1
Checking the valve position (starting position)
Set the valves according to the subsequent table. Shut-off valves may only be set to the OPEN or
CLOSED positions. Three-way-valves must be set so that the writing on the valve lever is horizontal,
e.g. “OPERATION”. Intermediate positions are not allowed.
Intermediate positions (10% to 100%) are allowed for valve S1.X. Valves with pneumatic swivel
drive: Switching position of magnetic valve “0” or “1”.
Valve
Position
Valve
Position
Valve
Position
H2*
F1
H1.1
OPEN
H13.X
OPERATION
H3*
F1
H1.2
OPEN
H14.X
OPERATION
D0
DRAIN
H1.3
OPEN
S1.X
CLOSED
D0.X
CLOSED
H1.4
CLOSED
V1.X
0
D3.X
CLOSED
H1.5
CLOSED
V2.X
0
D5
CLOSED
H1.6
CLOSED
V3.X
0
D6
CLOSED
H11.X
OPERATION
V12
0
H0.X
CLOSED
H12.1
OPERATION
V15
0
Valve
Position
* Only for type JZR 100-1-2 to JZR 500-3-6
For valve designations see R&I flow diagrams and signage at the wastewater treatment plant, “X” stands for a cipher
C-1.2.2 Check the filling level in the ships waste water tank
The filling level in the wastewater collection tank(s) and/or buffer tank(s) must be above the
switching point for the start of pump P5.1.
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JZR-„BIOMASTER®“
Operating Manual
I/I
Part C: Commissioning, operation (MECH)
Commissioning
C-1
Commissioning (continued)
C-1.2
Functional test (continued)
C-1
6
MAY 20
C-1.2.3 Notes
Waste water collection tank(s) and/or buffer tank(s) are separate assemblies which are either
already provided on site or which can be delivered on customer request by the company DVZSERVICES GmbH together with the waste water treatment plant JZR-“BIOMASTER®”.
One switching point (1) is provided as standard (pump P5.1 ON, pump P5.1 OFF).
As an option, either two (2) or four (4) filling level switch points each are provided for the wastewater
collection tank(s) and/or buffer tank(s). Effect of the switching points on the function of the
wastewater treatment plant (see D-1.1.10).
C-1.2.4 Note
The DVZ-JZR-”BIOMASTER®” is equipped with a three-pin sensing electrode. The different pin
lengths have corresponding control functions.
Longest pin = Low, medium pin = High, shortest pin = HighHigh.
Once the filling level LOW is reached or fallen short of, pump P5 is started if a corresponding level is
present in the wastewater collection tank and/or buffer tank. If the pump should not start due to an
insufficient level, pumps P1 and P2 will be stopped with a time delay. The plant switches to STANDBY-MODE.
If the pump is started due to a sufficient level, wastewater is conveyed from the wastewater
collection tank and/or buffer tank into the plant until HIGH is reached. The pump P5 is switched off
automatically here. As soon as HIGH is reached, pumps P1 and P2 start.
If the level HIGH-HIGH is reached, a HIGH-LEVEL-ALARM is created automatically; pump P5 is
switched off and pumps P1 and P2 remain in operation.
C-1.2.5 Connect to clear water tube
Attach A5 to clear water tube, consider a non-return facility (customer-provided). Water temperature
20°C/68°F +/-5°C/9°F, water pressure MAX 1.5 bar.
C-1.2.6 Fill wastewater treatment plant with clear water
Fill the reactor chamber:
Switch valve D3.X to FRESH WATER and up fill the bioreactor to a filling level of 75%. Read the filling
level at level indicator SG01. Once the filling level has been reached, switch valve D0.X to DRAIN.
Please observe: If necessary, continuously clear water up to a filling level of 75% because clear
water (permeate) is continuously discharged via the membrane(s) during the water run.
C-1.2.7
Bleed tubes, pumps, filters and membrane(s)
Open the bleeder valves and bleeder screws, bleed carefully and close them again.
Open the shut-off valves between the wastewater treatment plant and the buffer tank(s) and/or
wastewater collection tank(s). Clear water must be present in all pumps.
C-1.2.8
Caution
Eccentric screw pumps and centrifugal pumps must never run dry.
If the pump runs without the medium to be transported, inner parts and gaskets will be damaged or
destroyed. Bleed the pumps carefully.
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I/I
Operating Manual
JZR-„BIOMASTER®“
Part C: Commissioning, operation (MECH)
Commissioning
C-1
Commissioning (continued)
C-1.2
Functional test (continued)
C-1
7
MAY 20
C-1.2.9 Performing a direction of rotation check for pumps and fans
Activate all pumps and fans individually (see D-1.3.5.1).
Check the direction of rotation. The direction arrow is located on the motor casing of the pump /
casing.
C-1.2.10 Activate the compressed air supply
MIN pressure: 4 bar/ 58 psi, MAX pressure: 6 bar / 87 psi.
JZR 10-1-1 does not have a pneumatic connection.
C-1.2.11 Starting the waste water treatment plant in AUTOMATIC-MODE
Start the AUTOMATIC-MODE (see D-1.3.7).Further functions and ALARM messages are tested with
the water run.
C-1.2.12 Membrane (BMSU) conditioning
The “BMSU conditioning” cleaning program runs in AUTOMATIC MODE and CANNOT be influenced
by the plant operator.
For this, pump P2 is switched off for 10 seconds every 127 seconds.
C-1.2.13 Setting the pressure-sustaining valve
Pressure-sustaining valve PHV1 increases or decreases the amount of clear water (permeate).
Increasing the flow: Turn the set screw on pressure-sustaining valve PHV1 clockwise.
Decreasing the flow: Turn the set screw on pressure-sustaining valve PHV1 counter clockwise.
C-1.2.14 Setting the amount of clear water (permeate)
Type
V [l/h]
Type
V [l/h]
Type
V [l/h]
Type
V [l/h]
JZR 10-1-1
84
JZR 100-1-2
420
JZR 250-2-4
525
JZR 500-3-6
700
JZR 25-1-1
210
JZR 150-1-2
630
JZR 300-2-4
630
JZR 50-1-1
420
JZR 200-2-4
420
JZR 400-2-6
560
The values given in the table are maximum values! Target value = 0.7 x table value. Flow values per membrane (BMSU).
Wastewater treatment plants with one membrane (BMSU):
Read the amount of clear water (permeate) at the float-type flow meter FI1.1.
The V target value is 70% of the table value. Example: JZR 25-1-1: 0.7 x 210 l/h = 147 l/h
Increase the pressure with pressure-sustaining valve PHV1 as necessary, up to a maximum of 3.9
bar. BMSU-PRESSURE-ALARM at 4.0 bar.
Wastewater treatment plants with two to six membranes (BMSU):
Read the amount of clear water (permeate) at float-type flow meter FI1.X.
The V-target value is 70% of the table value. Example: JZR 200-2-4: 0.7 x 420 l/h = 294 l/h
The V-target value for JZR 200-2-4 (4 membranes) 4 x 294 l/h = 1176 l/h. (continued)
Wastewater treatment plants with two to six membranes (BMSU):
The FI1.X float-type flow meters are equipped with a magnetic switch. A FLOW-LOW-ALARM is
triggered at a flow volume of 50% of the maximum value.
Increase the pressure with pressure-sustaining valve PHV1 as necessary, up to a maximum of 3.9
bar. BMSU-PRESSURE-ALARM at 4.0 bar.
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JZR-„BIOMASTER®“
Operating Manual
Part C: Commissioning, operation (MECH)
Commissioning
C-1
Commissioning (continued)
C-1.2
Functional test (continued)
I/I
C-1
8
MAY 20
C-1.2.15 Checking the tightness
Check whether flanged connections, sleeve connections, hoses and compression glands are tight.
Eliminate leakage.
C-1.2.16 Checking the SIDE CLEANING MODE
SIDE CLEANING (head-to-tail flushing) is an automatic cleaning program for the membrane (BMSU).
It inverts the flow direction of the pre-cleaned wastewater in the membrane at fixed intervals. SIDE
CLEANING can also be activated manually with the control electronics outside the defined timely
intervals when necessary. The time interval of the SIDE CLEANING MODE depends on the membrane
type. The membrane type can be taken from the type plate of the membrane (BMSU): Type 1, type
2, type 3 or type 4.
Type 1 and type 2:
The interval of the SIDE CLEANING MODE is set so that every membrane installed in the wastewater
treatment plant is flushed once per hour. The intervals are distributed evenly over one hour, for
example: In case of six installed membranes, a SIDE CLEANING takes place every 10 minutes. The
flushing process lasts 24 seconds, during which the head side and the tail side of the membrane
(BMSU) are flushed for 12 seconds each.
Type 3 and type 4:
The SIDE CLEANING MODE is set so that every membrane (BMSU) installed in the wastewater
treatment plant is flushed twice per hour. The intervals are distributed evenly over one hour, for
example: In case of six installed membranes, a SIDE CLEANING takes place every 5 minutes. The
flushing process lasts 24 seconds, during which the head side and the tail side of the membrane
(BMSU) are flushed for 12 seconds each.
Start the AUTOMATIC-MODE (see D-1.3.7). Select the membrane for SIDE CLEANING (only for two
(2) to six (6) membranes) (see D-1.3.8). Start SIDE CLEANING manually (see D-1.3.8.1).Shut-off
valves V1.X, V2.X V12 and V3.X (V3.X only JZR 100-1-2 to JZR 500-3-6) with pneumatic drives open
and close automatically in an alternating 12 second cycle.
Check whether shut-off valves V1.X, V2.X, V12 and V3.X (V3.X only JZR 100-1-2 to JZR 500-3-6)
open and close at the times stated.
C-1.2.17 Checking the CLOG-ALARM
Check whether the CLOG-ALARM for filters F1/F2 triggers (see D-1.3.9 et seq.). CLOG-ALARM is
activated at a back pressure of 2.0 bar, if the filters F1/F2 are completely clogged. To check, slowly
throttle valve H1.1; do not close it. If a back pressure of 2.0 bar is reached, the wastewater treatment
plant ceases operating automatically. Read the pressure at manometer PIF1, PIF2.
The pressure is registered electronically with pressure switch PS3. Open valve H1.1 after the check.
C-1.2.18 Checking the BMSU-PRESSURE-ALARM
Check whether the BMSU-PRESSURE-ALARM triggers (see D-1.3.10). BMSU-PRESSURE- ALARM is
triggered at a back pressure of 4 bar if the membranes (BMSU) are completely clogged. To check,
slowly throttle shut-off valve at connection A3 (customer-provided); do not close it. If a back
pressure of 4 bar is reached, the wastewater treatment plant ceases operating automatically. Read
the pressure at manometer PI1.X. The pressure is registered electronically with pressure switch
PS1. Open the shut-off valve at connection A3 (customer-provided) after the check.
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C-1
Part C: Commissioning, operation (MECH)
Commissioning
C-1
Commissioning (continued)
C-1.2
Functional test (continued)
C-1.2.19
Checking the FLOW-LOW-ALARM
9
MAY 20
Check whether the FLOW-LOW-ALARM triggers (see D-1.3.11 et seq.). FLOW-LOW-ALARM triggers
when the volume flow at float-type flow meter FI1.X falls short of a minimum value for a period of
10 minutes. To check turn the set-screw at pressure-sustaining valve PHV1 counter-clockwise.
Reduce the pressure to 0 bar. Read the pressure at manometer PI1.X. If the volume flow is fallen
short of at a membrane for 10 minutes, the wastewater treatment plant continues to operate. The
minimum volume flow is registered by an optional reed switch at float-type flow meter FI1.X. After
the check, set the amount of clear water (permeate) for all membranes (BMSU) (see C-1.2.14).
C-1.2.20 Checking the CLEANING-IN-PLACE (CIP) mode
Set the valves according to the table to the position for the CIP function. The test is performed
without membrane cleaning agents.
Valve
Position
Function
Valve
Position
Function
H11.X
CIP
Cleaning
H11.X
OPERATION
Normal operation
H12*
CIP
Cleaning
H12*
OPERATION
Normal operation
H13.X
CIP
Cleaning
H13.X
OPERATION
Normal operation
H14.X
CIP
Cleaning
H14.X
OPERATION
Normal operation
H0.X
OPEN
Cleaning
H0.X
CLOSED
Normal operation
* only for JZR 10-1-1 to JZR 50-1-1
For valve designations see R&U flow diagrams and signage at the wastewater treatment plant
Check the CLEANING-IN-PLACE MODE (CIP) (see D-1.3.13). The energy contribution of the
circulating pump P1.X causes a slow increase of the temperature of the circulated water. Read the
temperature at thermometer TI2.X. The temperature is electronically registered with temperature
switch TS1. If the temperature reaches 60 °C / 140 °F a message at the display of the control unit
will occur. Set the valves according to the table to the OPERATION position.
C-1.2.21 Checking the HIGH-LEVEL ALARM
Check whether HIGH-LEVEL-ALARM (HighHigh) triggers (see D-1.3.14). The HIGH-LEVEL-ALARM
(HighHigh) triggers when the filling level reaches the upper pin of the sensor electrode. Fill up the
bioreactor with clear water. Read the filling level at level indicator SG01. With a filling level of
approx. 135 mm below the tank lid, the operation of the wastewater treatment plant is automatically
stopped and a HIGH-LEVEL-ALARM (HighHigh) is triggered. Pump out clear water.
C-1.2.23 Checking the DESLUDGE MODE
For sludge removal switch over to MANUAL-MODE (see D-1.3.15 et seq.).
Set the valves according to the table to the position for the sludge removal function.
Desludging
Normal operation
H12.1
H1.21
H12.1
H1.21
Desludging point
to connection
Secondary reactor
Calming chamber
A11 (sludge tank)
DESLUDGE
OPEN
OPERATION
OPEN
A3 (over board)
OPERATION
OPEN
OPERATION
OPEN
For valve designations see R&U flow diagrams and signage at the wastewater treatment plant 1 H1.2 is always open.
After sludge removal, return valve H12.1 to the “OPERATION” position. Fill up bio reactor again.
CAUTION: Valve H1.2 remains open (“OPEN” position).
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Operating Manual
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Part C: Commissioning, operation (MECH)
Commissioning
C-1
Commissioning (continued)
C-1.2
Functional test (continued)
C-1
10
MAY 20
C-1.2.24 Observe the temperature in the bioreactor
The temperature in the bioreactor must not exceed 45 °C / 113 °F. Read the temperature at
thermometer TI 1. If the temperature is above 45 °C / 113 °F, let the wastewater treatment plant
cool or feed in clear water (water temperature 20 °C / 68 °F +/-5 °C/ 9°F).
C-1.2.25 Separate the clear water tube
Set valve D0 to DRAIN position. Separate connection A15 from the clear water tube. The functional
test is complete.
C-1.3
Start-up
C-1.3.1 Set the valves
Set the valves according to the table.
Valves with pneumatic swivel drive: Switching position of magnetic valve “0” or “1”.
Valve
Position
Valve
Position
Valve
Position
H2*
F1
H1.1
OPEN
H13.X
OPERATION
H3*
F1
H1.2
OPEN
H14.X
OPERATION
D0
DRAIN
H1.3
OPEN
S1.X
CLOSED
D0.X
CLOSED
H1.4
CLOSED
V1.X
0
D3.X
CLOSED
H1.5
CLOSED
V2.X
0
D5
CLOSED
H1.6
CLOSED
V3.X
0
D6
CLOSED
H11.X
OPERATION
V12
0
H0.X
CLOSED
H12.1
OPERATION
V15
0
Valve
Position
* Only for type JZR 100-1-2 to JZR 500-3-6
For valve designations see R&I flow diagrams and signage at the wastewater treatment plant, “X” stands for a cipher
C-1.3.2 Open the shut-off valve to the ships waste water tank
Shut-off valves are customer-provided.
C-1.3.3
Start the AUTOMATIC-MODE
Start the waste water treatment plant in AUTOMATIC-MODE (see D-1.3.7).
C-1.3.4
Membrane (BMSU) conditioning
The “BMSU conditioning” cleaning program runs in AUTOMATIC MODE and CANNOT be influenced
by the plant operator.
For this, pump P2 is switched off for 10 seconds every 127 seconds.
C-1.3.5 Set the amount of clear water (permeate)
Set pressure-sustaining valve PHV1 to approximately 1.0 bar.
Increasing the pressure: Turn the set screw at pressure-sustaining valve PHV1 clockwise.
Reducing the pressure: Turn the set screw at pressure-sustaining valve PHV1 counter clockwise.
Read the pressure at manometer PI1.1 (PI1.X).
Pressure-sustaining valve PHV1 increases or decreases the amount of clear water (permeate).
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Part C: Commissioning, operation (MECH)
Commissioning
C-1
Commissioning (continued)
C-1.3
Start-up (continued)
C-1
11
MAY 20
C-1.3.5 Set the amount of clear water (permeate) (continued)
Type
V [l/h]
Type
V [l/h]
Type
V [l/h]
Type
V [l/h]
JZR 10-1-1
84
JZR 100-1-2
420
JZR 250-2-4
525
JZR 500-3-6
700
JZR 25-1-1
210
JZR 150-1-2
630
JZR 300-2-4
630
560
JZR 50-1-1
420
JZR 200-2-4
420
JZR 400-2-6
The values given in the table are maximum values! Target value = 0.7 x table value. Flow values per membrane (BMSU).
Read the amount of clear water (permeate) at float-type flow meter FI1.1.
The V-target value is 70% of the table value. Example: JZR 25-1-1: 0.7 x 210 l/h = 147 l/h
Float-type flow meters FI1.X are equipped with a magnetic switch. A FLOW-LOW-ALARM is triggered
at a flow volume of 50% of the maximum value: the wastewater treatment plant continues to
operate, immediately perform a CLEANING-IN-PLACE (CIP) of the affected membrane.
Increase the pressure with pressure-sustaining valve PHV1 as necessary, up to a maximum of 3.9
bars. BMSU-PRESSURE-ALARM at 4.0 bar: the wastewater treatment plant stops to operate, perform
CLEANING-IN-PLACE (CIP) of the membranes immediately.
C-1.3.6 Note
After a prolonged operation time of the membrane(s) (BMSU), the clear water passage is
increasingly clogged by fine contamination, thus decreasing the amount of clear water (permeate).
The back pressure must be manually adapted to the desired amount of clear water with pressuresustaining valve PHV 1.
In case of wastewater treatment plants with several membranes, individual membranes (BMSU) can
become contaminated to different degrees. The desired clear water (permeate) target value is
reached by a manual adjustment of the back pressure.
A BSMU PRESSURE ALARM is triggered at a back pressure of 4.0 bar. In this operating condition all
pumps are switched off except for pump P3/6.
Immediately perform CLEANING-IN-PLACE (CIP).
C-1.3.7 Finishing the commissioning
The biological processes in the wastewater treatment plant start as soon as black and grey water is
supplied continuously to the bioreactor. After approximately three hours (or more depending on the
supplied organic load), commissioning is finished and the wastewater treatment plant is ready to
operate. The start-up process is complete.
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Operating Manual
Part C: Commissioning, operation (MECH)
Commissioning
C-1
Commissioning (continued)
C-1.4
Glossary
I/I
C-1
12
MAY 20
Term
Definition
Calming chamber
Treated wastewater from the secondary reactor is fed
into this part, which has a special geometric shape,
passing over a weir and a calming section.
Secondary reactor
The wastewater treated in the primary reactor is
collected here. Additionally, untreated wastewater from
the wastewater collection tank is supplied
continuously.
Primary reactor
Works according to the patented principle of the Jet
Zone Loop Reactor. This permits the fast and intensive
mixing of wastewater enriched with varying levels of
microorganisms (biomass) and atmospheric oxygen.
Bioreactor, three-zone-bioreactor
The part of the wastewater treatment plant which
includes the primary reactor, the secondary reactor and
the calming chamber.
Grey water
Faeces-free wastewater from sinks and showers, but
not from galleys.
Black water
Wastewater containing faeces with toilet paper.
Sea water, salt water
Sea water with an average salinity of 3.5 %.
Brackish water
Sea water mixed with river water with a salinity of
0.05 % to 1 %.
Clear water
Hygienically-acceptable water which is not of drinking
water quality.
Clear water (permeate)
Wastewater cleaned by the DVZ-BMSU with a value
according to IMO MEPC.159 (55) specifications.
DVZ-BMSU
The DVZ Biomass Separation Unit (BMSU) is a
semipermeable membrane with special technical
characteristics.
DVZ-PL
The DVZ Permeat Lift is a lifting station for clear water
(permeate). The DVZ-PL is optionally available as a
separate installation.
ships waste water tank(customer-provided) Collection tank for black and grey water.
In the event of a constructional separation of the substance flows, separate wastewater collection tanks must
be provided for grey and black water.
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C-2
Operation
C-2.1
Intended use
Operating Manual
Part C: Commissioning, operation (MECH)
Operation (MECH)
I/I
C-2
13
MAY 20
The DVZ-JZR “BIOMASTER®” wastewater treatment plant is solely suitable for the biological
cleaning of grey and black water according to IMO MEPC 159 (55) and IMO MEPC 227 (64) on e.g.
seagoing vessels, riverboats, yachts, naval vessels and offshore constructions.
The Equipment conforms to the requirements of “Technical Regulations on the Safety of Sea
Transport Items” (it is approved as the resolution of the Government of the Russian Federation of
August 12, 2010 No. 620). All-Production Classification Code of Products 64 1600. The product is
labelled with conformity mark (RF Government Order No.696 dated 19.11.2003).
The DVZ-JZR “BIOMASTER®” wastewater treatment plant is unsuitable for the treatment of catering
waste as well as wastewaters containing acids, lyes and oil, or ballast water.
The wastewater treatment plant must not be operated with sea water, brackish water or condensate.
The rating of the DVZ-JZR “BIOMASTER®” wastewater treatment plant presupposes a proportion of
at least 80 litres of grey water per day and person as an operating condition.
A buffer tank or a wastewater collection tank must be upstream of the DVZ-JZR “BIOMASTER®”
wastewater treatment plant.
C-2.2
Safety note
The wastewater treatment plant may only be stored, transported, assembled, operated, maintained
and disposed of by qualified specialist staff. Qualified specialist staff are persons who have a
qualification reflecting their activity, e.g.:
1.
2.
3.
4.
C-2.3
Training or instruction as a skilled worker in the areas of ship engine technology, shipboard
electrical systems or wastewater treatment for vessels and offshore constructions.
Training or instruction with respect to the use of personal protection equipment according to
the acknowledged rules of safety engineering.
Training and instruction with respect to work and health protection as well as with respect to
the Accident Prevention Regulations and the Accident Prevention Regulations for Enterprises
engaged in Seafaring.
Training and instruction with respect to the IMO International Safety Management Code (ISM
code)
Danger
The wastewater treatment plant contains wastewaters and effluent sludge with pathogenic bacteria,
viruses and fungi.
Contact with wastewater or effluent sludge can lead to severe diseases or cause death.
Personal safety equipment must be worn during all work carried out at the wastewater treatment
plant:
Hand protection, face protection, safety glasses, head protection, body protection, foot protection.
Never eat or drink in or near the wastewater treatment plant. Observe hygiene rules. Wash hands
thoroughly.
C-2.4
Operation of the wastewater treatment plant
The DVZ-JZR “BIOMASTER®” wastewater treatment plant is a semiautomatic, biological wastewater
treatment plant. Depending on the operating mode and the load of the wastewater treatment plant,
either constant monitoring or checks every 12 hours are required in the context of normal
watchkeeping.
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Part C: Commissioning, operation (MECH)
Operation (MECH)
C-2
Operation (continued)
C-2.4
Operation of the wastewater treatment plant (continued)
C-2
14
MAY 20
C-2.4.1 Note
Experience shows that the organic load of the wastewater treatment plant is particularly high during
watch changes, shortly after meals or during events on board. For these periods we recommend
more frequent monitoring of the wastewater treatment plant.
C-2.4.2 Valve position for operation
Set the valves according to the table.
Valves with pneumatic swivel drive: Switching position of magnetic valve “0” or “1”.
Valve
Position
Valve
Position
Valve
Position
H2*
F1
H1.1
OPEN
H13.X
OPERATION
H3*
F1
H1.2
OPEN
H14.X
OPERATION
D0
DRAIN
H1.3
OPEN
S1.X
CLOSED
D0.X
CLOSED
H1.4
CLOSED
V1.X
0
D3.X
CLOSED
H1.5
CLOSED
V2.X
0
D5
CLOSED
H1.6
CLOSED
V3.X
0
D6
CLOSED
H11.X
OPERATION
V12
0
H0.X
CLOSED
H12.1
OPERATION
V15
0
Valve
Position
* Only for type JZR 100-1-2 to JZR 500-3-6
For valve designations see R&I flow diagrams and signage at the wastewater treatment plant, “X” stands for a cipher
C-2.4.3 Checking the temperature (operating range, operating limits)
Read the temperature in the bioreactor at thermometer TI1.
Normal operating range:
5 °C / 41 °F to 40 °C / 104 °F
Maximum operating range: 40 °C / 104 °F to 45 °C / 113 °F
MIN and MAX operating limits: ≤5 °C / 41 °F and ≥45 °C / 113 °F
C-2.4.4
Caution
Temperatures <5°C / 41°F or frost (≤0°C / 32°F) will damage or destroy the wastewater treatment
plant. Heat the wastewater treatment plant to a temperature between 5 °C / 41 °F and a maximum
of 40 °C / 104 °F.
If necessary, fill/heat with clear water.
Never add antifreeze agents to the wastewater treatment plant.
This will prevent its biological cleaning capacity. The membranes (BMSU) are destroyed.
Below 5 °C / 41 °F, the biological cleaning ability becomes heavily reduced or even impossible.
Heat up the bioreactor to a temperature between 5 °C / 41 °F and a maximum of 40 °C / 104 °F.
If necessary, fill/heat with clear water.
Above 45 °C / 113 °F, the biological cleaning ability becomes heavily reduced or even impossible.
Cool the bioreactor to 40 °C / 104 °F.
If necessary, fill/cool down with clear water.
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Part C: Commissioning, operation (MECH)
Operation (MECH)
C-2
Operation (continued)
C-2.4
Operation of the wastewater treatment plant (continued)
C-2.4.5
Cooling or heating the bioreactor
C-2
15
MAY 20
Attach connection A15 to clear water tube, consider a non-return facility (customer-provided). Water
temperature 20 °C/68 °F +/-5 °C/9 °F, water pressure MAX 1.5 bar. Set valve D0 to the FRESHWATER
position, open valve HM14.X. Switch valve D3.X to FRESH WATER, fill the bioreactor to a maximum filling
level of 96 %. Read the filling level at level indicator SG01. As soon as the temperature is reached at
thermometer TI1, or as soon as the filling level is reached, switch valve D3.X to DRAIN position. Separate
connection A15 from the clear water tube.
C-2.4.6
Checking the bleeder tubes (bioreactor)
Activated carbon filters (customer-provided), installed as odour barriers in the bleeding tubes, can
become clogged with micro-organisms over time so that effective bleeding of the bioreactor
becomes impossible. The consequences of this are increased foam formation and increased
pressure in the bioreactor.
C-2.4.7 Organic load
The organic load of the wastewater treatment plant depends on the supplied volume of grey and
black water per time unit.
In case of an expected high load and/or in case of a BMSU-PRESSURE-PRE-ALARM, clean the BMSU
membrane(s) with the CLEANING-IN-PLACE function (CIP), if necessary remove sludge (see C2.4.20).
In case of a low organic load, foam may form in the bioreactor.
C-2.4.8
Membrane (BMSU) conditioning
The “BMSU conditioning” cleaning program runs in AUTOMATIC MODE and CANNOT be influenced
by the plant operator.
For this, pump P2 is switched off for 10 seconds every 127 seconds.
C-2.4.9 Checking the pressure-sustaining valve
Pressure-sustaining valve PHV1 increases or decreases the amount of clear water (permeate).
Increasing the pressure: Turn the set screw at pressure-sustaining valve PHV1 clockwise.
Reducing the pressure: Turn the set screw at pressure-sustaining valve PHV1 counter clockwise.
Read the pressure at manometer PI1.1 (PI1.X).
C-2.4.10 Checking the clear water volume
Type
V [l/h]
Type
V [l/h]
Type
V [l/h]
Type
V [l/h]
JZR 10-1-1
84
JZR 100-1-2
420
JZR 250-2-4
525
JZR 500-3-6
700
JZR 25-1-1
210
JZR 150-1-2
630
JZR 300-2-4
630
JZR 50-1-1
420
JZR 200-2-4
420
JZR 400-2-6
560
The values given in the table are maximum values! Target value = 0.7 x table value. Flow values per membrane (BMSU).
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Operating Manual
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Part C: Commissioning, operation (MECH)
Operation (MECH)
C-2
Operation (continued)
C-2.4
Operation of the wastewater treatment plant (continued)
C-2
16
MAY 20
C-2.4.10 Checking the clear water volume (continued)
Wastewater treatment plants with one membrane (BMSU):
Read the amount of clear water (permeate) at the float-type flow meter FI1.1.
The V target value is 70% of the table value. Example: JZR 25-1-1: 0.7 x 210 l/h = 147 l/h
Increase the pressure with pressure-sustaining valve PHV1 as necessary, up to a maximum of 3.9
bar.
BMSU-PRESSURE-ALARM at 4.0 bar: the wastewater treatment plant continues to operate, perform
CLEANING-IN-PLACE (CIP) of the membrane immediately.
Wastewater treatment plants with two to six membranes (BMSU):
Read the amount of clear water (permeate) at float-type flow meter FI1.X.
The V target value is 70% of the table value. Example: JZR 200-2-4: 0.7 x 420 l/h = 294 l/h
The V target value for JZR 200-2-4 (4 membranes) 4 x 294 l/h = 1176 l/h
Membranes (BMSU) can become contaminated to different degrees. Thus, the amount of clear water
(permeate) can vary at float-type flow meters FI1.X.
The float-type flow meters FI1.X are equipped with a magnetic switch. A FLOW-LOW-ALARM is
triggered at a flow volume of 50% of the maximum value: the wastewater treatment plant continues
to operate, immediately perform a CLEANING-IN-PLACE (CIP) of the affected membrane.
Increase the pressure with pressure-sustaining valve PHV1 as necessary, up to a maximum of 3.9
bar. BMSU-PRESSURE-ALARM at 4.0 bar: The wastewater treatment plant continues to operate,
perform CLEANING-IN-PLACE (CIP) of the membranes immediately.
C-2.4.11 Note
After prolonged operation of the membrane(s) (BMSU), the clear water passage is increasingly
clogged by fine contamination, thus decreasing the amount of clear water (permeate). The back
pressure must be manually adapted to the desired amount of clear water with the pressuresustaining valve PHV 1.
In case of wastewater treatment plants with several membranes, individual membranes (BMSU) can
become contaminated to different degrees. The desired clear water (permeate) target value is
reached by a manual adjustment of the back pressure.
A BSMU PRESSURE ALARM is triggered at a back pressure of 4.0 bar. In this operating condition all
pumps are switched off except for pump P3/6. Immediately perform CLEANING-IN-PLACE (CIP).
C-2.4.12 BMSU-PRESSURE-ALARM
BMSU-PRESSURE-ALARM is activated at a back pressure of 4.0 bar if the membranes (BMSU) are
completely clogged. If a back pressure of 4.0 bar is reached, the wastewater treatment plant ceases
operating automatically. Read the pressure at manometer PI1.X. In this operating condition all pumps
are switched off except for pump P3/6. Perform CLEANING-IN-PLACE (CIP) of the membrane(s)
immediately.
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Part C: Commissioning, operation (MECH)
Operation (MECH)
C-2
Operation (continued)
C-2.4
Operation of the wastewater treatment plant (continued)
C-2
17
MAY 20
C-2.4.13 FLOW-LOW-ALARM
FLOW-LOW-ALARM triggers when the volume flow at float-type flow meter FI2.X falls short of a
minimum value for a period of 10 minutes. If the volume flow falls short at a membrane for 10
minutes, the wastewater treatment plant continues to operate. Perform CLEANING-IN-PLACE (CIP) of
the membrane(s) in the short term.
C-2.4.14 High-Level-Alarm
The HIGH-LEVEL-ALARM (HighHigh) triggers when the filling level in the control tank reaches the
upper pin of the sensor electrode. Read the filling level at level indicator SG01. With a filling level of
>97 %, the operation of the wastewater treatment plant is automatically stopped and a HIGHLEVEL-ALARM (HighHigh) is triggered.
Reduce the filling level to 75 % with pump P2.
C-2.4.15 Note
The DVZ-JZR-”BIOMASTER®” is equipped with a three-pin probe (sensor electrode). The different pin
lengths have corresponding control functions.
Longest pin = Low, medium pin = High, shortest pin = HighHigh.
Once the filling level LOW is reached or fallen short of, pump P5 is started if a corresponding level is
present in the wastewater collection tank and/or buffer tank. If the pump should not start due to an
insufficient level, pumps P1 and P2 will be stopped with a time delay. The plant switches to STANDBY-MODE.
If the pump is started due to a sufficient level, wastewater is conveyed from the wastewater
collection tank and/or buffer tank into the plant until HIGH is reached. The pump P5 is switched off
automatically here. As soon as the HIGH point is reached, pumps P1 and P2 start.
If the level HIGH-HIGH is reached, a HIGH-LEVEL-ALARM is created automatically; pump P5 is
switched off and pumps P1 and P2 remain in operation.
C-2.4.16 CLOG-ALARM
CLOG-ALARM is activated at a back pressure of 2.0 bar, if the filters F1/F2 are completely clogged. If
a back pressure of 2.0 bar is reached, the wastewater treatment plant ceases operating
automatically. Read the pressure at manometer PIF1, PIF2.
Wastewater treatment plants with one filter F1:
Clean filter F1 immediately.
Wastewater treatment plant with two filters (F1/F2):
Switch over valves H2 and H3 to filter F2 (F1). Clean filter F1 (F2) immediately.
C-2.4.17 Membrane (BMSU) conditioning
The “BMSU conditioning” cleaning program runs in AUTOMATIC MODE and CANNOT be influenced
by the plant operator.
For this, pump P2 is switched off for 10 seconds every 127 seconds.
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Operation (MECH)
C-2
Operation (continued)
C-2.4
Operation of the wastewater treatment plant (continued)
C-2
18
MAY 20
C-2.4.18 Start SIDE CLEANING MODE manually
Perform a SIDE CLEANING of the membrane (BMSU) prior to every CLEANING-IN-PLACE (CIP). Start
SIDE CLEANING manually (see D-2.3.9).
C-2.4.19 CLEANING-IN-PLACE (CIP)
Prepare the wastewater treatment plant for the CLEANING-IN-PLACE (CIP) and subsequently perform
the CLEANING-IN-PLACE (CIP) (see D-2.3.10).
C-2.4.19.1Danger
Membrane cleaning agents are strongly corrosive and cause severe eye damage.
Severe injuries to the hands, eyes, face and body are possible. Severe damage to health is possible
if ingested.
Personal safety equipment must be worn during all work at the wastewater treatment plant: Hand
protection, face protection, safety glasses, head protection, body protection, foot protection.
In the event of contact with the eyes or skin, immediately rinse with drinking water, use an eye bath
and immediately consult a physician.
Read the safety data sheet and the operating manual of the manufacturer.
C-2.4.19.2Caution
Valves H11.X, H13.X and H14.X must be set to the CIP position before the CLEANING-IN-PLACE and
set manually to the OPERATION position after the CLEANING-IN-PLACE.
If valves are not set manually to the indicated position, parts of the wastewater treatment plant will
be damaged or destroyed. Membrane cleaning agent may leak.
C-2.4.19.3Perform a CLEANING-IN-PLACE (CIP)
Wastewater treatment plants with one membrane (BMSU):
During the temperature and time-limited CLEANING-IN-PLACE process, the membrane (BMSU) is
unable to separate clear water from pre-cleaned wastewater. During this time, the wastewater
treatment plant is not available for cleaning wastewater.
Wastewater treatment plants with two to six membranes (BMSU):
The membranes (BMSU) which are not being cleaned remain available for wastewater cleaning
during the temperature- and time-limited CLEANING-IN-PLACE. Only one membrane can be cleaned
at a time.
Use a membrane cleaning agent, e.g. Osmotech 2691® or Osmotech 2610®.
Before starting the CIP Process, please execute the Side-Cleaning manually (see C-2.4.18).
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Operation (MECH)
C-2
Operation (continued)
C-2.4
Operation of the wastewater treatment plant (continued)
C-2
19
MAY 20
C-2.4.19 CLEANING-IN-PLACE (CIP) (continued)
C-2.4.19.3Perform a CLEANING-IN-PLACE (CIP) (continued)
1. Open the bleeder valve (if used) 1.
2. Loosen and remove screw cap 2.
3. Open the shut-off valves 3/6 of level indicator 8
completely.
4. Add cleaning agent to the CIP storage tank ❹
5. If too much cleaning agent has been added, drain it
into an appropriate container via outlet valve 7.
6. Screw on the screw cap 2 tightly.
Set the valves according to the table.
Valve
Position
Function
Valve
Position
Function
H11.X
CIP
Cleaning
H11.X
OPERATION
Normal operation
H13.X
CIP
Cleaning
H13.X
OPERATION
Normal operation
H14.X
CIP
Cleaning
H14.X
OPERATION
Normal operation
H0.X
OPEN
Cleaning
H0.X
CLOSED
Normal operation
D0
DRAIN
D0
FRESHWATER
Flushing
membrane (s)
D3
OPEN
D3
CLOSED
Normal operation
D3.X**
OPEN
D3.X
CLOSED
Normal operation
membrane X
HM14.X
OPEN
HM14.X
CLOSED
Flushing,
Normal operation
membrane (s)
Emptying
membrane (s)
Emptying
membrane (s)
Flushing,
emptying
membrane X
Bleeding
membrane X
* only for JZR 10-1-1 to JZR 50-1-1, ** only for JZR 100-1-2 to JZR 500-3-6, „X” stands for “1” to “6”
For valve designations see R&U flow diagrams and signage at the wastewater treatment plant
Wastewater treatment plants with one membrane (BMSU):
1. Drain the membrane (BMSU):
Valve D0 to the DRAIN position, open valve D3.1, open valve HM14.1.
Completely empty membrane 1
2. Flush the membrane (BMSU) with clear water:
Valve D0 to the FRESHWATER position. Fill the membrane until clear water comes out of valve
HM14.1. Close valves HM14.1 and D3.1, set valve D0 to the DRAIN position.
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I/I
Operating Manual
JZR-„BIOMASTER®“
C-2
Part C: Commissioning, operation (MECH)
Operation (MECH)
C-2
Operation (continued)
C-2.4
Operation of the wastewater treatment plant (continued)
20
MAY 20
C-2.4.19 CLEANING-IN-PLACE (CIP) (continued)
Wastewater treatment plants with two to six membranes (BMSU):
1. Drain the membrane (BMSU):
Set valve D0 to the DRAIN position, open valve D3, open valve D3.X, open valve
HM14.1.Completely empty membrane X (BMSU). “X” stands for membrane 1 to membrane 6
(optional)
2. Flush the membrane (BMSU) with clear water:
Valve D0 to the FRESHWATER position. Fill the membrane until clear water comes out of valve
HM14.X. Close valves HM14.X, D3.X and D3, set valve D0 to the DRAIN position.
In the event of strong contamination flush the membrane several times, activate the CLEANING-INPLACE MODE (CIP) (see D-2.3.10). The energy contribution of circulating pump P1.X causes a slow
increase of the temperature of the circulated water. Read the temperature at thermometer TI2.X. The
cleaning process is ended automatically at a temperature of 60 °C / 140 °F. After 2.5 hours an alarm
message is triggered stating that the CIP can be ended. Set the valves according to the table to the
OPERATION position.
Set the target value of the clear water (permeate) volume according to C-2.4.10.
C-2.4.20 DESLUDGE MODE, removal of sludge in bioreactor
The sludge volume in the bioreactor depends on the organic load of the wastewater treatment plant.
If the biomass increase in the bioreactor is greater than necessary, surplus sludge must be removed
manually at variable, load-dependent intervals (at least once per week).
C-2.4.20.1DESLUDGE MODE, manual removal of sludge in bioreactor
For sludge removal switch over to MANUAL-MODE (see D-2.3.12 et seq.).
Set the valves according to the table to the position for the sludge removal function.
Desludging
Normal operation
Desludging point
to connection
H12.1
H1.21
H12.1
H1.21
Secondary reactor
Calming chamber
A11 (sludge tank)
DESLUDGE
OPEN
OPERATION
OPEN
A3 (over board)
OPERATION
OPEN
OPERATION
OPEN
For valve designations see R&U flow diagrams and signage at the wastewater treatment plant 1 H1.2 is always open.
1. Set the plant to MANUAL-MODE (see D-2.3.6).
2. Set the valves according to the above table.
3. Start the automatic desludge (see D-2.3.12).
The pump runs for a pre-set time and pumps sludge from the first and second chamber (preclarification tank and clarification tank) of the STP container to the set connection A3.1 or A13.
The pump stops automatically after the pre-set time.
4. Fill up bioreactor again.
5. Set back the valves.
After sludge removal, return valves H12 and H12.1 to the “OPERATION” position, close valves H4
and H5 and open valve H7.
6. Switch over from MANUAL-MODE to AUTOMATIC MODE (see D-2.3.8).
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JZR-„BIOMASTER®“
Operating Manual
Part C: Commissioning, operation (MECH)
Operation (MECH)
C-2
Operation (continued)
C-2.4
Operation of the wastewater treatment plant (continued)
I/I
C-2
21
MAY 20
C-2.4.20 DESLUDGE MODE, removal of sludge in bioreactor (continued)
C-2.4.20.2Automatic De-Sludge Valve
The automatic de-sludge valve V15 is a 3-way valve for the automatic desludging of the sewage
treatment plant. It is a pneumatic operated valve which is controlled by an adjusted time. The valve
will switch the outlet of the valve from “back to the STP” to “sludge tank” for an adjusted time. This
could increase the interval between two de-sludging-cycles. Nevertheless the STP tank has to be
desludged manually in regular intervals completely.
The parameters of the valve could be adjusted to the situation on board respectively to the needs of
the system. The adjustment is three-stage and the standard adjustment is programmed to stage 1.
But this could be changed to stage 2 or stage 3.
The installation of the automatic desludge valve will not replace the maintenance procedure of
desludging the sewage treatment plant.
C-2.4.20.3Water Counter (optional)
The optional water counter could be used as a helpful hint for operator and shows in combination
with the switchbox, when the manual desludging of the sewage treatment plant shall be carried out.
At the pre-adjusted value that corresponds to the weekly nominal maximum capacity of the plant, an
alarm message will occur at the switchbox, that the sewage treatment plant shall be de-sludged
now. The parameters are programmed in the workshop but could be adjusted on board, if necessary.
The water counter presents also a reasonable optional possibility for the operator to check the
water/permeate amount that the sewage treatment plant has produced.
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JZR-„BIOMASTER®“
Operating Manual
Part C: Commissioning, operation (MECH)
Operation (MECH)
C-2
Operation (continued)
C-2.4
Operation of the wastewater treatment plant (continued)
I/I
C-2
22
MAY 20
C-2.4.21 Holding Tank Function (optional)
With the Holding Tank Function it is possible to discharge an external tank by using the optional
connection A13 and the pump P3/6 at the sewage treatment plant. For this function a tank level
(Minimum = LOW-Signal) of the related tank is necessary.
To empty the tank the AUTOMATIC-MODE of the sewage treatment plant must be stopped. The
mode could now be changed to DISCHARGE-MODE.
Before starting the mode, valve H1.2 must be CLOSED, valve H1.6 must be OPENED and valve H12.1
must be switched to DISCHARGE position
Start the pump P3/6 manually (see D-1.3.5). The pump will stop automatically when the level in the
tank reaches LOW-Level. A manual stopping of the pump is possible also.
After finishing the Holding Tank Function, the valve H1.6 must be CLOSED; valve H12.1 must be
switched to OPERATION and valve H1.2 must be OPENED. The sewage treatment plant must be
started in AUTOMATIC-MODE again.
ATTENTION!
The related manual valves must be switched to the correct position for discharging the connected
tank. After the discharge the valves must be switched back to the correct position for the automatic
operation of the sewage treatment plant.
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JZR-„BIOMASTER®“
C-2
Operation (continued)
C-2.5
Glossary
Operating Manual
Part C: Commissioning, operation (MECH)
Operation (MECH)
I/I
C-2
23
MAY 20
Term
Definition
Calming chamber
Treated wastewater from the secondary reactor is fed
into this part, which has a special geometric shape,
passing over a weir and a calming section.
Secondary reactor
The wastewater treated in the primary reactor is collected here. Additionally, untreated wastewater from the
wastewater collection tank is supplied continuously.
Primary reactor
Works according to the patented principle of the Jet
Zone Loop Reactor. This permits the fast and intensive
mixing of wastewater enriched with varying levels of
microorganisms (biomass) and atmospheric oxygen.
Bioreactor, three-zone-bioreactor
The part of the wastewater treatment plant which includes the primary reactor, the secondary reactor and the
calming chamber.
Biomass, activated sludge
The concentration of micro-organisms which degrade
organic substances including inorganic and organic
components during the aerobic cleaning of wastewater.
Grey water
Faeces-free wastewater from sinks and showers, but
not from galleys.
Black water
Wastewater containing faeces with toilet paper.
Sea water, salt water
Sea water with an average salinity of 3.5 %.
Brackish water
Sea water mixed with river water with a salinity of
0.05 % to 1 %.
Clear water
Hygienically-acceptable water which is not of drinking
water quality.
Clear water (permeate)
Wastewater cleaned by the DVZ-BMSU with a value
according to IMO MEPC.159 (55) specifcations.
DVZ-BMSU
The DVZ Biomass Separation Unit (BMSU) is a semipermeable membrane with special technical characteristics.
DVZ-PL
The DVZ Permeat Lift is a lifting station for clear water
(permeate). The DVZ-PL is optionally available as a
separate installation.
ships waste water tank (customer-provided) Collection tank for black and grey water.
In the event of a constructional separation of the
substance flows, separate wastewater collection tanks
must be provided for grey and black water.
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JZR-„BIOMASTER®“
Operating Manual
Part D: Commissioning, operation (ELEC)
Table of contents
I/I
D-TOC
1
MAY 20
D-TOC
Table of contents ....................................................................................................................... 1
D-1
Commissioning .....................................................................................................................3
D-1.1
Provision of readiness for operation .............................................................................................3
D-1.1.1
Danger ....................................................................................................................................3
D-1.1.2
EMERGENCY OFF pushbutton (optionally) ...................................................................................... 3
D-1.1.3
Caution ................................................................................................................................... 3
D-1.1.4
Supply voltage .......................................................................................................................... 4
D-1.1.5
On-board voltage ....................................................................................................................... 4
D-1.1.6
Caution ................................................................................................................................... 4
D-1.1.7
Voltage supply of the wastewater treatment plant ........................................................................4
D-1.1.8
Voltage supply for external assemblies ........................................................................................4
D-1.1.9
Signal inputs from external switches / transmitters ......................................................................4
D-1.1.10
Signal input, level of ships waste water tank ................................................................................4
D-1.1.11
Signal outputs ..........................................................................................................................4
D-1.1.12
Note ........................................................................................................................................5
D-1.2
Operating elements..................................................................................................................5
D-1.2.1
Switching cabinet operating elements (example) ..........................................................................5
D-1.2.2
Console of the wastewater treatment plant ..................................................................................5
D-1.2.3
Operating elements of the programmable logic control (PLC) ........................................................6
D-1.2.4
Alarm messages .....................................................................................................................6
D-1.3
Functional test ..........................................................................................................................9
D-1.3.1
Check the signal input for the levels of the ships waste water tank ................................................9
D-1.3.2
Note ........................................................................................................................................9
D-1.3.3
Check the filling level in the ships waste water tank .....................................................................9
D-1.3.4
Switch the plant on....................................................................................................................9
D-1.3.5
Perform a direction of rotation check for pumps and fans .............................................................9
D-1.3.5.1 Manual start and stop of pumps and fans ..................................................................................10
D-1.3.6
Caution .................................................................................................................................11
D-1.3.7
Start the wastewater treatment plant in AUTOMATIC-MODE .......................................................12
D-1.3.8
Manual start of SIDE CLEANING ...............................................................................................12
D-1.3.8.1 SIDE CLEANING process ............................................................................................................. 12
D-1.3.9
Checking the CLOG-ALARM .....................................................................................................13
D-1.3.10
Checking the BSMU-PRESSURE-ALARM ....................................................................................13
D-1.3.11
Check the FLOW-LOW-ALARM .................................................................................................13
D-1.3.12
Check the CLEANING-IN-PLACE MODE (CIP) .............................................................................. 14
D-1.3.13
Checking the HIGH-LEVEL-ALARM (HighHigh) ............................................................................. 15
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JZR-„BIOMASTER®“
Operating Manual
Part D: Commissioning, operation (ELEC)
Table of contents
I/I
D-TOC
2
MAY 20
D-1.3.14
Check the DESLUDGE MODE (to connection A3.1) ...................................................................... 15
D-2
Operation ............................................................................................................................ 17
D-2.1
Intended use.......................................................................................................................... 17
D-2.2
Safety note ............................................................................................................................ 17
D-2.2.1
Danger ................................................................................................................................. 17
D-2.2.2
Caution ................................................................................................................................ 17
D-2.3
Operation of the wastewater treatment plant ............................................................................. 18
D-2.3.1
Note ..................................................................................................................................... 18
D-2.3.2
Operating elements ............................................................................................................... 18
D-2.3.2.1 Switching cabinet operating elements (example) ....................................................................... 18
D-2.3.2.2 Console of the wastewater treatment plant ............................................................................... 18
D-2.3.3
Operating elements of the programmable logic control (PLC) ..................................................... 19
D-2.3.4
Normal operation and alarm messages ..................................................................................... 19
D-2.3.4.1 Note ..................................................................................................................................... 22
D-2.3.5
Switching the plant on ............................................................................................................ 22
D-2.3.6
Manual start and stop of pumps and fans ................................................................................. 23
D-2.3.7
Caution ................................................................................................................................ 24
D-2.3.8
Starting the wastewater treatment plant in AUTOMATIC-MODE .................................................. 25
D-2.3.9
Manual start of SIDE CLEANING .............................................................................................. 25
D-2.3.9.1 SIDE CLEANING process .............................................................................................................25
D-2.3.10
CLEANING-IN-PLACE MODE (CIP) ..............................................................................................26
D-2.3.11
Starting the DESLUDGE MODE (to connection A3.1).................................................................... 27
D-APX1
Electric Wiring Diagram ........................................................................................................... 29
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JZR-„BIOMASTER®“
Operating Manual
I/I
Part D: Commissioning, operation (ELEC)
Commissioning
D-1
Commissioning
D-1.1
Provision of readiness for operation
D-1
3
MAY 20
The wastewater treatment plant can only be put into service after all mechanical connections have
been installed correctly according to part B, Storage, Transport, Installation .
D-1.1.1
Danger
The terminal strips in the switching cabinet are live during all phases of operation and after the
actuation of the EMERGENCY OFF pushbutton.
The electric current can cause severe injury or death.
Disconnect the wastewater treatment plant from voltage prior to installation and maintenance
works.
D-1.1.2
EMERGENCY OFF pushbutton (optionally)
Hit the red knob in case of danger.
All pump motors and magnetic valves are immediately free of voltage. The AUTOMATIC-MODE is
stopped. Manually-started pump motors are immediately free of voltage.
After unlocking the EMERGENCY-OFF pushbutton, all pump motors and magnetic valves remain free
voltage until the operator starts the AUTOMATIC-MODE, or until the operator starts pump motors
manually.
To unlock turn the red knob of the EMERGENCY OFF pushbutton clockwise.
D-1.1.3 Caution
Only qualified personnel may perform the electrical connection. Qualified specialist staff are persons
familiarized with the installation and commissioning of electrical installations and who have a
qualification reflecting their activity, e.g.:
1. Training as an electrician or electrically trained person (DIN EN 50110-1).
2. Training or instruction in the use of appropriate safety equipment according to the standard of
the safety technology for electric circuits.
3. Training and instruction with respect to work and health protection as well as with respect to the
Accident Prevention Regulations and the Accident Prevention Regulations for Enterprises
engaged in Seafaring.
Only under the supervision of an electrician may an electrically trained person perform simple
maintenance tasks or checks.
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D-1
Operating Manual
I/I
Part D: Commissioning, operation (ELEC)
Commissioning
D-1
4
MAY 20
Commissioning (continued)
D-1.1 Provision of readiness for operation (continued)
D-1.1.4 Supply voltage
The supply voltage of the wastewater treatment plant is stated on the type plate. The type plate is
located on the front side of the switching cabinet of the wastewater treatment plant. The type plate
indicates either 400 V / 50 Hz, 440 V / 60 Hz or customer-specific special voltages as supply
voltage. Compare the supply voltage to the on-board voltage prior to connecting.
D-1.1.5 On-board voltage
The on-board voltage may have deviations according to the Unified Requirements “Electrical
Installations” (UR E) of the International Association of Classification Societies (IACS).
D-1.1.6 Caution
If the on-board voltage is higher or lower than indicated on the type plate of the wastewater
treatment plant, electrical components of the wastewater treatment plant will be destroyed or will
not achieve the necessary power.
Compare the supply voltage stated on the type plate to the on-board voltage.
Do not connect the wastewater treatment plant to the on-board network if the on-board voltage
does not correspond to the supply voltage.
D-1.1.7
Voltage supply of the wastewater treatment plant
All electric connections are documented in the connection plan in Appendix D-APX1.
D-1.1.8
Voltage supply for external assemblies
External assemblies such as the DVZ-PL lifting station, vacuum pumps and other assemblies are
optionally fed with network voltage and controlled by the wastewater treatment plant. All electric
connections are documented in the connection plan in Appendix D-APX1.
D-1.1.9 Signal inputs from external switches / transmitters
Digital and analogue signals, e.g. from pressure, temperature, level switches or transmitters, are
optionally processed by the control electronics of the wastewater treatment plant. All electric
connections are documented in the connection plan in Appendix D-APX1.
D-1.1.10 Signal input, level of ships waste water tank
Depending on the version, one (1) switching point (SP), optionally two (2) or four (4) switching points
(SP), are provided for the external wastewater collection tank(s) or buffer tank(s):
1.
2.
3.
SP1: Pump P5.1 ON (Standard),
SP1: LOW-LEVEL BUFFER-TANK,
SP1: LOW-LOW-LEVEL BUFFER-TANK,
SP3: HIGH-LEVEL BUFFER-TANK,
SP1: Pump P5.1 OFF (Standard)
SP2: HIGH-LEVEL BUFFER-TANK
SP2: LOW-LEVEL BUFFER-TANK
SP4: HIGH-HIGH-LEVEL BUFFER-TANK
One switching point (1) is provided as standard (pump P5.1 ON, pump P5.1 OFF).
D-1.1.11 Signal outputs
Digital and analogue signals, e.g. from pressure, temperature, level or alarm messages can be
received by the control electronics of the wastewater treatment plant. All electric connections are
documented in the connection plan in Appendix D-APX1.
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JZR-„BIOMASTER®“
D-1
Operating Manual
I/I
Part D: Commissioning, operation (ELEC)
Commissioning
D-1
5
MAY 20
Commissioning (continued)
D-1.1 Provision of readiness for operation (continued)
D-1.1.12 Note
Waste water collection tank(s) and/or buffer tank(s) are separate assemblies which are either
already provided on site or which can be delivered on customer request by the company DVZSERVICES GmbH together with the waste water treatment plant JZR-“BIOMASTER®”.
One switching point (1) is provided as standard (pump P5.1 ON, pump P5.1 OFF
As an option, either two (2) or four (4) filling level switch points each are provided for the wastewater
collection tank(s) and/or buffer tank(s).
D-1.2
Operating elements
D-1.2.1 Switching cabinet operating elements (example)
1 Main switch
2 Optional additional operating elements:
Signal lamps, pushbuttons, selector switches
3 Console for the wastewater treatment plant,
programmable logic controller (LOGO!)
❹ Rotating lock with T-handle
5 Nameplate on inside of switching cabinet door
D-1.2.2 Console of the wastewater treatment plant
1 Four-line display
2 Direction keys
3 programmable function keys (F)
❹ Cancel or confirmation key
5 Weekday indication (Mo = Monday, Tu =
Tuesday, We = Wednesday, Th = Thursday, Fr =
Friday, Sa = Saturday, Su = Sunday) and time
6 Message in display
The LOGO! is password protected. User name
and password can be requested from DVZ
Services.
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Operating Manual
JZR-„BIOMASTER®“
Part D: Commissioning, operation (ELEC)
Commissioning
D-1
Commissioning (continued)
D-1.2
Operating elements (continued)
D-1.2.3
Operating elements of the programmable logic control (PLC)
I/I
D-1
6
MAY 20
Select functions with a function key on the frame of the operator unit.
1 Function key F1 “alarm reset”: for starting the
plant and for opening alarm messages
2 Function key F2 “Manual side cleaning”: for
starting the manual SIDE CLEANING
3 Function key F3: it is programmed related to the
ordered function and the project manual for the
switchbox must be noticed for this function.
❹ Function key F4 “Alarm receipt”: for confirming
the acknowledgement of the alarm message.
The LOGO! is password protected. User name
and password can be requested from DVZ
Services.
D-1.2.4 Alarm messages
Alarm messages are displayed as text on the LOGO! display during Auto mode. Press the function
key F4 ❹ in order to acknowledge them. Press the key F1 1 in order to display them again.
We
H H : MM
S T P
h i g H
Y Y Y Y - MM - DD
l e v e l
The following standard alarm messages are provided for the DVZ-JZR-“BIOMASTER”:
HIGH LEVEL ALARM
WD
H H : MM
S T P
h i g h
Y Y Y Y - MM - DD
l e v e l
(continued)
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Operating Manual
JZR-„BIOMASTER®“
I/I
Part D: Commissioning, operation (ELEC)
Commissioning
D-1
Commissioning (continued)
D-1.2
Operating elements (continued)
D-1
MAY 20
D-1.2.4 Alarm messages (continued)
MOTOR TRIPPED
WD
H H : MM
Y Y Y Y - MM - D D
m o t o r
t r i p p e d
HIGH PRESSURE PS1 (CIP)
WD
H H : MM
Y Y Y Y - MM - D D
h i g h
p r e s s u r e
P S 1
( p l e a s e
C I P )
TEMPERATURE SWITCH TS1
WD
H H : MM
Y Y Y Y - MM - D D
t e m pe r a t u r e
OK
C I P
f i n i s h e d
FLOW LOW ALARM
WD
H H : MM
f l o w
Y Y Y Y - MM - DD
l o w
mem b r a n e
p l e a s e
X
C I P
(continued)
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7
Operating Manual
JZR-„BIOMASTER®“
Part D: Commissioning, operation (ELEC)
Commissioning
D-1
Commissioning (continued)
D-1.2
Operating elements (continued)
I/I
D-1
MAY 20
D-1.2.4 Alarm messages (continued)
PRESSURE ALARM FILTER
WD
H H : MM
h i g h
Y Y Y Y - MM - DD
p r e s s u r e
i n l e t
f i l t e r
P 5 . X
s t o p p e d
DESLUDGE WARNING
WD
H H : MM
Y Y Y Y - MM - D D
d e s l u d g e
w a r n i n g
X X X X X
l t r
r e a c h e d
DESLUDGE ALARM
WD
H H : MM
Y Y Y Y - MM - DD
d e s l u d g e
w a r n i n g
X X X X X
l
t r
r e a c h e d
CIP TOO LONG
WD
H H : MM
T h e
C I P
t a k e s
Y Y Y Y - MM - DD
p r o c e s s
m o r e
n o w
t h e n
2 . 5
h o u r s .
y o u
c a n
C I P
p r o c e s s .
s t o p
t h e
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8
Operating Manual
JZR-„BIOMASTER®“
I/I
Part D: Commissioning, operation (ELEC)
Commissioning
D-1
Commissioning (continued)
D-1.3
Functional test
D-1
9
MAY 20
Perform the following steps consecutively:
D-1.3.1
Check the signal input for the levels of the ships waste water tank
Depending on the version, one (1) switching point (SP) is provided for the external wastewater
collection tank(s) or buffer tank(s):
SP1: Pump P5.1 ON (standard), SP1: Pump P5.1 OFF (standard)
D-1.3.2 Note
The DVZ-JZR-”BIOMASTER®” is equipped with a three-pin sensing electrode. The different pin
lengths have corresponding control functions.
Longest pin = Low, medium pin = High, shortest pin = HighHigh.
Once the filling level LOW is reached or fallen short of, pump P5 is started if a corresponding level is
present in the wastewater collection tank and/or buffer tank. If the pump should not start due to an
insufficient level, pumps P1 and P2 will be stopped with a time delay. The plant switches to STANDBY-MODE.
If the pump is started due to a sufficient level, wastewater is conveyed from the wastewater
collection tank and/or buffer tank into the plant until HIGH is reached. The pump P5 is switched off
automatically here. As soon as HIGH is reached, pumps P1 and P2 start.
If the level HIGH-HIGH is reached, a HIGH-LEVEL-ALARM is created automatically; pump P5 is
switched off and pumps P1 and P2 remain in operation.
D-1.3.3 Check the filling level in the ships waste water tank
The filling level in the wastewater collection tank(s) and/or buffer tank(s) must be above the
switching point for the start of pump P5.1.
D-1.3.4 Switch the plant on
1. For switching the plant on, turn on the main
switch.
We
H H : MM
S T P
h i g H
l e v e l
Y Y Y Y - MM - DD
2. The message “Start up OK” is displayed for
approximately 10 seconds.
3. The plant is ready for operation once this
message disappears.
D-1.3.5 Perform a direction of rotation check for pumps and fans
Activate all pumps and fans individually.
Check the direction of rotation. The direction arrow is located on the motor casing of the pump /
casing.
Preconditions:
1. Filling level 50% to 97%
2. Set selector switch “manual-0-auto” to manual.
3. Set the compact starter in the control box of the corresponding pump / fan to “0” (OFF).
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JZR-„BIOMASTER®“
Operating Manual
Part D: Commissioning, operation (ELEC)
Commissioning
D-1
Commissioning (continued)
D-1.3
Functional test (continued)
I/I
D-1
10
MAY 20
D-1.3.5 Perform a direction of rotation check for pumps and fans (continued)
D-1.3.5.1 Manual start and stop of pumps and fans
To run the sewage treatment plant in manual mode, press the “STP stop” button at the switchbox.
The automatic mode will stop.
All pumps could be started manually in the control panel by using the yellow control kits. You need
to switch off the protective motor switch to run the related pump manually.
Plug in the control kit (included in scope of delivery) into the compact starter
(continued)
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JZR-„BIOMASTER®“
Operating Manual
Part D: Commissioning, operation (ELEC)
Commissioning
D-1
Commissioning (continued)
D-1.3
Functional test (continued)
I/I
D-1
11
MAY 20
D-1.3.5 Performing a direction of rotation check for pumps and fans (continued)
D-1.3.5.1 Manual start and stop of pumps and fans (continued)
Now the related pump could be started manually by switching on and off the protective motor
switch.
D-1.3.6 Caution
Eccentric screw pumps and centrifugal pumps must never run dry.
If the pump runs without the medium to be transported, inner parts and gaskets will be damaged
or destroyed.
Deaerate the pumps carefully.
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JZR-„BIOMASTER®“
Operating Manual
Part D: Commissioning, operation (ELEC)
Commissioning
D-1
Commissioning (continued)
D-1.3
Functional test (continued)
I/I
D-1
12
MAY 20
D-1.3.7 Start the wastewater treatment plant in AUTOMATIC-MODE.
1. Filling level 50% to 97%
2. Push the push button “STP auto”.
3. Now all functions operate in AUTOMATIC MODE:
• Discharge pump P3/6 is running
• Pumps P1.1, P1,X and P2 start and stop at
LEVEL HIGH and LEVEL LOW
• Pump P5 is ready for filling the plant
D-1.3.8
Manual start of SIDE CLEANING
1. Filling level 50% to 97%
2. Press the key F2 2 “manual side cleaning”.
3. For plants with 2 to 4 membranes:
Membrane 1 is flushed by pressing the key F2 2;
when the SIDE CLEANING process has ended,
membrane 2-6 can be flushed by pressing key F2
2 again. If F2 2 is pressed after that, membrane
1 is flushed again, and so on.
D-1.3.8.1 SIDE CLEANING process
After pressing the F2, the SIDE CLEANING process is performed as follows:
1.
2.
3.
4.
5.
6.
7.
8.
Pumps P1.1 and P2 stop
Valve V12 switches and valve V1opens
Pump P3/6 starts
Valve V2 opens
Valve V1 closes two seconds later
Pump P3/6 stops
Valve V2 closes and valve V12 switches back
Pumps P1.1 and P2 start again
The entire sequence lasts approximately 30 seconds. If not started manually, the process will repeat
every 60 minutes automatically.
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Operating Manual
JZR-„BIOMASTER®“
Part D: Commissioning, operation (ELEC)
Commissioning
D-1
Commissioning (continued)
D-1.3
Functional test (continued)
I/I
D-1
13
MAY 20
D-1.3.9 Checking the CLOG-ALARM
WD
HH : MM
h i g h
p r e s s u r e
i n l e t
P 5 . X
Y Y Y Y - MM - DD
f i l t e r
s t o p p e d
1. Filling level 50% to 97%.
2. Slowly throttle valve H1.1; do not close it. If a back
pressure of 2.0 bars is reached, the wastewater
treatment plant ceases operating automatically.
Read the pressure at manometer PIF1, PIF2.
3. Acknowledge the alarm message with key F4 ❹.
4. For re-calling the alarm (it must still be active),
press key F1 “alarm reset” 1. If more than one
alarm messages are present, the one with the
highest priority is displayed. For all other messages
press the direction key “down”.
5. Open valve H1.1 after the check.
D-1.3.10 Checking the BSMU-PRESSURE-ALARM
WD
H H : MM
Y Y Y Y - MM - D D
h i g h
p r e s s u r e
P S 1
( p l e a s e
C I P )
1. Filling level 50% to 97%.
2. Slowly throttle the shut-off valve at connection A3
(customer-provided); do not close it. BMSUPRESSURE-ALARM triggers at a back pressure of
4.0 bar. Read the pressure at manometer PI1.1
(PI1.X). Alarm message “High pressure PS1 (CIP)”.
3. Acknowledge the alarm message with key F4 ❹.
4. For re-calling the alarm (it must still be active),
press key F1 “alarm reset” 1. If more than one
alarm messages are present, the one with the
highest priority is displayed. For all other messages
press the direction key “down”.
5. Open the shut-off valve at connection A3
(customer-provided) after the check.
D-1.3.11 Check the FLOW-LOW-ALARM
WD
H H : MM
f l o w
Y Y Y Y - MM - D D
l o w
me m b r a n e
p l e a s e
X
C I P
1. Filling level 50% to 97%.
2. Turn the set screw at pressure-sustaining valve
PHV1 counter-clockwise. Reduce the pressure to 0
bars. Read the pressure at manometer PI1.1
(PI1.X). The alarm message “Flow low membrane X
please CIP” is displayed after 10 minutes.
3. Acknowledge the alarm message with key F4 ❹.
4. For re-calling the alarm (it must still be active),
press key F1 “alarm reset” 1. If more than one
alarm messages are present, the one with the
highest priority is displayed. For all other messages
press the direction key “down”.
5. After the check, turn the set screw on pressuresustaining valve PHV1 clockwise. Set the amount
of clear water (permeate) for all membranes
(BMSU) (see C-1.2.15)
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JZR-„BIOMASTER®“
Operating Manual
Part D: Commissioning, operation (ELEC)
Commissioning
D-1
Commissioning (continued)
D-1.3
Functional test (continued)
I/I
D-1
14
MAY 20
D-1.3.12 Check the CLEANING-IN-PLACE MODE (CIP)
1. Filling level 50% to 97%.
2. Prior to execute the CIP process, perform a manual
SIDE CLEANING process (see D-1.3.8) in order to
make the CIP process more effective.
3. Push the push button “STP stop” 1 to stop the
plant in auto mode.
4. Set the valves H11.X, H13.X and H14.X to the
position “CIP”.
5. Push the push button “CIP start/stop” 2. Pumps
P1.1 and P2 perform the CIP process and clean the
membrane.
6. Adjust the pressure with the pressure holding valve
PHV1 to 3bar and monitor the output at flow
indicator FI1.X.
WD
H H : MM
YY Y Y - MM - D D
t e m p e r a t u r e
O K
C I P
f i n i s h e d
7. Check pressure and increase if necessary, hourly
(turn direction of PHV1 clockwise). The target is to
reach the maximum nominal Capacity of the
membrane with a pressure less 4 bar. Among other
thing, this capacity depends on the used medium
and the operation mode, see also table C-1.2.15 in
the instruction manual.
8. When the nominal capacity is reached, the
pressure could be decreased with the PHV1, so the
nominal capacity persist nut with less pressure.
9. The target is to keep the nominal output with the
lowest possible pressure, optimal is 1 bar.
10. The temperature switch TS1 located in the CIP tank
triggers an alarm once the temperature has risen to
60 °C. The display shows the message
“Temperature OK CIP finished”.
11. Push the push button “CIP start/stop” 2 to finish
the CIP.
12. Set valves H11.X, H13.X and H14.X to the position
“OPERATION”.
13. Push the push button “STP auto” 3 to start the
plant in auto mode.
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JZR-„BIOMASTER®“
Operating Manual
I/I
Part D: Commissioning, operation (ELEC)
Commissioning
D-1
Commissioning (continued)
D-1.3
Functional test (continued)
D-1
15
MAY 20
D-1.3.13 Checking the HIGH-LEVEL-ALARM (HighHigh)
WD
H H : MM
S T P
h i g h
Y Y Y Y - MM - DD
1. Fill up the plant until the upper pin of the sensor
electrode is reached, approx. 135 mm below the
tank lid.
2. The alarm message “STP high level” is displayed.
l e v e l
3. Acknowledge the alarm message with key F4 ❹.
4. For re-calling the alarm (it must still be active),
press key F1 “Start-up / Alarm reset” 1. If more
than one alarm messages are present, the one with
the highest priority is displayed. For all other
messages press the direction key “down”.
5. Pump out clear water (see C-1.2.19).
D-1.3.14 Check the DESLUDGE MODE (to connection A3.1)
1. Filling level 50% to 97%.
2. Push the button “STP stop” 1 to stop the plant in
AUTO-MODE.
3. Open valve H1.2.
4. Set valve H12.1 to “DISCHARGE”.
5. Push button “desludge start” 2.
6. For a time pre-set according to the individual plant
size, pump P3/6 conveys sludge from the reactor
tank to a sludge tank or over board (only outside
the 12 m mile zone) via the connection A11.
7. The pump P3/6 stops automatically after the time
has elapsed.
8. Set valve H12.1 to “OPERATION”.
9. Leave valve H1.2.
10. Push the push button “STP auto” 3 to start the
plant in AUTO-MODE.
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This page has been left blank intentionally.
JZR-„BIOMASTER®“
D-2
Operation
D-2.1
Intended use
Operating Manual
Part D: Commissioning, operation (ELEC)
Operation
I/I
D-2
17
MAY 20
The DVZ-JZR “BIOMASTER®” wastewater treatment plant is solely suitable for the biological
cleaning of grey and black water according to IMO MEPC 159 (55) and IMO MEPC 227 (64) on e.g.
seagoing vessels, riverboats, yachts, naval vessels and offshore constructions.
The Equipment conforms to the requirements of “Technical Regulations on the Safety of Sea
Transport Items” (it is approved as the resolution of the Government of the Russian Federation of
August 12, 2010 No. 620). All-Production Classification Code of Products 64 1600. The product is
labelled with conformity mark (RF Government Order No.696 dated 19.11.2003).
The DVZ-JZR “BIOMASTER®” wastewater treatment plant is unsuitable for the treatment of catering
waste as well as wastewaters containing acids, lye’s and oil, or ballast water. The wastewater
treatment plant must not be operated with sea water, brackish water or condensate. The rating of
the DVZ-JZR “BIOMASTER®” wastewater treatment plant presupposes a proportion of at least 80
litres of grey water per day and person as an operating condition. A buffer tank or a wastewater
collection tank must be upstream of the DVZ-JZR “BIOMASTER®” wastewater treatment plant.
D-2.2
Safety note
The wastewater treatment plant may only be stored, transported, assembled, operated, maintained
and disposed of by qualified specialist staff. Qualified specialist staffs are persons, who have a
qualification reflecting their activity, e.g.:
1. Training or instruction as a skilled worker in the areas of ship engine technology, shipboard
electrical systems or wastewater treatment for vessels and offshore constructions.
2. Training or instruction with respect to the use of personal protection equipment according to the
acknowledged rules of safety engineering.
3. Training and instruction with respect to work and health protection as well as with respect to the
Accident Prevention Regulations and the Accident Prevention Regulations for Enterprises
engaged in Seafaring.
4. Training and instruction with respect to the IMO International Safety Management Code (ISM
code.
D-2.2.1 Danger
The terminal strips in the switching cabinet are live during all phases of operation.
The electric current can cause severe injury or death.
Disconnect the wastewater treatment plant from voltage prior to installation and maintenance works.
D-2.2.2 Caution
Only qualified personnel may perform the electrical connection. Qualified specialist staff are persons
familiarized with the installation and commissioning of electrical installations and who have a
qualification reflecting their activity, e.g.:
1. Training as an electrician or electrically trained person (DIN EN 50110-1).
2. Training or instruction in the use of appropriate safety equipment according to the standard of
the safety technology for electric circuits.
3. Training and instruction with respect to work and health protection as well as with respect to
the accident prevention regulations and the Accident Prevention Regulations for Enterprises
engaged in Seafaring.
Only under the supervision of an electrician may an electrically trained person perform simple
maintenance tasks or checks.
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JZR-„BIOMASTER®“
Operating Manual
Part D: Commissioning, operation (ELEC)
Operation
D-2
Operation (continued)
D-2.3
Operation of the wastewater treatment plant
I/I
D-2
18
MAY 20
The DVZ-JZR “BIOMASTER®” wastewater treatment plant is a semiautomatic wastewater treatment
plant. Depending on the operating mode and the load of the wastewater treatment plant, either
constant monitoring or checks every 12 hours are required in the context of normal watchkeeping.
D-2.3.1 Note
Experience shows that the organic load of the wastewater treatment plant is particularly high during
watch changes, shortly after meals or during events on board. For these periods we recommend a
more frequent control of the wastewater treatment plant
D-2.3.2 Operating elements
D-2.3.2.1 Switching cabinet operating elements (example)
1 Main switch
2 Optional additional operating elements:
Signal lamps, pushbuttons, selector switches
3 Console for the wastewater treatment plant,
programmable logic controller (LOGO!)
❹ Rotating lock with T-handle
5 Nameplate on inside of switching cabinet door
D-2.3.2.2 Console of the wastewater treatment plant
1 Four-line display
2 Direction keys
3 programmable function keys (F)
❹ Cancel or confirmation key
5 Weekday indication (Mo = Monday, Tu =
Tuesday, We = Wednesday, Th = Thursday, Fr =
Friday, Sa = Saturday, Su = Sunday) and time
6 Message in display
The LOGO! is password protected. User name
and password can be requested from DVZ
Services.
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JZR-„BIOMASTER®“
Operating Manual
Part D: Commissioning, operation (ELEC)
Operation
D-2
Operation (continued)
D-2.3
Operation of the wastewater treatment plant (continued)
I/I
D-2
19
MAY 20
D-2.3.3 Operating elements of the programmable logic control (PLC)
Selection of functions with a function key on the frame of the operator unit.
1 Function key F1 “alarm reset”: for starting the
plant and for opening alarm messages
2 Functions key F2 “Manual side cleaning”: for
starting the manual SIDE CLEANING
3 Function key F3: it is programmed related to the
ordered function and the project manual for the
switchbox must be noticed for this function.
❹ Function key F4 “Alarm receipt”: for confirming the
acknowledgement of the alarm message.
The LOGO! is password protected. User name and
password can be requested from DVZ Services.
D-2.3.4 Normal operation and alarm messages
Alarm messages are displayed as text on the LOGO! display during Auto mode. Press the function
key F4 ❹ in order to acknowledge them. Press the key F1 1 in order to display them again.
We
H H : MM
S T P
h i g H
Y Y Y Y - MM - DD
l e v e l
The following standard alarm messages are provided for the DVZ-JZR-“BIOMASTER”:
HIGH LEVEL ALARM
WD
H H : MM
S T P
h i g h
Y Y Y Y - MM - DD
l e v e l
(continued)
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Operating Manual
JZR-„BIOMASTER®“
I/I
Part D: Commissioning, operation (ELEC)
Operation
D-2
Operation (continued)
D-2.3
Operation of the wastewater treatment plant (continued)
D-2.3.4
Normal operation and alarm messages (continued)
D-2
20
MAY 20
MOTOR TRIPPED
WD
H H : MM
Y Y Y Y - MM - DD
m o t o r
t r i p p e d
HIGH PRESSURE PS1 (CIP)
WD
H H : MM
Y Y Y Y - MM - DD
h i g h
p r e s s u r e
P S 1
( p l e a s
e
C I P )
TEMPERATURE SWITCH TS1
WD
H H : MM
Y Y Y Y - MM - DD
t e m pe r a t u
r e
OK
C I P
f i n i s h
e d
FLOW LOW ALARM
WD
H H : MM
f l o w
Y Y Y Y - MM - D D
l o w
me m b r a n e
p l e a s e
X
C I P
(continued)
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Operating Manual
JZR-„BIOMASTER®“
Part D: Commissioning, operation (ELEC)
Operation
D-2
Operation (continued)
D-2.3
Operation of the wastewater treatment plant (continued)
D-2.3.4
Normal operation and alarm messages (continued)
I/I
D-2
21
MAY 20
PRESSURE ALARM FILTER
WD
H H : MM
h i g h
Y Y Y Y - MM - D D
p r e s s u r e
i n l e t
f i l t e r
P 5 . X
s t o p p e d
DESLUDGE WARNING
WD
H H : MM
Y Y Y Y - MM - DD
d e s l u d g e
w a r n i n g
X X X X X
l
t r
r e a c h e d
DESLUDGE ALARM
WD
H H : MM
Y Y Y Y - MM - D D
d e s l u d g e
w a r n i n g
X X X X X
l t r
r e a c h e d
CIP TOO LONG
WD
H H : MM
T h e
C I P
t a k e s
2 . 5
Y Y Y Y - MM - D D
p r o c e s s
m o r e
n o w
t h e n
h o u r s .
y o u
c a n
C I P
p r o c e s s .
s t o p
t h e
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Operating Manual
JZR-„BIOMASTER®“
I/I
Part D: Commissioning, operation (ELEC)
Operation
D-2
Operation (continued)
D-2.3
Operation of the wastewater treatment plant (continued)
D-2.3.4
Normal operation and alarm messages (continued)
D-2
22
MAY 20
D-2.3.4.1 Note
The DVZ-JZR-”BIOMASTER®” is equipped with a three-pin sensing electrode. The different pin
lengths have corresponding control functions.
Longest pin = Low, medium pin = High, shortest pin = HighHigh.
Once the filling level LOW is reached or fallen short of, pump P5 is started if a corresponding level is
present in the wastewater collection tank and/or buffer tank. If the pump should not start due to an
insufficient level, pumps P1 and P2 will be stopped with a time delay. The plant switches to STANDBY-MODE.
If the pump is started due to a sufficient level, wastewater is conveyed from the wastewater
collection tank and/or buffer tank into the plant until HIGH is reached. The pump P5 is switched off
automatically here. As soon as HIGH is reached, pumps P1 and P2 start.
If the level HIGH-HIGH is reached, a HIGH-LEVEL-ALARM is created automatically; pump P5 is
switched off and pumps P1 and P2 remain in operation.
D-2.3.5 Switching the plant on
1. For switching the plant on, turn on the
main switch.
We
H H : MM
S T P
h i g H
l e v e l
Y Y Y Y - MM - DD
2. The message “Start up OK” is displayed for
approximately 10 seconds.
3. The plant is ready for operation once this
message disappears.
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Operating Manual
Part D: Commissioning, operation (ELEC)
Operation
D-2
Operation (continued)
D-2.3
Operation of the wastewater treatment plant (continued)
I/I
D-2
23
MAY 20
D-2.3.6 Manual start and stop of pumps and fans
To run the sewage treatment plant in manual mode, press the “STP stop” button at the switchbox.
The automatic mode will stop.
All pumps could be started manually in the control panel by using the yellow control kits. You need
to switch off the protective motor switch to run the related pump manually.
Plug in the control kit (included in scope of delivery) into the compact starter
(continued)
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JZR-„BIOMASTER®“
Operating Manual
Part D: Commissioning, operation (ELEC)
Operation
D-2
Operation (continued)
D-2.3
Operation of the wastewater treatment plant (continued)
D-2.3.6
Manual start and stop of pumps and fans (continued)
I/I
D-2
24
MAY 20
Now the related pump could be started manually by switching on and off the protective motor
switch.
D-2.3.7 Caution
Eccentric screw pumps and centrifugal pumps must never run dry.
If the pump runs without the medium to be transported, inner parts and gaskets will be damaged or
destroyed.
Bleed the pumps carefully.
(continued)
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JZR-„BIOMASTER®“
Operating Manual
Part D: Commissioning, operation (ELEC)
Operation
D-2
Operation (continued)
D-2.3
Operation of the wastewater treatment plant (continued)
I/I
D-2
25
MAY 20
D-2.3.8 Starting the wastewater treatment plant in AUTOMATIC-MODE
4. Filling level 50% to 97%
5. Push the push button “STP auto”.
6. Now all functions operate in AUTOMATIC MODE:
• Discharge pump P3/6 is running
• Pumps P1.1, P1,X and P2 start and stop at
LEVEL HIGH and LEVEL LOW
• Pump P5 is ready for filling the plant
D-2.3.9
Manual start of SIDE CLEANING
1. Filling level 50% to 97%
2. Press the key F2 2 “manual side cleaning”.
3. For plants with 2 to 4 membranes:
Membrane 1 is flushed by pressing the key F2 2;
when the SIDE CLEANING process has ended,
membrane 2-4 can be flushed by pressing key F2
2 again. If F2 2 is pressed after that, membrane
1 is flushed again, and so on.
D-2.3.9.1 SIDE CLEANING process
After pressing the F2, the SIDE CLEANING process is performed as follows:
1.
2.
3.
4.
5.
6.
7.
8.
Pumps P1.1 and P2 stop
Valve V12 switches and valve V1opens
Pump P3/6 starts
Valve V2 opens
Valve V1 closes two seconds later
Pump P3/6 stops
Valve V2 closes and valve V12 switches back
Pumps P1.1 and P2 start again
The entire sequence lasts approximately 30 seconds. If not started manually, the process will repeat
every 60 minutes automatically.
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Part D: Commissioning, operation (ELEC)
Operation
D-2
Operation (continued)
D-2.3
Operation of the wastewater treatment plant (continued)
I/I
D-2
26
MAY 20
D-2.3.10 CLEANING-IN-PLACE MODE (CIP)
1. Filling level 50% to 97%.
2. Prior to execute the CIP process, perform a manual
SIDE CLEANING process (see D-1.3.8) in order to
make the CIP process more effective.
3. Push the push button “STP stop” 1 to stop the
plant in auto mode.
4. Set the valves H11.X, H13.X and H14.X to the
position “CIP”.
5. Push the push button “CIP start/stop” 2. Pumps
P1.1 and P2 perform the CIP process and clean the
membrane.
WD
H H : MM
YY Y Y - MM - D D
t e m p e r a t u r e
O K
C I P
f i n i s h e d
6. Adjust the pressure with the pressure holding valve
PHV1 to 3bar and monitor the output at flow
indicator FI1.X.
7. Check pressure and increase if necessary, hourly
(turn direction of PHV1 clockwise). The target is to
reach the maximum nominal Capacity of the
membrane with a pressure less 4 bar. Among other
thing, this capacity depends on the used medium
and the operation mode, see also table C-1.2.15 in
the instruction manual.
8. When the nominal capacity is reached, the
pressure could be decreased with the PHV1, so the
nominal capacity persist nut with less pressure.
9. The target is to keep the nominal output with the
lowest possible pressure, optimal is 1 bar.
10. The temperature switch TS1 located in the CIP tank
triggers an alarm once the temperature has risen to
60 °C. The display shows the message
“Temperature OK CIP finished”.
11. Push the push button “CIP start/stop” 2 to finish
the CIP.
12. Set valves H11.X, H13.X and H14.X to the position
“OPERATION”.
13. Push the push button “STP auto” 3 to start the
plant in auto mode.
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Part D: Commissioning, operation (ELEC)
Operation
D-2
Operation (continued)
D-2.3
Operation of the wastewater treatment plant (continued)
D-2
27
MAY 20
D-2.3.11 Starting the DESLUDGE MODE (to connection A3.1)
1. Filling level 50% to 97%.
2. Push the button “STP stop” 1 to stop the plant in
AUTO-MODE.
3. Open valve H1.2.
4. Set valve H12.1 to “DISCHARGE”.
5. Push button “desludge start” 2.
6. For a time pre-set according to the individual plant
size, pump P3/6 conveys sludge from the reactor
tank to a sludge tank or over board (only outside
the 12 m mile zone) via the connection A11.
7. The pump P3/6 stops automatically after the time
has elapsed.
8. Set valve H12.1 to “OPERATION”.
9. Leave valve H1.2.
10. Push the push button “STP auto” 3 to start the
plant in AUTO-MODE.
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JZR-„BIOMASTER®“
Operating Manual
Part D: Commissioning, operation (ELEC)
Operation (ELEC)
I/I
D-APX
29
MAY 20
D-APX1 Electric Wiring Diagram
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Function
I/I
E-1
1
MAY 20
E-TOC
Table of Content ........................................................................................................................ 1
E-1.2
Safety note ............................................................................................................................... 5
E-1.3
Danger ....................................................................................................................................5
E-1.4
Operation of the wastewater treatment plant................................................................................5
E-1.4.1
Note ........................................................................................................................................6
E-1.5
Danger ....................................................................................................................................6
E-1.6
Caution ................................................................................................................................... 6
E-1.7
Maintenance intervals ...............................................................................................................6
E-1.8
Daily maintenance ..................................................................................................................7
E-1.8.1
Visual inspection of the waste water treatment plant ....................................................................7
E-1.8.2
Check of the general condition of the waste water treatment plant ................................................7
E-1.8.3
Checking the pressure-sustaining valve ......................................................................................7
E-1.8.4
Valve position for operation .........................................................................................................7
E-1.8.5
Checking the clear water volume ................................................................................................ 7
E-1.8.6
Note ........................................................................................................................................8
E-1.8.7
Checking the temperature (operating range, operating limits) ........................................................8
E-1.8.7.1
Caution ....................................................................................................................................9
E-1.8.7.2
Cooling or heating the bioreactor .................................................................................................9
E-1.8.8
Ensure that pumps do not run dry ............................................................................................... 9
E-1.8.8.1
Note ........................................................................................................................................9
E-1.9
Weekly maintenance .............................................................................................................10
E-1.9.1
DESLUDGE MODE, removal of sludge in bioreactor ......................................................................10
E-1.9.2
Checking the bleeder tubes (bioreactor) .....................................................................................10
E-1.10
Desludging of the waste water holding tank and/or buffer tank....................................................10
E-1.11
Yearly maintenance ...............................................................................................................10
E-1.11.1
General functional check ..........................................................................................................10
E-1.12
Maintenance as required ..........................................................................................................10
E-1.12.1
Organic load ...........................................................................................................................11
E-1.12.2
Membrane (BMSU) conditioning .................................................................................................11
E-1.12.3
Starting the SIDE CLEANING MODE manually............................................................................... 11
E-1.12.4
CLEANING-IN-PLACE (CIP) ........................................................................................................ 11
E-1.12.4.1 Danger ...................................................................................................................................11
E-1.12.4.2 Caution...................................................................................................................................11
E-1.12.4.3 Perform a CLEANING-IN-PLACE (CIP) ........................................................................................11
E-1.13
JZR reactor ............................................................................................................................13
E-2
Maintenance of pumps and fans ...............................................................................................15
E-2.1
BMSU overflow pump P1..........................................................................................................15
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Operating Manual
Part E: Maintenance
Maintenance of Function
I/I
E-1
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MAY 20
E-2.1.1
Maintenance ......................................................................................................................... 16
E-2.1.2
Maintenance instructions for prolonged periods of inactivity ....................................................... 16
E-2.1.3
Bearing lubrication ................................................................................................................ 16
E-2.1.3.1 Relubrication unit ................................................................................................................... 17
E-2.1.3.2 Greasing intervals.................................................................................................................. 17
E-2.1.4
Seals .................................................................................................................................... 18
E-2.1.5
Cleaning .............................................................................................................................. 18
E-2.1.6
Tightening torques for nuts and bolts........................................................................................ 18
E-2.1.7
Disturbance / Cause / Trouble Shooting .................................................................................... 18
E-2.1.8
Disassembly / Assembly .......................................................................................................... 20
E-2.1.8.1 Disassembly ........................................................................................................................ 21
E-2.1.8.2 Assembly ............................................................................................................................. 23
E-2.2
Feeding Pump P2 ................................................................................................................... 61
E-2.2.1
Pumps in General ................................................................................................................... 61
E-2.2.2
Lubrication ........................................................................................................................... 61
E-2.2.3
Shaft Sealing through Single Mechanical Seal ........................................................................... 62
E-2.2.4
Trouble-Shooting and Remedying ............................................................................................. 64
E-2.2.4.1 Trouble Chart ........................................................................................................................ 64
E-2.2.4.2 How do you trace the kind of problem to find the possible cause? .............................................. 64
E-2.2.5
Dismantling and Assembly of the Pump Housing ....................................................................... 66
E-2.2.5.1 Dismantling .......................................................................................................................... 67
E-2.2.5.2 Assembly ............................................................................................................................. 69
E-2.2.6
Dismantling and Assembly of the Rotating Parts ........................................................................ 72
E-2.2.6.1 Removal of Rotor and Coupling Rod ......................................................................................... 72
E-2.2.6.2 Fitting the Rotor and Coupling Rod ........................................................................................... 75
E-2.2.7
Removal and Fitting of the Connecting Shaft with Shaft Seal ...................................................... 79
E-2.2.7.1 Removal .............................................................................................................................. 79
E-2.2.7.2 Fitting ................................................................................................................................... 79
E-2.2.7
Removal and Fitting of the Single Mechanical Seal .................................................................... 80
E-2.3
CIP-Pump P4 .......................................................................................................................... 81
E-2.3.1
Pumps in General ................................................................................................................... 81
E-2.3.2
Lubrication ........................................................................................................................... 81
E-2.3.3
Shaft Sealing through Single Mechanical Seal ........................................................................... 82
E-2.3.4
Trouble-Shooting and Remedying ............................................................................................. 84
E-2.3.4.1 Trouble Chart ........................................................................................................................ 84
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E-2.3.4.2
How do you trace the kind of problem to find the possible cause? ...............................................84
E-2.3.5
Dismantling and Assembly of the Pump Housing ........................................................................86
E-2.3.5.1
Dismantling ..........................................................................................................................87
E-2.3.5.2
Assembly ..............................................................................................................................89
E-2.3.6
Dismantling and Assembly of the Rotating Parts ........................................................................92
E-2.3.6.1
Removal of Rotor and Coupling Rod ..........................................................................................92
E-2.3.6.2
Fitting the Rotor and Coupling Rod ............................................................................................95
E-2.3.7
Removal and Fitting of the Connecting Shaft with Shaft Seal.......................................................99
E-2.3.7.1
Removal ...............................................................................................................................99
E-2.3.7.2
Fitting ....................................................................................................................................99
E-2.3.7
Removal and Fitting of the Single Mechanical Seal .................................................................. 100
E-2.4
Transfer Pump P5................................................................................................................. 101
E-2.4.1
Pumps in General ................................................................................................................. 101
E-2.4.2
Lubrication ......................................................................................................................... 101
E-2.4.3
Shaft Sealing through Single Mechanical Seal......................................................................... 102
E-2.4.4
Trouble-Shooting and Remedying........................................................................................... 104
E-2.4.4.1
Trouble Chart ...................................................................................................................... 104
E-2.4.4.2
How do you trace the kind of problem to find the possible cause? ............................................ 104
E-2.4.5
Dismantling and Assembly of the Pump Housing ..................................................................... 106
E-2.4.5.1
Dismantling ....................................................................................................................... 107
E-2.4.5.2
Assembly ........................................................................................................................... 109
E-2.4.6
Dismantling and Assembly of the Rotating Parts ..................................................................... 112
E-2.4.6.1
Removal of Rotor and Coupling Rod ....................................................................................... 112
E-2.4.6.2
Fitting the Rotor and Coupling Rod ......................................................................................... 115
E-2.4.7
Removal and Fitting of the Connecting Shaft with Shaft Seal.................................................... 119
E-2.4.7.1
Removal ............................................................................................................................ 119
E-2.4.7.2
Fitting ................................................................................................................................. 119
E-2.4.7
Removal and Fitting of the Single Mechanical Seal .................................................................. 120
E-2.5
Discharge Pump P3/6............................................................................................................ 121
E-2.5.1
Maintenance ....................................................................................................................... 121
E-2.5.2
Lubrication of the mechanical seal ......................................................................................... 121
E-2.6
Blower G1 ........................................................................................................................... 122
E-2.6.1
Servicing indications ............................................................................................................ 122
E-2.6.1.1
Ball bearings ...................................................................................................................... 122
E-2.6.1.2
Seals and radial shaft sealing rings ........................................................................................ 122
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Maintenance of Function
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E-2.6.1.3 Micro-filters ......................................................................................................................... 122
E-2.6.1.4 Cleaning ............................................................................................................................ 123
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E-1
Maintenance of function
E-1.1
Intended use
Operating Manual
Part E: Maintenance
Maintenance of Function
I/I
E-1
5
MAY 20
The DVZ-JZR “BIOMASTER®” wastewater treatment plant is solely suitable for the biological
cleaning of grey and black water according to IMO MEPC 159 (55) and IMO MEPC 227 (64) on e.g.
seagoing vessels, riverboats, yachts, naval vessels and offshore constructions.
The Equipment conforms to the requirements of “Technical Regulations on the Safety of Sea
Transport Items” (it is approved as the resolution of the Government of the Russian Federation of
August 12, 2010 No. 620). All-Production Classification Code of Products 64 1600. The product is
labelled with conformity mark (RF Government Order No.696 dated 19.11.2003).
The DVZ-JZR “BIOMASTER®” wastewater treatment plant is unsuitable for the treatment of
catering waste as well as wastewater containing acids, lyes and oil, or ballast water.
The wastewater treatment plant must not be operated with sea water, brackish water or condensate.
The rating of the DVZ-JZR “BIOMASTER®” wastewater treatment plant presupposes a proportion of
at least 80 litres of grey water per day and person as an operating condition. A buffer tank or a
wastewater collection tank must be upstream of the DVZ-JZR “BIOMASTER®” wastewater treatment
plant.
E-1.2
Safety note
The wastewater treatment plant may only be stored, transported, assembled, operated,
maintained and disposed of by qualified specialist staff. Qualified specialist staff are persons who
have a qualification reflecting their activity, e.g.:
5. Training or instruction as a skilled worker in the areas of ship engine technology, shipboard
electrical systems or wastewater treatment for vessels and offshore constructions.
6. Training or instruction with respect to the use of personal protection equipment according
to the acknowledged rules of safety engineering.
7. Training and instruction with respect to work and health protection as well as with respect to
the Accident Prevention Regulations and the Accident Prevention Regulations for Enterprises
engaged in Seafaring.
8. Training and instruction according to the IMO International Safety Management Code (ISM
code).
E-1.3
Danger
The wastewater treatment plant contains wastewaters and effluent sludge with pathogenic bacteria,
viruses and fungi.
Contact with wastewater or effluent sludge can lead to severe diseases or cause death.
Personal safety equipment must be worn during all work carried out at the wastewater treatment
plant:
Hand protection, face protection, safety glasses, head protection, body protection, foot protection.
Never eat or drink in or near the wastewater treatment plant. Observe hygiene rules. Wash hands
thoroughly.
E-1.4
Operation of the wastewater treatment plant
The DVZ-JZR “BIOMASTER®” wastewater treatment plant is a semiautomatic, biological wastewater
treatment plant. Depending on the operating mode and the load of the wastewater treatment plant,
either constant monitoring or checks every 12 hours are required in the context of normal
watchkeeping.
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Part E: Maintenance
Maintenance of Function
I/I
E-1
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MAY 20
E-1
Maintenance of function (continued)
E-1.4.1
Note
Experience shows that the organic load of the wastewater treatment plant is particularly high during
watch changes, shortly after meals or during events on board. For these periods we recommend
more frequent monitoring of the wastewater treatment plant.
E-1.5
Danger
The terminal strips in the switching cabinet are live during all phases of operation and after the
actuation of the EMERGENCY OFF pushbutton.
The electric current can cause severe injury or death.
Disconnect the wastewater treatment plant from voltage prior to installation and maintenance
works.
E-1.6
Caution
Only qualified personnel may perform the electrical connection. Qualified specialist staff are persons
familiarized with the installation and commissioning of electrical installations and who have a
qualification reflecting their activity, e.g.:
1. Training as an electrician or electrically trained person (DIN EN 50110-1).
2. Training or instruction in the use of appropriate safety equipment according to the standard of
the safety technology for electric circuits.
3. Training and instruction with respect to work and health protection as well as with respect to the
Accident Prevention Regulations and the Accident Prevention Regulations for Enterprises
engaged in Seafaring.
Only under the supervision of an electrician may an electrically trained person perform simple
maintenance tasks or checks.
E-1.7
Maintenance intervals
In the various areas of the plant, different maintenance intervals are required for the maintenance of
the waste water treatment plant DVZ-JZR-“BIOMASTER®”. For an optimal function of the plant, we
recommend the intervals given below.
Interval
Daily
Weekly
Monthly
Yearly
Whenever
necessary
Type of maintenance
- Visual inspection of the waste water treatment plant
- Check of the general condition of the waste water treatment plant
- Check of the working pressure and setting of the pressure-sustaining valve PHV
- Check of the produced permeate amount
- Check temperature; if necessary, cool or heat
- Ensure that pumps do not run dry
- Check valve positions
- Desludging of the waste-water treatment plant
- Checking the primary air
- Checking the bleeder tubes
- Desludging of the waste water holding tank and/or buffer tank
- General functional check of the plant for malfunctions
- Perform side cleaning
- Perform CIP
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Part E: Maintenance
Maintenance of Function
E-1
Maintenance of function (continued)
E-1.8
Daily maintenance
E-1.8.1
Visual inspection of the waste water treatment plant
E-1
7
MAY 20
The connections, tubes, and fittings must be checked during the visual inspection. If leakage or
other impairments are found, these must be rectified as quickly as possible.
E-1.8.2
Check of the general condition of the waste water treatment plant
Check whether the waste water treatment plant works correctly. E. g.:
- Is there production of permeate?
- Are there any stored alarms in the control box?
- Is the any change in the water colour in the sight glass SG01?
- Is there any odour nuisance?
Eliminate found defects as soon as possible.
E-1.8.3
Checking the pressure-sustaining valve
Pressure-sustaining valve PHV1 increases or decreases the amount of clear water (permeate).
Increasing the pressure: Turn the set screw at pressure-sustaining valve PHV1 clockwise.
Reducing the pressure: Turn the set screw at pressure-sustaining valve PHV1 counterclockwise.
Read the pressure at manometer PI1.1 (PI1.X).
E-1.8.4
Valve position for operation
Set the valves according to the table.
Valves with pneumatic swivel drive: Switching position of magnetic valve “0” or “1”.
Valve
Position
Valve
Position
Valve
Position
H2*
F1
H1.1
OPEN
H13.X
OPERATION
H3*
F1
H1.2
OPEN
H14.X
OPERATION
D0
DRAIN
H1.3
OPEN
S1.X
CLOSED
D0.X
CLOSED
H1.4
CLOSED
V1.X
0
D3.X
CLOSED
H1.5
CLOSED
V2.X
0
D5
CLOSED
H1.6
CLOSED
V3.X
0
D6
CLOSED
H11.X
OPERATION
V12
0
H0.X
CLOSED
H12.1
OPERATION
V15
0
Valve
Position
* Only for type JZR 100-1-2 to JZR 500-3-6
For valve designations see R&I flow diagrams and signage at the wastewater treatment plant, “X” stands for a cipher
E-1.8.5
Checking the clear water volume
Type
V [l/h]
Type
V [l/h]
Type
V [l/h]
Type
V [l/h]
JZR 10-1-1
84
JZR 100-1-2
420
JZR 250-2-4
525
JZR 500-3-6
700
JZR 25-1-1
210
JZR 150-1-2
630
JZR 300-2-4
630
JZR 50-1-1
420
JZR 200-2-4
420
JZR 400-2-6
560
The values given in the table are maximum values! Target value = 0.7 x table value. Flow values per membrane (BMSU).
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Function
E-1
Maintenance of function (continued)
E-1.8
Daily maintenance (continued)
E-1.8.5
Checking the clear water volume (continued)
I/I
E-1
8
MAY 20
Wastewater treatment plants with one membrane (BMSU):
Read the amount of clear water (permeate) at the float-type flow meter FI1.1.
The V target value is 70% of the table value. Example: JZR 25-1-1: 0.7 x 210 l/h = 147 l/h
Increase the pressure with pressure-sustaining valve PHV1 as necessary, up to a maximum of 3.9
bar.
BMSU-PRESSURE-PRE-ALARM at 4.0 bar: the wastewater treatment plant continues to operate,
perform CLEANING-IN-PLACE (CIP) of the membrane in the short term.
Wastewater treatment plants with two to six membranes (BMSU):
Read the amount of clear water (permeate) at float-type flow meter FI1.X.
The V target value is 70% of the table value. Example: JZR 200-2-4: 0.7 x 420 l/h = 294 l/h
The V target value for JZR 200-2-4 (4 membranes) 4 x 294 l/h = 1176 l/h
Membranes (BMSU) can become contaminated to different degrees. Thus, the amount of clear water
(permeate) can vary at float-type flow meters FI1.X.
The float-type flow meters FI1.X are equipped with a magnetic switch. A FLOW-LOW-ALARM is
triggered at a flow volume of 50% of the maximum value: the wastewater treatment plant continues
to operate, immediately perform a CLEANING-IN-PLACE (CIP) of the affected membrane.
Increase the pressure with pressure-sustaining valve PHV1 as necessary, up to a maximum of 3.9
bar. BMSU-PRESSURE-PRE-ALARM at 4.0 bar: The wastewater treatment plant continues to operate,
perform CLEANING-IN-PLACE (CIP) of the membranes in the short term.
E-1.8.6 Note
After prolonged operation of the membrane(s) (BMSU), the clear water passage is increasingly
clogged by fine contamination, thus decreasing the amount of clear water (permeate). The back
pressure must be manually adapted to the desired amount of clear water with the pressuresustaining valve PHV 1.
In case of wastewater treatment plants with several membranes, individual membranes (BMSU) can
become contaminated to different degrees. The desired clear water (permeate) target value is
reached by a manual adjustment of the back pressure.
A BSMU PRESSURE ALARM is triggered at a back pressure of 4.0 bar. In this operating condition all
pumps are switched off except for pump P3/6. Immediately perform CLEANING-IN-PLACE (CIP).
E-1.8.7
Checking the temperature (operating range, operating limits)
Read the temperature in the bioreactor at thermometer TI1.
Normal operating range:
5 °C / 41 °F to 40 °C / 104 °F
Maximum operating range: 40 °C / 104 °F to 45 °C / 113 °F
MIN and MAX operating limits: ≤5 °C / 41 °F and ≥45 °C / 113 °F
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Part E: Maintenance
Maintenance of Function
E-1
Maintenance of function (continued)
E-1.8
Daily maintenance (continued)
E-1
9
MAY 20
E-1.8.7 Checking the temperature (operating range, operating limits) (continued)
E-1.8.7.1 Caution
Temperatures <5°C / 41°F or frost (≤0°C / 32°F) will damage or destroy the wastewater treatment
plant. Heat the wastewater treatment plant to a temperature between 5 °C / 41 °F and a maximum
of 40 °C / 104 °F.
If necessary, fill/heat with clear water.
Never add antifreeze agents to the wastewater treatment plant.
This will prevent its biological cleaning capacity. The membranes (BMSU) are destroyed.
Below 5 °C / 41 °F, the biological cleaning ability becomes heavily reduced or even impossible.
Heat up the bioreactor to a temperature between 5 °C / 41 °F and a maximum of 40 °C / 104 °F.
If necessary, fill/heat with clear water.
Above 45 °C / 113 °F, the biological cleaning ability becomes heavily reduced or even impossible.
Cool the bioreactor to 40 °C / 104 °F.
If necessary, fill/cool down with clear water.
E-1.8.7.2 Cooling or heating the bioreactor
Attach connection A15 to clear water tube, consider a non-return facility (customer-provided). Water
temperature 20 °C/68 °F +/-5 °C/9 °F, water pressure MAX 1.5 bar. Set valve D0 to the FRESHWATER
position, open valve HM14.X. Switch valve D3.X to FRESH WATER, fill the bioreactor to a maximum filling
level of 96 %. Read the filling level at level indicator SG01. As soon as the temperature is reached at
thermometer TI1, or as soon as the filling level is reached, switch valve D3.X to DRAIN position. Separate
connection A15 from the clear water tube.
E-1.8.8
Ensure that pumps do not run dry
Check the valve positions and the filling status in the waste water collection tank and/or buffer tank.
This ensures that the pumps do not run dry!
E-1.8.8.1 Note
The DVZ-JZR-”BIOMASTER®” is equipped with a three-pin sensing electrode. The different pin
lengths have corresponding control functions.
Longest pin = Low, medium pin = High, shortest pin = HighHigh.
Once the filling level LOW is reached or fallen short of, pump P5 is started if a corresponding level is
present in the wastewater collection tank and/or buffer tank. If the pump should not start due to an
insufficient level, pumps P1 and P2 will be stopped with a time delay. The plant switches to STANDBY-MODE. In this mode.
If the pump is started due to a sufficient level, wastewater is conveyed from the wastewater
collection tank and/or buffer tank into the plant until HIGH is reached. The pump P5 is switched off
automatically here. As soon as HIGH is reached, pumps P1 and P2 start.
If the level HIGH-HIGH is reached, a HIGH-LEVEL-ALARM is created automatically; pump P5 is
switched off and pumps P1 and P2 remain in operation.
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Operating Manual
JZR-„BIOMASTER®“
E-1
Part E: Maintenance
Maintenance of Function
E-1
Maintenance of function (continued)
E-1.9
Weekly maintenance
E-1.9.1
DESLUDGE MODE, removal of sludge in bioreactor
10
MAY 20
The sludge volume in the bioreactor depends on the organic load of the wastewater treatment plant.
If the biomass increase in the bioreactor is greater than necessary, surplus sludge must be removed
manually at variable, load-dependent intervals (at least once per week).
For sludge removal switch over to MANUAL-MODE (see D-2.3.12 et seq.).
Set the valves according to the table to the position for the sludge removal function.
Desludging
Normal operation
Desludging point
to connection
H12.1
H1.21
Secondary reactor
Calming chamber
A11 (sludge tank)
DESLUDGE
OPEN
H12.1
H1.21
OPERATION
OPEN
A3 (over board)
OPERATION
OPEN
OPERATION
For valve designations see R&U flow diagrams and signage at the wastewater treatment plant 1 H1.2 is always open.
OPEN
1. Set the plant to MANUAL-MODE (see D-2.3.6).
2. Set the valves according to the above table.
3. Start the automatic desludge (see D-2.3.12).
The pump runs for a pre-set time and pumps sludge from the first and second chamber (preclarification tank and clarification tank) of the STP container to the set connection A3.1 or A13.
The pump stops automatically after the pre-set time.
4. Fill up bioreactor again.
5. Set back the valves.
After sludge removal, return valves H12 and H12.1 to the “OPERATION” position, close valves H4
and H5 and open valve H7.
6. Switch over from MANUAL-MODE to AUTOMATIC MODE (see D-2.3.8).
E-1.9.2
Checking the bleeder tubes (bioreactor)
Activated carbon filters (customer-provided), installed as odour barriers in the bleeding tubes, can
become clogged with micro-organisms over time so that effective bleeding of the bioreactor
becomes impossible. The consequences of this are increased foam formation and increased
pressure in the bioreactor.
E-1.10
Desludging of the waste water holding tank and/or buffer tank
The waste water collection tank and/or the buffer tank should be desludged once a month in order to
ensure an optimal and trouble-free operation. This should be performed outside the 12-mile zone, or
depending on the country. Please observe the local regulations and the class regulations in any case.
E-1.11
Yearly maintenance
E-1.11.1 General functional check
A general functional check must be performed at the plant once a year in order to ensure an optimal
and trouble-free operation. During this functional check, to be performed similar to the
commissioning, undiscovered malfunctions can be detected. Detected malfunctions must be
rectified immediately by qualified specialist staff.
E-1.12
Maintenance as required
Depending to the need and load of the unit, maintenance has to be done accordingly.
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E-1
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Part E: Maintenance
Maintenance of Function
E-1
11
MAY 20
Maintenance of function (continued)
E-1.12 Maintenance as required (continued)
E-1.12.1 Organic load
The organic load of the wastewater treatment plant depends on the supplied volume of grey and
black water per time unit.
In case of an expected high load and/or in case of a BMSU-PRESSURE-ALARM, clean the BMSU
membrane(s) with the CLEANING-IN-PLACE function (CIP), if necessary remove sludge (see C2.4.20).
In case of a low organic load, foam may form in the bioreactor.
E-1.12.2 Membrane (BMSU) conditioning
The “BMSU conditioning” cleaning program runs in AUTOMATIC MODE and CANNOT be influenced
by the plant operator.
For this, pump P2 is switched off for 10 seconds every 127 seconds.
E-1.12.3 Starting the SIDE CLEANING MODE manually
Perform a SIDE CLEANING of the membrane (BMSU) prior to every CLEANING-IN-PLACE (CIP). Start
SIDE CLEANING manually (see D-2.3.9).
E-1.12.4 CLEANING-IN-PLACE (CIP)
Prepare the wastewater treatment plant for the CLEANING-IN-PLACE (CIP) and subsequently perform
the CLEANING-IN-PLACE (CIP) (see D-2.3.10).
E-1.12.4.1 Danger
Membrane cleaning agents are strongly corrosive and cause severe eye damage.
Severe injuries to the hands, eyes, face and body are possible. Severe damage to health is possible
if ingested.
Personal safety equipment must be worn during all work at the wastewater treatment plant: Hand
protection, face protection, safety glasses, head protection, body protection, foot protection.
In the event of contact with the eyes or skin, immediately rinse with drinking water, use an eye bath
and immediately consult a physician.
Read the safety data sheet and the operating manual of the manufacturer.
E-1.12.4.2 Caution
Valves H11.X, H13.X and H14.X must be set to the CIP position before the CLEANING-IN-PLACE and
set manually to the OPERATION position after the CLEANING-IN-PLACE.
If valves are not set manually to the indicated position, parts of the wastewater treatment plant will
be damaged or destroyed. Membrane cleaning agent may leak.
E-1.12.4.3 Perform a CLEANING-IN-PLACE (CIP)
Wastewater treatment plants with one membrane (BMSU):
During the temperature and time-limited CLEANING-IN-PLACE process, the membrane (BMSU) is
unable to separate clear water from pre-cleaned wastewater. During this time, the wastewater
treatment plant is not available for cleaning wastewater .
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Operating Manual
JZR-„BIOMASTER®“
Part E: Maintenance
Maintenance of Function
E-1
Maintenance of function (continued)
E-1.12
Maintenance as required (continued)
E-1
12
MAY 20
E-1.12.4 CLEANING-IN-PLACE (CIP) (continued)
E-1.12.4.3 Perform a CLEANING-IN-PLACE (CIP) (continued)
Wastewater treatment plants with two to six membranes (BMSU):
The membranes (BMSU) which are not being cleaned remain available for wastewater cleaning
during the temperature- and time-limited CLEANING-IN-PLACE. Only one membrane can be cleaned
at a time.
Use a membrane cleaning agent, e.g. Osmotech 2691® or Osmotech 2610®.
Before starting the CIP Process, please execute the Side-Cleaning manually (see C-2.4.18).
7. Open the bleeder valve (if used) 1.
8. Loosen and remove screw cap 2.
9. Open the shut-off valves 3/6 of level indicator 8
completely.
10. Add cleaning agent to the CIP storage tank ❹
11. If too much cleaning agent has been added, drain it
into an appropriate container via outlet valve 7.
12. Screw on the screw cap 2 tightly.
Set the valves according to the table.
Valve
Position
Function
Valve
Position
Function
H11.X
CIP
Cleaning
H11.X
OPERATION
Normal operation
H13.X
CIP
Cleaning
H13.X
OPERATION
Normal operation
H14.X
CIP
Cleaning
H14.X
OPERATION
Normal operation
H0.X
OPEN
Cleaning
H0.X
CLOSED
Normal operation
D0
FRESHWATER
Flushing
membrane (s)
D3
CLOSED
Normal operation
D3.X
CLOSED
Normal operation
membrane X
HM14.X
CLOSED
Flushing,
Normal operation
membrane (s)
D0
DRAIN
D3
OPEN
D3.X**
OPEN
HM14.X
OPEN
Emptying
membrane (s)
Emptying
membrane (s)
Flushing,
emptying
membrane X
Bleeding
membrane X
* only for JZR 10-1-1 to JZR 50-1-1, ** only for JZR 100-1-2 to JZR 500-3-6, „X” stands for “1” to “6”
For valve designations see R&U flow diagrams and signage at the wastewater treatment plant
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Part E: Maintenance
Maintenance of Function
E-1
Maintenance of function (continued)
E-1.12
Maintenance as required (continued)
E-1
13
MAY 20
E-1.12.4 CLEANING-IN-PLACE (CIP) (continued)
E-1.12.4.3 Perform a CLEANING-IN-PLACE (CIP) (continued)
Wastewater treatment plants with one membrane (BMSU):
1. Drain the membrane (BMSU):
Valve D0 to the DRAIN position, open valve D3.1, open valve HM14.1.
Completely empty membrane 1
2. Flush the membrane (BMSU) with clear water:
Valve D0 to the FRESHWATER position. Fill the membrane until clear water comes out of valve
HM14.1. Close valves HM14.1 and D3.1, set valve D0 to the DRAIN position.
Wastewater treatment plants with two to six membranes (BMSU):
1. Drain the membrane (BMSU):
Set valve D0 to the DRAIN position, open valve D3, open valve D3.X, open valve
HM14.1.Completely empty membrane X (BMSU). “X” stands for membrane 1 to membrane 6
(optional)
2. Flush the membrane (BMSU) with clear water:
Valve D0 to the FRESHWATER position. Fill the membrane until clear water comes out of valve
HM14.X. Close valves HM14.X, D3.X and D3, set valve D0 to the DRAIN position.
In the event of strong contamination flush the membrane several times, activate the CLEANING-INPLACE MODE (CIP) (see D-2.3.10). The energy contribution of circulating pump P1.X causes a slow
increase of the temperature of the circulated water. Read the temperature at thermometer TI2.X. The
cleaning process is ended automatically at a temperature of 60 °C / 140 °F. After 2.5 hours an alarm
message is triggered stating that the CIP can be ended. Set the valves according to the table to the
OPERATION position.
Set the target value of the clear water (permeate) volume according to C-2.4.10.
E-1.13
JZR reactor
Entry of a large object into the JZR reactor can lead to a clogging of the nozzle inside the reactor.
This blockage can be eliminated by briefly lifting the tube lance.
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JZR-„BIOMASTER®“
Operating Manual
I/I
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans
E-2.1
BMSU overflow pump P1
E-2
15
MAY 20
Maintenance and cleaning work should only be implemented by specialist personnel. These
personnel are to be provided with personal protective equipment (e.g. protective gloves).
Important!
According to EN 60204-1 a person is considered as being a specialist if they
-
are able to use their professional training, knowledge and experience as well as knowledge of
the relevant standards to assess the work they have been assigned and
are also able to identify any potential dangers.
Important!
Only use appliances and tools that are expressly intended for this work.
Clean and maintain the pump in regular intervals. This will ensure trouble-free operation of the
pump.
Danger!
The rotating impeller can cut or crush hands and arms.
Allow the impeller to come to a complete standstill.
Secure the pump from rolling and toppling over.
(continued)
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Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.1
BMSU overflow pump P1 (continued)
E-2
16
MAY 20
Notice!
Pumped media can be hazardous to health.
Always wear personal protective equipment such as protective gloves and glasses.
The pump is subjected to vibrations during operation, which can cause the screw and clamp
connections to become loose. Inspect the pump in regular intervals for any loose connections.
Remove any dust deposits and impurities on a regular basis.
Caution!
Injuries may be caused when maintaining and cleaning the pump.
Observe the safety regulations and the generally recognised "codes of practice".
E-2.1.1
Maintenance
When conducting maintenance and repair work watch out for:
-
crushing hazards and
dangers caused by electric current.
Decontaminate the pump after pumping any media that is hazardous to health.
Warning!
When the pump is removed from the pipe network there is a risk of toppling which can result in
serious injury.
Secure the pump during transport using separate lifting accessories.
Only set up the pump on a sufficiently solid surface that is level in all directions. Also secure it to
prevent it from toppling over.
Important!
Collect any waste and emissions in appropriate containers and dispose of them properly.
E-2.1.2
Maintenance instructions for prolonged periods of inactivity
Protect the pumps from atmospheric influences (UV light, sunlight, high humidity levels, frost, etc.).
Caution!
Insufficient rotary motion of the motor shaft leads to the impeller becoming jammed and a failure of
the mechanical seal! To counteract this rotate the motor shaft repeatedly by hand in weekly
intervals.
Danger!
Ensure the proper function of the mechanical seal by monitoring it regularly.
E-2.1.3
Bearing lubrication
Anti-friction bearings are provided pre-lubricated.
(continued)
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Operating Manual
JZR-„BIOMASTER®“
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.1
BMSU overflow pump P1 (continued)
I/I
E-2
17
MAY 20
E-2.1.3 Bearing lubrication (continued)
Important!
Anti-friction bearings that are used at a speed of
- 1500 (1800) min-1 after 20,000 hours of operation
- 3000 (3600) min-1 after 10,000 hours of operation
however, this should be every 3 years at the latest.
E-2.1.3.1 Relubrication unit
Depending on the motor manufacturer a standard relubrication unit is available for motors operating
at 1500 (1800) min-1
- from 1.1 kW for both bearings or
- from 1.1 kW for the anti-friction bearing (drive side) and from 7.5 kW for both bearings.
Motors that cannot be relubricated are those rated
- 0.55 (0.66) and 0.75 (0.9) kW
- 3000 (3600) min-1
Warning!
Lubricant is hazardous to health.
Do not swallow lubricant.
Important!
- Do not over-lubricate the bearing.
- Dispose of any lubrication properly.
E-2.1.3.2 Greasing intervals
Motor [kW]
1,1/1,3
1,5/1,8
2,2/2,6
3,0/3,6
4,0/4,8
5,5/6,6
7,5/9,0
11,0/13,2
15,0/18,0
18,5/22,2
22,0/26,4
30,0/36,0
37,0/44,4
45,0/54,0
55,0/66,0
Anti-friction bearing (drive side)
Greasing Interval [h] Grease Quantity [g]
5000
7
5000
7
5000
10
5000
10
5000
10
4000
16
4000
16
3500
22
3500
22
3000
32
3000
32
3000
40
3000
50
3000
50
3000
55
Anti-friction bearing (non drive side)
Greasing Interval [h] Grease Quantity [g]
10000
3
10000
3
10000
5
10000
5
10000
5
8000
8
8000
8
7000
11
7000
11
6000
13
6000
13
6000
18
6000
20
6000
20
6000
25
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Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.1
BMSU overflow pump P1 (continued)
E-2
18
MAY 20
E-2.1.4 Seals
In general a mechanical seal does not require maintenance.
Only exchange the mechanical seal as a complete unit. This ensures optimal shaft sealing.
E-2.1.5 Cleaning
Remove any sediment deposits when dismounting or dis-mantling the pump using mechanical
means if necessary. Doing this will ensure flawless operation.
Before decommissioning and storing the pump after a pro-longed period of operation rinse it
thoroughly with clear water and then clean it carefully. Hardened dirt deposits, limescale etc. could
block the impeller and the motor shaft.
Danger!
The rotating impeller can cut or crush hands and arms.
It is imperative that the motor is kept clean. This will ensure adequate aeration.
E-2.1.6
Tightening torques for nuts and bolts
Stainless (A4)
Thread
Non-stainless
8.8
10.9
[Nm]
[Nm]
[Nm]
M8
18,5
23,0
32,0
M10
37,0
46,0
64,0
M12
57,0
80,0
110,0
M16
135,0
195,0
275,0
M20
230,0
385,0
540,0
Important!
Tighten all nuts and bolts (clockwise) during assembly as prescribed.
E-2.1.7
Disturbance / Cause / Trouble Shooting
The facts and information described in this manual with regard to "disturbance, cause and
troubleshooting" are addressed to specialists in terms of
- Electrical/electronics
- Mechanical/maintenance.
These personnel are to be provided with the appropriate tools and inspection equipment.
If the specified measures prove to be unsuccessful, please contact the manufacturer.
Important!
Only use appliances and tools that are expressly intended for this work.
Operational disturbances are not anticipated if this manual is complied with in full.
Only dismantle the pump if all other measures have failed. If malfunctions are still evident, please
contact our customer service department.
(continued)
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.1
BMSU overflow pump P1 (continued)
E-2.1.7
Disturbance / Cause / Trouble Shooting (continued)
Disturbance
Pump doesn't pump!
Danger of running dry!
Cause
The pump and/or pipeline is not
completely filled.
Supply pipe and/or impeller
obstructed.
Motor doesn't run.
Head too high.
The delivery of the pump
is too low.
Density of the pumped medium
is too high.
Incorrect direction of rotation of
the pump.
Impeller is loose or worn.
The pump pumps against high
pressure.
Pipeline and/or pump obstructed.
Running on two phases.
Pump vibrates or
makes a noise.
Incorrect direction of rotation of
the pump.
Impeller is loose or worn.
Pump doesn't operate in the
specified operating range.
Anti-friction bearing defective.
Anti-friction bearing not
lubricated properly.
Pump installed under tension.
Cavitation
I/I
E-2
19
MAY 20
Trouble Shooting
De-aerate and fill the pump and
pressure pipe.
Clean the supply.
Remove any sediment deposits
from the pump/pipeline.
Check the electrical installation.
Check the plant for any
impurities and/or the layout of
the pump.
Dilute the pumped medium
or alter the process.
Check the direction of rotation
and exchange two phases to the
motor if necessary.
Inspect the impeller and replace
if necessary.
Measure the pressure. Change
the configuration, check the
layout of the pump.
Check the pipeline and/or
pump and clean if necessary.
Exchange the defective locking
device or check the connections.
Check the direction of rotation
and exchange two phases to the
motor if necessary.
Inspect the impeller and replace
if necessary.
Check the operating conditions.
Exchange anti-friction bearing.
Clean anti-friction bearing and
relubricate.
Connecting pipes must be laid in
an unstressed manner.
Check supply for obstructions.
Check the duty point and adjust if
necessary.
(continued)
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.1
BMSU overflow pump P1 (continued)
E-2.1.7
Disturbance / Cause / Trouble Shooting (continued)
Disturbance
Pump runs but
immediately switches off.
Cause
The motor circuit breaker has
been triggered. Incorrect direction
of rotation of the pump.
Power input too high.
Density of the pumped medium
is too high.
Pump doesn't operate in the
specified operating range.
An obstructed pump has triggered
the motor protection relay.
Pump switches too often.
Motor connected incorrectly.
Bearing becomes
hot
Bearing running without
lubrication: lack of grease.
Too much grease in the bearing
Pump installed under tension.
Electric motor is
overly warm.
Anti-friction bearing defective.
Incorrect direction of rotation of
the pump.
Pump doesn't operate in the
specified operating range.
Supply pipe and/or impeller
obstructed.
Motor connected incorrectly.
Pump switches
too often.
E-2.1.8
I/I
E-2
20
MAY 20
Trouble Shooting
Check the direction of rotation.
Check the free movement of the
pump.
Dilute the pumped medium
or alter the process.
Check the operating conditions.
Check the free movement of the
pump.
Observe operating mode.
Connect motor to correct
operating voltage.
Top up grease, replace bearing if
necessary.
Remove surplus grease until the
balls are just covered by grease.
Connecting pipes must be laid in
an unstressed manner.
Exchange anti-friction bearing.
Check the direction of rotation
and exchange two phases to the
motor if necessary.
Check the operating conditions.
Clean the supply.
Remove any sediment deposits
from the pump/pipeline.
Connect motor to correct
operating voltage.
Observe operating mode.
Disassembly / Assembly
The pump is predominantly manufactured from steel. Dis-pose of the pump, oils and any cleaning
agents in accordance with the applicable local environmental regulations.
Cleaning implements (such as brushes, rags, etc.) are to be disposed of in accordance with the
applicable environmental regulations or manufacturer's instructions.
Repairs may only be performed by qualified personnel.
(continued)
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JZR-„BIOMASTER®“
Operating Manual
I/I
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.1
BMSU overflow pump P1 (continued)
E-2.1.8
Disassembly / Assembly (continued)
E-2
21
MAY 20
Important!
Tighten all nuts and bolts (clockwise) during assembly as prescribed.
Important!
Refrain from using excessive force while disassembling and assembling the pump.
E-2.1.8.1 Disassembly
It is possible to disassemble the interchangeable module of the pump without loosening the intake
connection and pressure flange from the pipework. The interchangeable module consists of a block
motor (802), intermediate casing (113), impeller (230) and mechanical seal (433).
Warning!
Electric current can result in death.
Disconnect the block motor (802) according to the 5 safety rules.
The five safety rules are as follows:
1.
2.
3.
4.
5.
Disconnect.
Secure against reactivation.
De-energise.
Earth and short-circuit.
Cover or shield any adjacent live parts.
Caution!
Ensure the pump casing is free from pressure. Only then should you empty the pump.
In the case of the design with the base rail, first loosen the connecting bolts from the block motor
(802) and rail (593).
After emptying the pump, loosen the return pipe (704) on the intermediate casing (113).
1.
Loosen the connecting bolts from the pump casing (101)
and intermediate casing (113).
2.
Prise the complete inter-changeable module on the
intermediate casing (113) from the centering of the pump
casing (101) using two jack screws.
(continued)
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JZR-„BIOMASTER®“
Operating Manual
I/I
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.1
BMSU overflow pump P1 (continued)
E-2.1.8
Disassembly / Assembly (continued)
E-2
22
MAY 20
E-2.1.8.1 Disassembly (continued)
3.
Remove the loosened inter-changeable module from the
pump casing (101).
4.
Loosen the nut (920).
5.
Remove the washer (554).
6.
Extract the impeller (230).
7.
Remove the key (940) from the keyseat.
8.
Loosen the connecting bolts from the block motor (802)
and intermediate casing (113).
(continued)
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.1
BMSU overflow pump P1 (continued)
E-2.1.8
Disassembly / Assembly (continued)
I/I
E-2
23
MAY 20
E-2.1.8.1 Disassembly (continued)
9.
Pull the intermediate casing (113) over the motor shaft
(819).
Notice!
A damaged fitting surface does not guarantee a precise seal.
Do not damage the seating for the O-ring.
10.
Remove all components of the mechanical seal (433) from
the intermediate casing (113).
11.
Clean the chrome-nickel steel motor shaft of any residue
and sediment deposits using fine emery cloth.
Clean any deposits from the seating for the O-ring.
Important!
Replace any seals that are removed. This ensures precise sealing.
E-2.1.8.2 Assembly
Before starting to reassemble the pump all of the dismantled parts are to be
-
checked for signs of damage and wear,
cleaned and
replaced with original spare parts if necessary.
Important!
Nuts (920) with a self-locking plastic ring are to be replaced when reattaching the impeller.
Important!
To reduce friction during assembly lubricate all sliding surfaces of the elastomers with low surface
tension water (added detergent).
Warning - do not use oil or grease!
(continued)
OM_2020051900_DVZ-JZR-BIOMASTER-JZRY01001_EN - Subject to technical modification without notice DVZ-SERVICES GmbH | Boschstraße 9 | D-28857 Syke | Germany | FON +49 (0) 4242 16 93 8 0 | FAX +49 (0) 4242 16 93 8 99 | WEB www.dvz-services.de | MAIL info@dvz-services.de
JZR-„BIOMASTER®“
Operating Manual
I/I
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.1
BMSU overflow pump P1 (continued)
E-2.1.8
Disassembly / Assembly (continued)
E-2
24
MAY 20
E-2.1.8.2 Assembly (continued)
1.
When inserting the pressure-sensitive counter ring ensure
- an even distribution of pressure,
- you use a clean pin with a soft seating and
- that no foreign particles are located on the sliding surfaces.
Insert the counter ring with the O-ring into the intermediate
casing (113) by hand.
2.
Slide assembly aids (accessories) onto the motor shaft
(819) (if available).
Important!
Do not damage the counter ring of the mechanical seal on the
thread and change-over of the motor shaft or press at an angle!
3.
Carefully slide the intermediate casing (113) over the motor
shaft (819) and onto the centering of the block motor (802).
4.
Screw the intermediate casing (113) to the block motor
(802).
Installation of the mechanical seal
Important!
-
Make sure you degrease the shaft surface!
The pretension of the spring is obtained through the installation of the impeller.
5.
Carefully slide the rotating sliding ring with bellows and
spring over the motor shaft shoulder and up to the
integrated counter ring using a screwing motion.
(continued)
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.1
BMSU overflow pump P1 (continued)
E-2.1.8
Disassembly / Assembly (continued)
I/I
E-2
25
MAY 20
E-2.1.8.2 Assembly (continued)
5.
Use assembly aids (accessories) (if available) to ensure an
optimal seating of the mechanical seal on the motor shaft
(819).
6.
Insert the key (940) into the motor shaft groove.
7.
Slide the impeller (230) onto the motor shaft (819).
8.
Slide the washer (554) onto the motor shaft (819).
9.
Tighten the nut (920).
Important!
Turn back jack screws beforehand.
10.
Place the gasket (400/400.1) or O-ring (412) between the
pump casing (101) and the intermediate casing (113). Then
insert the complete interchangeable module into the
centering of the pump casing.
(continued)
OM_2020051900_DVZ-JZR-BIOMASTER-JZRY01001_EN - Subject to technical modification without notice DVZ-SERVICES GmbH | Boschstraße 9 | D-28857 Syke | Germany | FON +49 (0) 4242 16 93 8 0 | FAX +49 (0) 4242 16 93 8 99 | WEB www.dvz-services.de | MAIL info@dvz-services.de
JZR-„BIOMASTER®“
Operating Manual
I/I
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.1
BMSU overflow pump P1 (continued)
E-2.1.8
Disassembly / Assembly (continued)
E-2
26
MAY 20
E-2.1.8.2 Assembly (continued)
Important!
-
Too large an air gap results in significant performance
reduction of the pump.
The air gap setting is not applicable for closed multi
vane impellers.
Air gap setting for open multi vane impellers:
-
Air gap between the front side of the blade and mating
surface of the pump casing: 0.3 - 0.5 mm.
- Check with a depth gauge
1) Impeller gap too narrow:
Place a second gasket (400/400.1) between the pump
casing (101) and intermediate casing (113) if the
impeller (230) runs in the opposite direction on the pump
casing (101).
2) Impeller gap too wide:
Place a shim behind the impeller (230) to compensate
the air gap.
11.
Screw the pump casing (101) to the intermediate casing
(113).
Important!
In the case of the design with the base rail, screw together the block motor (802) and rail (593).
-
Check the free run of the impeller (230) by turning it!
Establish the electrical connection of the block motor!
Observe the connection type (refer to the name plate on the motor)
Observe the "right-hand" direction of rotation
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.2
Feeding Pump P2
E-2.2.1
Pumps in General
I/I
E-2
61
MAY 20
The pumps should be regularly rinsed or cleaned if deposits of medium are likely to build up
(sedimentation).
If the pump needs to be opened to do this, ensure that the pump and motor are switched off and
cannot be turned on accidently (eg. by removing the fuse).
Periodical standstill to allow for cleaning during operation depends on the medium and type of
operation.
The pump can be cleaned:
-
E-2.2.2
through the cleaning ports provided in the pump housing
manually by dismantling the pump
Lubrication
The pump does not require frequent lubrication.
Where no manufacturer’s instructions are available and when normal conditions of use exist:
-
Strip down the drive unit
Remove the bearings
Clean all parts
Renew the lubricant
every 5000 operating hours or at least every two years.
Pump model with “mechanical seals” (sectional drawing W251.000):
The lubricating should be done:
-
when putting into operation
after every 350 hours of operation
before and after operation interruptions of 6 - 8 weeks.
(continued)
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JZR-„BIOMASTER®“
Operating Manual
I/I
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.2
Feeding Pump P2 (continued)
E-2.2.3
Shaft Sealing through Single Mechanical Seal
E-2
62
MAY 20
There are various constructions of mechanical seals. Especially advantageous is the use of standard
mechanical seals according to DIN 24960. These seals have regardless of their brand the same
fitting dimensions which makes them interchangeable. Mechanical seals with a coil spring can only
be used for pumps which are run in one direction of rotation.
-
The seal specification of a pump is recorded on the order confirmation sheet.
Pumps fitted with direction dependent seals should never be run in the opposite direction of the
rotation arrow.
If excessive leakages occur the spring tension and the seal surfaces should be checked, and the
seal be replaced, if necessary.
Single mechanical seals usually work without any additional equipment. Their application range can
be increased by operating them with a rinsing or cooling system.
a) Quench, in accordance with ISO 5199, Appendix E, Plan Nos. 08, 09, 10 or 13 or API 610,
Appendix D, Plan No. 62.
Quench is the designation commonly used in sealing engineering for an arrangement that applies a
non-pressurized external fluid to the atmospheric side of a mechanical seal. The quench is used
when
–
a single mechanical seal will not work or only to a limited extent without auxiliary measures or
–
a double mechanical seal with pressurized buffer fluid is not necessary.
Recommended for the following applications:
–
Low temperature (danger of freezing)
–
Operation in a vacuum (dry running)
– Media which must be isolated from the atmosphere (e.g. due to build-up of solid deposits or
because of less severe damage to the environment, like smell).
Leakages will be transported away by the quenching liquid. In vacuum operation dry running of the
seals is avoided.
(continued)
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.2
Feeding Pump P2 (continued)
E-2.2.3
Shaft Sealing through Single Mechanical Seal (continued)
I/I
E-2
63
MAY 20
No pressure higher than that of the pumped medium in front of the mechanical seal is allowed to
build up in the quenching area (1) behind the mechanical seal. Otherwise the counter ring will be
pushed out of the housing. Free discharge from (2) is necessary!
Closing off the quenching area from the atmosphere:
1.
In the case that high emission levels can be tolerated: Through a throttle bush (4). Cooling
liquid not permanently used, only released from time to time.
In the case that medium emission levels can be tolerated: By a radial shaft seal ring (3).
Permanent radial shaft seal lubrication through quenching liquid is necessary.
2.
The supply of the Quench liquid can be done in two ways:
1.
From a line via a throttle and shut-off valve with free outlet from the Quench space of the
mechanical seal as shown in the illustration.
from a reservoir, which is located max. one meter above the seal with a drain valve on the
quenching of the mechanical seal. The level in the reservoir has to be always visible from full
and almost empty. Follow-up intervals are set on the operating experience of the operator.
2.
b) Top lubrication
Attention: For vertically installed pumps with overhead drive as type BT:
On initial start-up the mechanical seal has not come in contact with the medium. It runs therefore
dry for a short period of time until the air is displaced from the pump housing.
-
On first start–up and if stood idle for longer periods lubricate the mechanical seal before
switching on the pump.
-
Apply water, glycerine or oil depending on their compatibility with the pumping medium and
the elastomer of the mechanical seal.
-
Fill the quench cup of the mechanical seal housing.
(continued)
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.2
Feeding Pump P2 (continued)
E-2.2.4
Trouble-Shooting and Remedying
I/I
E-2
64
MAY 20
E-2.2.4.1 Trouble Chart
The following chart lists possible problems as
-
the type
-
the likely reason / cause
-
the remedy
A problem may have various causes:
➔ several boxes in the vertical column are marked with a cross
A reason / cause may result in various problems:
➔ several boxes in the horizontal column are marked with a cross
E-2.2.4.2 How do you trace the kind of problem to find the possible cause?
-
the column describing a possible problem shows one or several boxes marked with a cross
on the corresponding lines you will find the possible reasons / cause and some hints how to
handle the problem
Thus the actual cause of the problem can be narrowed down and eventually detected.
-
if you find further cross-marked boxes on one of the lines and should there appear
corresponding problems as well, then the likely cause of the problem has been detected
The table helps in finding the root of the problem and will give you the remedy if it is straight
forward.
(continued)
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Operating Manual
JZR-„BIOMASTER®“
Part E: Maintenance
Maintenance of Pumps and Blowers
x
x
The shaft seal is leaking
The rotor life time is too short
The stator life time is too short
The drive is overloaded
The pump is stuck
The pump is running loudly
Trouble-Shooting and Remedying (continued)
Possible Problems
The pumped medium is
E-2.2.4
The pressure is too low
Feeding Pump P2 (continued)
The pumped medium is too little
E-2.2
The pump is no longer sucking
Maintenance of pumps and fans (continued)
The pump is no longer starting
E-2
x
Possible Causes
x x
x
In new pumps or
stators: the static
friction is too great.
The pump electrical equipment is not
compatible with the electrical supply..
x
x x x
The pressure is too high.
x
x x
x
x x x x
x
x x x
x
x x x
x
x x x x x
x x x
x x x x
The shaft seal is leaking.
x x
The rpm is too low.
x x x
With reduced diameter rotors: operating
temperature has not been reached.
x x x x
x x x
The stator has swollen, the elastomer
is not compatible with the medium.
The solids content of the medium is too
high and leads to blockages.
The liquid medium sediments or hardens
when left to stand.
There is air in the suction pipe.
The suction pipe is leaking.
x x x x
x x
There are foreign bodies in the pump.
The temperature of the liquid medium is
too high, the stator is too ductile.
x x
x x x x
x
The suction is too great or pressure too
low (cavitation).
The pump is running dry.
The stator is worn out.
I/I
E-2
65
MAY 20
Behebung der Remedy
Fill the pump up, then pump through
manually using a suitable appliance; if
necessary use glycerin as lubricant in the
stator.
Check order information. Examine
electrical installation (possibly 2 phase
operation).
Measure the pressure with a
manometer and check against order
details. Reduce the pressure or
change the drive.
Remove foreign bodies and eliminate
possible damage.
If the liquid medium temperature cannot
be lowered, use a reduced diameter rotor.
Check whether the liquid medium
agrees with the order requirements.
Possibly change stator material.
Increase the liquid part of the medium.
Clean the pump and rinse through after
each run.
Increase the suction liquid level, prevent
turbulence and air bubbles at the inlet.
Check seals and tighten pipe connections.
Stuffing box: tighten or renew.
Mechanical seal: renew seals, eliminate
solid deposits.
In the case of adjustable drives:
increase the rpm. If necessary change
the drive.
Warm up the pump (stator) to
operating temperature first of all.
Decrease suction resistance, lower
the temperature of the liquid medium,
install the pump at a lower location.
Fill up the pump, provide for dry
running protection, move the
pipes.
Replace with a new stator.
(continued)
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Part E: Maintenance
Maintenance of Pumps and Blowers
The shaft seal is leaking
The rotor life time is too short
The stator life time is too short
The drive is overloaded
The pump is stuck
The pump is running loudly
Trouble-Shooting and Remedying (continued)
Possible Problems
The pumped medium is
E-2.2.4
The pressure is too low
Feeding Pump P2 (continued)
The pumped medium is too little
E-2.2
The pump is no longer sucking
Maintenance of pumps and fans (continued)
The pump is no longer starting
E-2
Possible Causes
x x x
x
x x
The stator material is brittle.
x x x
x
x
The rotor is worn out.
x
The joints are worn out.
The pump and drive are not axially aligned.
x
x
x
x
x The roller bearings are destroyed.
The elastic element of the coupling is worn out.
x
The rpm is too high.
x
The viscosity is too high.
x
The specific weight of the medium is too
high.
x
x The stuffing box is incorrectly tightened.
x The packing is not suited to the liquid medium.
x Mechanical seal: rotation is incorrect.
seal: mechanical seal and mating
x Mechanical
ring have failed.
x
x Mechanical seal: elastomers damaged,
swollen or brittle.
E-2.2.5
I/I
Operating Manual
JZR-„BIOMASTER®“
E-2
66
MAY 20
Behebung der Remedy
Fit a new stator. Check the liquid medium
agrees with order details; if necessary
change the stator material.
Change rotor, establish the cause. Wear and
tear, corrosion, cavitation; if necessary
change to a different material or coating.
Replace relevant parts, carefully reseal
and lubricate.
Re-align the unit.
Use a new connection and re-align the pump.
Replace roller bearings, lubricate, reseal. At
higher temperatures observe the lubricant and
the bearings.
In the case of adjustable drives : lower the rpm.
If necessary change the drive.
Measure the viscosity and compare with order
details. If necessary adjust viscosity or change
the drive.
Measure specific weight and compare with
order details. If necessary adjust specific
weight or change the drive.
Service stuffing box according to page 7.4, if
necessary renew worn shaft.
Replace fitted packing with another packing
type.
Change electrical connection.
Replace relevant rings with new ones.
Replace elastomers. Check whether the liquid
medium agrees with order details, if
necessary change material.
Dismantling and Assembly of the Pump Housing
Removal and Fitting of End Connection, Stator and Pump Housing
The pump with attached pipework should be empty and must have cooled off. Disconnect the
pipework on the suction side and pressure side of the pump.
(continued)
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.2
Feeding Pump P2 (continued)
E-2.2.5
Dismantling and Assembly of the Pump Housing (continued)
I/I
E-2
67
MAY 20
E-2.2.5.1 Dismantling
-
Remove securing screws (S) from support feet (2035) to baseplate (G).
-
Unscrew hex nuts (3020) and remove with spring washers (3015).
Withdraw end connection (2005) and first support foot (2035/1) with washers (3070).
-
Support pump housing (2010) and stator (3005) with wooden blocks.
Loosen hex nuts (3020), where fitted, and remove thru bolts (3010).
Where fitted, remove second support foot (2035/2) and washers (3070).
(continued)
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.2
Feeding Pump P2 (continued)
E-2.2.5
Dismantling and Assembly of the Pump Housing (continued)
I/I
E-2
68
MAY 20
E-2.2.5.1 Dismantling (continued)
Caution for pumps with tubular rotors:
Where the walls of tubular rotors are worn in the wear zones, pumping medium may occur inside the
rotor and may come out when pulling off the stator. Ensure that protective measures have been
taken when pumping dangerous media!
-
Pull the stator (3005) out forward.
-
Remove the hex nuts (2030) with spring washers (2025).
Pull the pump housing (2010) off forward.
Pressure reduced execution:
-
Remove screws (2164) and spring washers (2167).
Pull the pump housing (2010) completely forward, off the mechanical seal housing of the shaft
sealing (W).
(continued)
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.2
Feeding Pump P2 (continued)
E-2.2.5
Dismantling and Assembly of the Pump Housing (continued)
I/I
E-2
69
MAY 20
E-2.2.5.1 Dismantling (continued)
E-2.2.5.2 Assembly
Refit in reverse order.
When refitting the stator (3005) check direction of stator (3005) is correct! The funnel-shaped inflow
side (E) of the stator (3005) must show to
-
the pump housing (2010) when rotation is anti- clockwise
the end connection (2005) when rotation is clockwise
when viewed on pump shaft end.
(continued)
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.2
Feeding Pump P2 (continued)
E-2.2.5
Dismantling and Assembly of the Pump Housing (continued)
I/I
E-2
70
MAY 20
E-2.2.5.2 Assembly (continued)
-
Elastomer stators (A) have integrated front side sealing profiles (D). They don't need additional
gaskets for sealing off the end connection (2005) and the pump housing (2010).
Solid stators (B) have no integrated front side sealing profiles. Therefore additional gaskets
(8005) should be installed to seal off the end connection (2005) as well as the pump housing
(2010).
Be careful when engaging the stator (3005) and rotor (1999). Do not trap your fingers. Do not reach
inside the stator.
-
Push stator (3005) with a rotating movement on to rotor (1999).
Apply an assembly device and some glycerine to ease engaging stator (3005) and rotor (1999).
When tightening the hex nuts (2030), a gap remains between the lantern (0085) and the pump
housing (2010) or the mechanical seal housing of the shaft sealing (W).
Do not try to close this gap by over-tightening the hex nuts (2030)!
Lantern (0085) can break!
(continued)
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JZR-„BIOMASTER®“
I/I
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.2
Feeding Pump P2 (continued)
E-2.2.5
Dismantling and Assembly of the Pump Housing (continued)
E-2
71
MAY 20
E-2.2.5.2 Assembly (continued)
Torque values for hex nuts (2030):
Size
M6
M8
M10
M12
M16
M20
M24
M30
Required torque [Nm]
8
15
30
45
75
20
100
120
Fastening the end connection (2005):
-
Screw hex nuts (3020/C) down into thru bolts (3010) as far as possible.
Slip on the first washers (3070), the support foot (2035/1), the second washers (3070), the end
stud (2005) and tighten with spring washers (3015) and hex nuts (3020/A).
Fasten support foot (2035/1) from behind with hex nuts (3020/C).
Ensure during refitting that the O-ring (8015) or, where a heating jacket (3025) is installed, the Orings (8030) are in perfect condition and will sit correctly.
Ensure that the drain plug (2015) is not screwed too tightly into the pump housing (2010), since
otherwise its conical thread may break the pump housing (2010).
The torque should be about 40 - 50 Nm.
(continued)
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.2
Feeding Pump P2 (continued)
E-2.2.5
Dismantling and Assembly of the Pump Housing (continued)
I/I
E-2
72
MAY 20
E-2.2.5.2 Assembly (continued)
E-2.2.6 Dismantling and Assembly of the Rotating Parts
E-2.2.6.1 Removal of Rotor and Coupling Rod
For removal of the rotor (1999) and coupling rod (1998) the pin joints should be dismantled as
follows:
-
Place the dismantled unit - consisting of bearing housing (0005) with drive shaft (1005) or drive
stool (0085) with drive (A) and connecting shaft (1050), coupling rod (1998) and rotor (1999) - on
the workbench with a wooden block supporting the
-
Push circlip (5065) out of its groove and slip off over the head of rotor (1999), connecting shaft
(1050) or adapter (5055, 5056).
(continued)
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.2
Feeding Pump P2 (continued)
E-2.2.6
Dismantling and Assembly of the Rotating Parts (continued)
I/I
E-2
73
MAY 20
E-2.2.6.1 Removal of Rotor and Coupling Rod (continued)
Pumps fitted with a metallic rotor (1999):
-
If necessary hit the edge of sleeve (5110, 5115) at an angle with the help of a wooden block and
a plastic hammer. Taking care not to damage the O-rings (8060)!
-
Press the pin (5075) out of the head of rotor (1999), connecting shaft (1050) or adapter (5055,
5056). If necessary use a hammer and a thin cylindrical pin (DIN 6450 C).
Drain the oil into a receptacle.
-
(continued)
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.2
Feeding Pump P2 (continued)
E-2.2.6
Dismantling and Assembly of the Rotating Parts (continued)
I/I
E-2
74
MAY 20
E-2.2.6.1 Removal of Rotor and Coupling Rod (continued)
-
Using a screwdriver, carefully lever the SM-pin joint seal (8235) out of the head of rotor (1999),
connecting shaft (1050) or adapter (5055, 5056).
Taking care not to damage the SM-pin joint seal (8235).
-
Pull apart the rotor (1999)/ coupling rod (1998)/ drive shaft (1005) or connecting shaft (1050)
with adapter (5055, 5056) assembly.
Remove the O-rings (8060).
-
-
Push the SM-pin joint seal (8235) towards the head of coupling rod (1998). In the narrow
coupling rod section press the clamp ring (5425) out of the groove of the seal.
Slip the SM-pin joint seal (8235) and clamp ring (5425) off over the head of the coupling rod
(1998).
Where an adapter (5055, 5056) is fitted: See Page 10.3, Section 10.3: Removal and Fitting of
Adapters.
(continued)
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.2
Feeding Pump P2 (continued)
E-2.2.6
Dismantling and Assembly of the Rotating Parts (continued)
I/I
E-2
75
MAY 20
E-2.2.6.1 Removal of Rotor and Coupling Rod (continued)
E-2.2.6.2 Fitting the Rotor and Coupling Rod
For fitting the rotor (1999) with coupling rod (1998), the two pin joints should be assembled as
follows:
-
Slip the clamp ring (5425) over the head of coupling rod (1998).
-
Push the SM-pin joint seal (8235) over the head of coupling rod (1998) towards its narrow
section, there squeezing the clamp ring (5425) into the groove of the SM-pin joint seal (8235).
(continued)
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.2
Feeding Pump P2 (continued)
E-2.2.6
Dismantling and Assembly of the Rotating Parts (continued)
I/I
E-2
76
MAY 20
E-2.2.6.2 Fitting the Rotor and Coupling Rod (Continued)
-
Push the SM-pin joint seal (8235) with the correctly placed clamp ring (5425) up to the shoulder
of coupling rod (1998).
-
Slip the circlip (5065) on to the coupling rod (1998).
Slide the sleeve (5110) or (5115) on to coupling rod (1998) so the inside diameter of chamfering
(A) is being placed towards the coupling rod (1998) extension.
Chamfering (A) will later on ease the installation over the O-rings (8060).
Orient the head of coupling rod (1998) until it is in vertical position for the bore (B) for the pin
(5075).
-
-
-
Slide the coupling rod (1998) with SM-pin joint seal (8235) into the bore of rotor (1999),
connecting shaft (1050) or adapter (5055, 5056) and insert the pin (5075) from below and push
up to the upper edge of coupling rod (1998).
Support the pin (5075) against dropping out.
Slide the SM-pin joint seal (8235) into the rotor (1999), connecting shaft (1050)/ or adapter
(5055, 5056) only from below, and in a slightly slanted
(continued)
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.2
Feeding Pump P2 (continued)
E-2.2.6
Dismantling and Assembly of the Rotating Parts (continued)
I/I
E-2
77
MAY 20
E-2.2.6.2 Fitting the Rotor and Coupling Rod (Continued)
-
-
-
-
For lubrication, use an oil can which should be fitted with a thin plastic hose having an outside
diameter of not more than 4 mm.
Insert this hose into the upper oil port opening in the rotor (1999), connecting shaft (1050) or
adapter (5055, 5056). Then slide the hose end past the coupling rod (1998) all the way down to
the bottom section of the rotor head (1999) or connecting shaft (1050) or adapter (5055, 5056).
Slowly fill with lubricating oil up to the filling port.
Pull the hose out. Then insert the hose end through the small gap on the topside of SM-pin joint
seal (8235) and guide it down to the bottom of the hollow space between coupling rod (1998)
and SM-pin joint seal (8235).
Slowly fill with lubricating oil up to the gap.
(continued)
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.2
Feeding Pump P2 (continued)
E-2.2.6
Dismantling and Assembly of the Rotating Parts (continued)
I/I
E-2
78
MAY 20
E-2.2.6.2 Fitting the Rotor and Coupling Rod (Continued)
-
Pull the hose out.
Push the pin (5075) entirely into the bore of head of rotor (1999), connecting shaft (1050) or
adapter (5055, 5056) and retain in place.
Only now, press the SM-pin joint seal (8235) into the bore of head of rotor (1999), connecting
shaft (1050) or adapter (5055, 5056) and push up to the shoulder. In doing so the SM-pin joint
seal (8235) should be slightly bulbous around the outer surface.
-
Wipe off overflow oil. Use this oil for lubricating the O-rings (8060).
Slip the sleeve (5110) or (5115), with its chamfering (A) forward, on to the head of rotor (1999),
connecting shaft (1050) or adapter (5055, 5056) and push up to the shoulder.
-
Place the circlip (5065) into its groove on the rotor head (1999), connecting shaft (1050) or
adapter (5055, 5056) and carefully snap in place all around.
(continued)
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.2
Feeding Pump P2 (continued)
E-2.2.6
Dismantling and Assembly of the Rotating Parts (continued)
I/I
E-2
79
MAY 20
E-2.2.6.2 Fitting the Rotor and Coupling Rod (Continued)
-
Drive shaft (1005) or connecting shaft (1050) with adapter (5055, 5056), coupling rod (1998)
and rotor (1999) are now joined by means of the two pin joints.
Pump housing (2010), stator (3005) and end connection (2005) may now be fitted.
E-2.2.7 Removal and Fitting of the Connecting Shaft with Shaft Seal
E-2.2.7.1 Removal:
-
Push the circlip (1035) in the direction to the mechanical seal.
Remove pin (1030).
Remove the shaft seal housing (7005) and mechanical seal (7010) together with connecting shaft
(1050) and set ring (1035) from drive stool (0085) and the drive shaft.
The thread of cylindrical head screw (1040) can be used as forcing screw.
E-2.2.7.2 Fitting:
Apply grease into the bore of the connecting shaft (1050) to avoid rust (e.g. TCE-Metallic 600).
Assemble the shaft seal housing (7005) and mechanical seal (7010) together with connecting
shaft (1050) and set ring (1035) with drive stool (0085) and push connecting shaft (1050) on to
the drive shaft.
- At this please observe the installation direction of set ring (1035) (please see mark).
- Connect the connecting shaft (1050) and the drive shaft by pin (1030).
- Push set ring (1035) on pin (1030).
(continued)
-
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.2
Feeding Pump P2 (continued)
E-2.2.7
Removal and Fitting of the Single Mechanical Seal
-
-
-
I/I
E-2
80
MAY 20
Carefully slide out mechanical seal housing (7005) together with the parts of the mechanical seal
contained in it from connecting shaft (1050).
Carefully push mechanical seal (7010) stationary seat out of mechanical seal housing (7005).
Refitting is a simple reversal of the above procedure.
To reduce frictional forces during seal assembly, apply some glycerine to the shaft and the seal
housing in the area of the gaskets.
Special care must be taken when fitting double PTFE-coated gaskets: the joint of the outer
coating must point away from the seal assembly direction, otherwise the coating may open or be
pulled off!
Ensure that the distribution of pressure is uniform when inserting the pressure sensitive counter
rings. When inserting larger rings, use a suitable mandrel.
Do not allow any foreign bodies to get between the sliding surfaces.
Exactly keep to the seal installation dimensions and ensure that the sealing faces are correctly
pressed together (see table on sectional drawing W ... ).
Insert mechanical seal (7010) stationary seat into mechanical seal housing (7005).
Insert mechanical seal housing (7005) together with the stationary seat into the drive stool
without the installed connecting shaft (1050).
If necessary take the installation dimension from the table and add the thickness S of the set
ring (7086) when existing.
Mark this installation dimension on the connecting shaft (1050).
Fix the rotating unit of the mechanical seal (7010) on the connecting shaft (1050) depending on
the installation dimension so that the rotating unit of the mechanical seal (7010) or the set ring
(7086) is at the mark.
Insert connecting shaft (1050) with the rotating unit of the mechanical seal (7010) into drive
stool (0085) and install lip seal (7091, if existing.
Push the set ring (1035) on to connecting shaft (1050) and observe at this the installation
direction (see mark).
Push connecting shaft (1050) on to the drive shaft and connect with pin (1030). Push the set ring
(1035) on pin (1030).
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.3
CIP-Pump P4
E-2.3.1
Pumps in General
I/I
E-2
81
MAY 20
The pumps should be regularly rinsed or cleaned if deposits of medium are likely to build up
(sedimentation).
If the pump needs to be opened to do this, ensure that the pump and motor are switched off and
cannot be turned on accidently (eg. by removing the fuse).
Periodical standstill to allow for cleaning during operation depends on the medium and type of
operation.
The pump can be cleaned:
-
E-2.3.2
through the cleaning ports provided in the pump housing
manually by dismantling the pump
Lubrication
The pump does not require frequent lubrication.
Where no manufacturer’s instructions are available and when normal conditions of use exist:
-
Strip down the drive unit
Remove the bearings
Clean all parts
Renew the lubricant
every 5000 operating hours or at least every two years.
Pump model with “mechanical seals” (sectional drawing W251.000):
The lubricating should be done:
-
when putting into operation
after every 350 hours of operation
before and after operation interruptions of 6 - 8 weeks.
(continued)
OM_2020051900_DVZ-JZR-BIOMASTER-JZRY01001_EN - Subject to technical modification without notice DVZ-SERVICES GmbH | Boschstraße 9 | D-28857 Syke | Germany | FON +49 (0) 4242 16 93 8 0 | FAX +49 (0) 4242 16 93 8 99 | WEB www.dvz-services.de | MAIL info@dvz-services.de
JZR-„BIOMASTER®“
Operating Manual
I/I
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.3
CIP-Pump P4 (continued)
E-2.3.3
Shaft Sealing through Single Mechanical Seal
E-2
82
MAY 20
There are various constructions of mechanical seals. Especially advantageous is the use of standard
mechanical seals according to DIN 24960. These seals have regardless of their brand the same
fitting dimensions which makes them interchangeable. Mechanical seals with a coil spring can only
be used for pumps which are run in one direction of rotation.
-
The seal specification of a pump is recorded on the order confirmation sheet.
Pumps fitted with direction dependent seals should never be run in the opposite direction of the
rotation arrow.
If excessive leakages occur the spring tension and the seal surfaces should be checked, and the
seal be replaced, if necessary.
Single mechanical seals usually work without any additional equipment. Their application range can
be increased by operating them with a rinsing or cooling system.
a) Quench, in accordance with ISO 5199, Appendix E, Plan Nos. 08, 09, 10 or 13 or API 610,
Appendix D, Plan No. 62.
Quench is the designation commonly used in sealing engineering for an arrangement that applies a
non-pressurized external fluid to the atmospheric side of a mechanical seal. The quench is used
when
–
a single mechanical seal will not work or only to a limited extent without auxiliary measures or
–
a double mechanical seal with pressurized buffer fluid is not necessary.
Recommended for the following applications:
–
Low temperature (danger of freezing)
–
Operation in a vacuum (dry running)
– Media which must be isolated from the atmosphere (e.g. due to build-up of solid deposits or
because of less severe damage to the environment, like smell).
Leakages will be transported away by the quenching liquid. In vacuum operation dry running of the
seals is avoided.
(continued)
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.3
CIP-Pump P4 (continued)
E-2.3.3
Shaft Sealing through Single Mechanical Seal (continued)
I/I
E-2
83
MAY 20
No pressure higher than that of the pumped medium in front of the mechanical seal is allowed to
build up in the quenching area (1) behind the mechanical seal. Otherwise the counter ring will be
pushed out of the housing. Free discharge from (2) is necessary!
Closing off the quenching area from the atmosphere:
1.
In the case that high emission levels can be tolerated: Through a throttle bush (4). Cooling
liquid not permanently used, only released from time to time.
In the case that medium emission levels can be tolerated: By a radial shaft seal ring (3).
Permanent radial shaft seal lubrication through quenching liquid is necessary.
2.
The supply of the Quench liquid can be done in two ways:
1.
From a line via a throttle and shut-off valve with free outlet from the Quench space of the
mechanical seal as shown in the illustraion.
from a reservoir, which is located max. one meter above the seal with a drain valve on the
quenching of the mechanical seal. The level in the reservoir has to be always visible from full
and almost empty. Follow-up intervals are set on the operating experience of the operator.
2.
b) Top lubrication
Attention: For vertically installed pumps with overhead drive as type BT:
On initial start-up the mechanical seal has not come in contact with the medium. It runs therefore
dry for a short period of time until the air is displaced from the pump housing.
-
On first start–up and if stood idle for longer periods lubricate the mechanical seal before
switching on the pump.
-
Apply water, glycerin or oil depending on their compatibility with the pumping medium and
the elastomer of the mechanical seal.
-
Fill the quench cup of the mechanical seal housing.
(continued)
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.3
CIP-Pump P4 (continued)
E-2.3.4
Trouble-Shooting and Remedying
I/I
E-2
84
MAY 20
E-2.3.4.1 Trouble Chart
The following chart lists possible problems as
-
the type
-
the likely reason / cause
-
the remedy
A problem may have various causes:
➔ several boxes in the vertical column are marked with a cross
A reason / cause may result in various problems:
➔ several boxes in the horizontal column are marked with a cross
E-2.3.4.2 How do you trace the kind of problem to find the possible cause?
-
the column describing a possible problem shows one or several boxes marked with a cross
on the corresponding lines you will find the possible reasons / cause and some hints how to
handle the problem
Thus the actual cause of the problem can be narrowed down and eventually detected.
-
if you find further cross-marked boxes on one of the lines and should there appear
corresponding problems as well, then the likely cause of the problem has been detected
The table helps in finding the root of the problem and will give you the remedy if it is straight
forward.
(continued)
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Operating Manual
JZR-„BIOMASTER®“
Part E: Maintenance
Maintenance of Pumps and Blowers
x
x
The shaft seal is leaking
The rotor life time is too short
The stator life time is too short
The drive is overloaded
The pump is stuck
The pump is running loudly
Trouble-Shooting and Remedying (continued)
Possible Problems
The pumped medium is
E-2.3.4
The pressure is too low
CIP-Pump P4 (continued)
The pumped medium is too little
E-2.3
The pump is no longer sucking
Maintenance of pumps and fans (continued)
The pump is no longer starting
E-2
x
Possible Causes
x x
x
In new pumps or
stators: the static
friction is too great.
The pump electrical equipment is not
compatible with the electrical supply..
x
x x x
The pressure is too high.
x
x x
x
x x x x
x
x x x
x
x x x
x
x x x x x
x x x
x x x x
The shaft seal is leaking.
x x
The rpm is too low.
x x x
With reduced diameter rotors: operating
temperature has not been reached.
x x x x
x x x
The stator has swollen, the elastomer
is not compatible with the medium.
The solids content of the medium is too
high and leads to blockages.
The liquid medium sediments or hardens
when left to stand.
There is air in the suction pipe.
The suction pipe is leaking.
x x x x
x x
There are foreign bodies in the pump.
The temperature of the liquid medium is
too high, the stator is too ductile.
x x
x x x x
x
The suction is too great or pressure too
low (cavitation).
The pump is running dry.
The stator is worn out.
I/I
E-2
85
MAY 20
Behebung der Remedy
Fill the pump up, then pump through
manually using a suitable appliance; if
necessary use glycerin as lubricant in the
stator.
Check order information. Examine
electrical installation (possibly 2 phase
operation).
Measure the pressure with a
manometer and check against order
details. Reduce the pressure or
change the drive.
Remove foreign bodies and eliminate
possible damage.
If the liquid medium temperature cannot
be lowered, use a reduced diameter rotor.
Check whether the liquid medium
agrees with the order requirements.
Possibly change stator material.
Increase the liquid part of the medium.
Clean the pump and rinse through after
each run.
Increase the suction liquid level, prevent
turbulence and air bubbles at the inlet.
Check seals and tighten pipe connections.
Stuffing box: tighten or renew.
Mechanical seal: renew seals, eliminate
solid deposits.
In the case of adjustable drives:
increase the rpm. If necessary change
the drive.
Warm up the pump (stator) to
operating temperature first of all.
Decrease suction resistance, lower
the temperature of the liquid medium,
install the pump at a lower location.
Fill up the pump, provide for dry
running protection, move the
pipes.
Replace with a new stator.
(continued)
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Part E: Maintenance
Maintenance of Pumps and Blowers
The shaft seal is leaking
The rotor life time is too short
The stator life time is too short
The drive is overloaded
The pump is stuck
The pump is running loudly
Trouble-Shooting and Remedying (continued)
Possible Problems
The pumped medium is
E-2.3.4
The pressure is too low
CIP-Pump P4 (continued)
The pumped medium is too little
E-2.3
The pump is no longer sucking
Maintenance of pumps and fans (continued)
The pump is no longer starting
E-2
Possible Causes
x x x
x
x x
The stator material is brittle.
x x x
x
x
The rotor is worn out.
x
The joints are worn out.
The pump and drive are not axially aligned.
x
x
x
x
x The roller bearings are destroyed.
The elastic element of the coupling is worn out.
x
The rpm is too high.
x
The viscosity is too high.
x
The specific weight of the medium is too
high.
x
x The stuffing box is incorrectly tightened.
x The packing is not suited to the liquid medium.
x Mechanical seal: rotation is incorrect.
seal: mechanical seal and mating
x Mechanical
ring have failed.
x
x Mechanical seal: elastomers damaged,
swollen or brittle.
E-2.3.5
I/I
Operating Manual
JZR-„BIOMASTER®“
E-2
86
MAY 20
Behebung der Remedy
Fit a new stator. Check the liquid medium
agrees with order details; if necessary
change the stator material.
Change rotor, establish the cause. Wear and
tear, corrosion, cavitation; if necessary
change to a different material or coating.
Replace relevant parts, carefully reseal
and lubricate.
Re-align the unit.
Use a new connection and re-align the pump.
Replace roller bearings, lubricate, reseal. At
higher temperatures observe the lubricant and
the bearings.
In the case of adjustable drives : lower the rpm.
If necessary change the drive.
Measure the viscosity and compare with order
details. If necessary adjust viscosity or change
the drive.
Measure specific weight and compare with
order details. If necessary adjust specific
weight or change the drive.
Service stuffing box according to page 7.4, if
necessary renew worn shaft.
Replace fitted packing with another packing
type.
Change electrical connection.
Replace relevant rings with new ones.
Replace elastomers. Check whether the liquid
medium agrees with order details, if
necessary change material.
Dismantling and Assembly of the Pump Housing
Removal and Fitting of End Connection, Stator and Pump Housing
The pump with attached pipework should be empty and must have cooled off. Disconnect the
pipework on the suction side and pressure side of the pump.
(continued)
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.3
CIP-Pump P4 (continued)
E-2.3.5
Dismantling and Assembly of the Pump Housing (continued)
I/I
E-2
87
MAY 20
E-2.3.5.1 Dismantling
-
Remove securing screws (S) from support feet (2035) to baseplate (G).
-
Unscrew hex nuts (3020) and remove with spring washers (3015).
Withdraw end connection (2005) and first support foot (2035/1) with washers (3070).
-
Support pump housing (2010) and stator (3005) with wooden blocks.
Loosen hex nuts (3020), where fitted, and remove thru bolts (3010).
Where fitted, remove second support foot (2035/2) and washers (3070).
(continued)
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.3
CIP-Pump P4 (continued)
E-2.3.5
Dismantling and Assembly of the Pump Housing (continued)
I/I
E-2
88
MAY 20
E-2.3.5.1 Dismantling (continued)
Caution for pumps with tubular rotors:
Where the walls of tubular rotors are worn in the wear zones, pumping medium may occur inside the
rotor and may come out when pulling off the stator. Ensure that protective measures have been
taken when pumping dangerous media!
-
Pull the stator (3005) out forward.
-
Remove the hex nuts (2030) with spring washers (2025).
Pull the pump housing (2010) off forward.
Pressure reduced execution:
-
Remove screws (2164) and spring washers (2167).
Pull the pump housing (2010) completely forward, off the mechanical seal housing of the shaft
sealing (W).
(continued)
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.3
CIP-Pump P4 (continued)
E-2.3.5
Dismantling and Assembly of the Pump Housing (continued)
I/I
E-2
89
MAY 20
E-2.3.5.1 Dismantling (continued)
E-2.3.5.2 Assembly
Refit in reverse order.
When refitting the stator (3005) check direction of stator (3005) is correct! The funnel-shaped inflow
side (E) of the stator (3005) must show to
-
the pump housing (2010) when rotation is anti- clockwise
the end connection (2005) when rotation is clockwise
when viewed on pump shaft end.
(continued)
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.3
CIP-Pump P4 (continued)
E-2.3.5
Dismantling and Assembly of the Pump Housing (continued)
I/I
E-2
90
MAY 20
E-2.3.5.2 Assembly (continued)
-
Elastomer stators (A) have integrated front side sealing profiles (D). They don't need additional
gaskets for sealing off the end connection (2005) and the pump housing (2010).
Solid stators (B) have no integrated front side sealing profiles. Therefore additional gaskets
(8005) should be installed to seal off the end connection (2005) as well as the pump housing
(2010).
Be careful when engaging the stator (3005) and rotor (1999). Do not trap your fingers. Do not reach
inside the stator.
-
Push stator (3005) with a rotating movement on to rotor (1999).
Apply an assembly device and some glycerine to ease engaging stator (3005) and rotor (1999).
When tightening the hex nuts (2030), a gap remains between the lantern (0085) and the pump
housing (2010) or the mechanical seal housing of the shaft sealing (W).
Do not try to close this gap by over-tightening the hex nuts (2030)!
Lantern (0085) can break!
(continued)
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JZR-„BIOMASTER®“
I/I
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.3
CIP-Pump P4 (continued)
E-2.3.5
Dismantling and Assembly of the Pump Housing (continued)
E-2
91
MAY 20
E-2.3.5.2 Assembly (continued)
Torque values for hex nuts (2030):
Size
M6
M8
M10
M12
M16
M20
M24
M30
Required torque [Nm]
8
15
30
45
75
20
100
120
Fastening the end connection (2005):
-
Screw hex nuts (3020/C) down into thru bolts (3010) as far as possible.
Slip on the first washers (3070), the support foot (2035/1), the second washers (3070), the end
stud (2005) and tighten with spring washers (3015) and hex nuts (3020/A).
Fasten support foot (2035/1) from behind with hex nuts (3020/C).
Ensure during refitting that the O-ring (8015) or, where a heating jacket (3025) is installed, the Orings (8030) are in perfect condition and will sit correctly.
Ensure that the drain plug (2015) is not screwed too tightly into the pump housing (2010), since
otherwise its conical thread may break the pump housing (2010).
The torque should be about 40 - 50 Nm.
(continued)
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.3
CIP-Pump P4 (continued)
E-2.3.5
Dismantling and Assembly of the Pump Housing (continued)
I/I
E-2
92
MAY 20
E-2.3.5.2 Assembly (continued)
E-2.3.6 Dismantling and Assembly of the Rotating Parts
E-2.3.6.1 Removal of Rotor and Coupling Rod
For removal of the rotor (1999) and coupling rod (1998) the pin joints should be dismantled as
follows:
-
Place the dismantled unit - consisting of bearing housing (0005) with drive shaft (1005) or drive
stool (0085) with drive (A) and connecting shaft (1050), coupling rod (1998) and rotor (1999) - on
the workbench with a wooden block supporting the
-
Push circlip (5065) out of its groove and slip off over the head of rotor (1999), connecting shaft
(1050) or adapter (5055, 5056).
(continued)
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.3
CIP-Pump P4 (continued)
E-2.3.6
Dismantling and Assembly of the Rotating Parts (continued)
I/I
E-2
93
MAY 20
E-2.3.6.1 Removal of Rotor and Coupling Rod (continued)
Pumps fitted with a metallic rotor (1999):
-
If necessary hit the edge of sleeve (5110, 5115) at an angle with the help of a wooden block and
a plastic hammer. Taking care not to damage the O-rings (8060)!
-
Press the pin (5075) out of the head of rotor (1999), connecting shaft (1050) or adapter (5055,
5056). If necessary use a hammer and a thin cylindrical pin (DIN 6450 C).
Drain the oil into a receptacle.
-
(continued)
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.3
CIP-Pump P4 (continued)
E-2.3.6
Dismantling and Assembly of the Rotating Parts (continued)
I/I
E-2
94
MAY 20
E-2.3.6.1 Removal of Rotor and Coupling Rod (continued)
-
Using a screwdriver, carefully lever the SM-pin joint seal (8235) out of the head of rotor (1999),
connecting shaft (1050) or adapter (5055, 5056).
Taking care not to damage the SM-pin joint seal (8235).
-
Pull apart the rotor (1999)/ coupling rod (1998)/ drive shaft (1005) or connecting shaft (1050)
with adapter (5055, 5056) assembly.
Remove the O-rings (8060).
-
-
Push the SM-pin joint seal (8235) towards the head of coupling rod (1998). In the narrow
coupling rod section press the clamp ring (5425) out of the groove of the seal.
Slip the SM-pin joint seal (8235) and clamp ring (5425) off over the head of the coupling rod
(1998).
Where an adapter (5055, 5056) is fitted: See Page 10.3, Section 10.3: Removal and Fitting of
Adapters.
(continued)
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.3
CIP-Pump P4 (continued)
E-2.3.6
Dismantling and Assembly of the Rotating Parts (continued)
I/I
E-2
95
MAY 20
E-2.3.6.1 Removal of Rotor and Coupling Rod (continued)
E-2.3.6.2 Fitting the Rotor and Coupling Rod
For fitting the rotor (1999) with coupling rod (1998), the two pin joints should be assembled as
follows:
-
Slip the clamp ring (5425) over the head of coupling rod (1998).
-
Push the SM-pin joint seal (8235) over the head of coupling rod (1998) towards its narrow
section, there squeezing the clamp ring (5425) into the groove of the SM-pin joint seal (8235).
(continued)
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.3
CIP-Pump P4 (continued)
E-2.3.6
Dismantling and Assembly of the Rotating Parts (continued)
I/I
E-2
96
MAY 20
E-2.3.6.2 Fitting the Rotor and Coupling Rod (Continued)
-
Push the SM-pin joint seal (8235) with the correctly placed clamp ring (5425) up to the shoulder
of coupling rod (1998).
-
Slip the circlip (5065) on to the coupling rod (1998).
Slide the sleeve (5110) or (5115) on to coupling rod (1998) so the inside diameter of chamfering
(A) is being placed towards the coupling rod (1998) extension.
Chamfering (A) will later on ease the installation over the O-rings (8060).
Orient the head of coupling rod (1998) until it is in vertical position for the bore (B) for the pin
(5075).
-
-
-
Slide the coupling rod (1998) with SM-pin joint seal (8235) into the bore of rotor (1999),
connecting shaft (1050) or adapter (5055, 5056) and insert the pin (5075) from below and push
up to the upper edge of coupling rod (1998).
Support the pin (5075) against dropping out.
Slide the SM-pin joint seal (8235) into the rotor (1999), connecting shaft (1050)/ or adapter
(5055, 5056) only from below, and in a slightly slanted
(continued)
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.3
CIP-Pump P4 (continued)
E-2.3.6
Dismantling and Assembly of the Rotating Parts (continued)
I/I
E-2
97
MAY 20
E-2.3.6.2 Fitting the Rotor and Coupling Rod (Continued)
-
-
-
-
For lubrication, use an oil can which should be fitted with a thin plastic hose having an outside
diameter of not more than 4 mm.
Insert this hose into the upper oil port opening in the rotor (1999), connecting shaft (1050) or
adapter (5055, 5056). Then slide the hose end past the coupling rod (1998) all the way down to
the bottom section of the rotor head (1999) or connecting shaft (1050) or adapter (5055, 5056).
Slowly fill with lubricating oil up to the filling port.
Pull the hose out. Then insert the hose end through the small gap on the topside of SM-pin joint
seal (8235) and guide it down to the bottom of the hollow space between coupling rod (1998)
and SM-pin joint seal (8235).
Slowly fill with lubricating oil up to the gap.
(continued)
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.3
CIP-Pump P4 (continued)
E-2.3.6
Dismantling and Assembly of the Rotating Parts (continued)
I/I
E-2
98
MAY 20
E-2.3.6.2 Fitting the Rotor and Coupling Rod (Continued)
-
Pull the hose out.
Push the pin (5075) entirely into the bore of head of rotor (1999), connecting shaft (1050) or
adapter (5055, 5056) and retain in place.
Only now, press the SM-pin joint seal (8235) into the bore of head of rotor (1999), connecting
shaft (1050) or adapter (5055, 5056) and push up to the shoulder. In doing so the SM-pin joint
seal (8235) should be slightly bulbous around the outer surface.
-
Wipe off overflow oil. Use this oil for lubricating the O-rings (8060).
Slip the sleeve (5110) or (5115), with its chamfering (A) forward, on to the head of rotor (1999),
connecting shaft (1050) or adapter (5055, 5056) and push up to the shoulder.
-
Place the circlip (5065) into its groove on the rotor head (1999), connecting shaft (1050) or
adapter (5055, 5056) and carefully snap in place all around.
(continued)
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.3
CIP-Pump P4 (continued)
E-2.3.6
Dismantling and Assembly of the Rotating Parts (continued)
I/I
E-2
99
MAY 20
E-2.3.6.2 Fitting the Rotor and Coupling Rod (Continued)
-
Drive shaft (1005) or connecting shaft (1050) with adapter (5055, 5056), coupling rod (1998)
and rotor (1999) are now joined by means of the two pin joints.
Pump housing (2010), stator (3005) and end connection (2005) may now be fitted.
E-2.3.7 Removal and Fitting of the Connecting Shaft with Shaft Seal
E-2.3.7.1 Removal:
-
Push the circlip (1035) in the direction to the mechanical seal.
Remove pin (1030).
Remove the shaft seal housing (7005) and mechanical seal (7010) together with connecting shaft
(1050) and set ring (1035) from drive stool (0085) and the drive shaft.
The thread of cylindrical head screw (1040) can be used as forcing screw.
E-2.3.7.2 Fitting:
Apply grease into the bore of the connecting shaft (1050) to avoid rust (e.g. TCE-Metallic 600).
Assemble the shaft seal housing (7005) and mechanical seal (7010) together with connecting
shaft (1050) and set ring (1035) with drive stool (0085) and push connecting shaft (1050) on to
the drive shaft.
- At this please observe the installation direction of set ring (1035) (please see mark).
- Connect the connecting shaft (1050) and the drive shaft by pin (1030).
- Push set ring (1035) on pin (1030).
(continued)
-
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.3
CIP-Pump P4 (continued)
E-2.3.7
Removal and Fitting of the Single Mechanical Seal
-
-
-
I/I
E-2
100
MAY 20
Carefully slide out mechanical seal housing (7005) together with the parts of the mechanical seal
contained in it from connecting shaft (1050).
Carefully push mechanical seal (7010) stationary seat out of mechanical seal housing (7005).
Refitting is a simple reversal of the above procedure.
To reduce frictional forces during seal assembly, apply some glycerine to the shaft and the seal
housing in the area of the gaskets.
Special care must be taken when fitting double PTFE-coated gaskets: the joint of the outer
coating must point away from the seal assembly direction, otherwise the coating may open or be
pulled off!
Ensure that the distribution of pressure is uniform when inserting the pressure sensitive counter
rings. When inserting larger rings, use a suitable mandrel.
Do not allow any foreign bodies to get between the sliding surfaces.
Exactly keep to the seal installation dimensions and ensure that the sealing faces are correctly
pressed together (see table on sectional drawing W ... ).
Insert mechanical seal (7010) stationary seat into mechanical seal housing (7005).
Insert mechanical seal housing (7005) together with the stationary seat into the drive stool
without the installed connecting shaft (1050).
If necessary take the installation dimension from the table and add the thickness S of the set
ring (7086) when existing.
Mark this installation dimension on the connecting shaft (1050).
Fix the rotating unit of the mechanical seal (7010) on the connecting shaft (1050) depending on
the installation dimension so that the rotating unit of the mechanical seal (7010) or the set ring
(7086) is at the mark.
Insert connecting shaft (1050) with the rotating unit of the mechanical seal (7010) into drive
stool (0085) and install lip seal (7091, if existing.
Push the set ring (1035) on to connecting shaft (1050) and observe at this the installation
direction (see mark).
Push connecting shaft (1050) on to the drive shaft and connect with pin (1030). Push the set ring
(1035) on pin (1030).
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.4
Transfer Pump P5
E-2.4.1
Pumps in General
I/I
E-2
101
MAY 20
The pumps should be regularly rinsed or cleaned if deposits of medium are likely to build up
(sedimentation).
If the pump needs to be opened to do this, ensure that the pump and motor are switched off and
cannot be turned on accidently (eg. by removing the fuse).
Periodical standstill to allow for cleaning during operation depends on the medium and type of
operation.
The pump can be cleaned:
-
E-2.4.2
through the cleaning ports provided in the pump housing
manually by dismantling the pump
Lubrication
The pump does not require frequent lubrication.
Where no manufacturer’s instructions are available and when normal conditions of use exist:
-
Strip down the drive unit
Remove the bearings
Clean all parts
Renew the lubricant
every 5000 operating hours or at least every two years.
Pump model with “mechanical seals” (sectional drawing W251.000):
The lubricating should be done:
-
when putting into operation
after every 350 hours of operation
before and after operation interruptions of 6 - 8 weeks.
(continued)
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JZR-„BIOMASTER®“
Operating Manual
I/I
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.4
Transfer Pump P5 (continued)
E-2.4.3
Shaft Sealing through Single Mechanical Seal
E-2
102
MAY 20
There are various constructions of mechanical seals. Especially advantageous is the use of standard
mechanical seals according to DIN 24960. These seals have regardless of their brand the same
fitting dimensions which makes them interchangeable. Mechanical seals with a coil spring can only
be used for pumps which are run in one direction of rotation.
-
The seal specification of a pump is recorded on the order confirmation sheet.
Pumps fitted with direction dependent seals should never be run in the opposite direction of the
rotation arrow.
If excessive leakages occur the spring tension and the seal surfaces should be checked, and the
seal be replaced, if necessary.
Single mechanical seals usually work without any additional equipment. Their application range can
be increased by operating them with a rinsing or cooling system.
a) Quench, in accordance with ISO 5199, Appendix E, Plan Nos. 08, 09, 10 or 13 or API 610,
Appendix D, Plan No. 62.
Quench is the designation commonly used in sealing engineering for an arrangement that applies a
non-pressurized external fluid to the atmospheric side of a mechanical seal. The quench is used
when
–
a single mechanical seal will not work or only to a limited extent without auxiliary measures or
–
a double mechanical seal with pressurized buffer fluid is not necessary.
Recommended for the following applications:
–
Low temperature (danger of freezing)
–
Operation in a vacuum (dry running)
– Media which must be isolated from the atmosphere (e.g. due to build-up of solid deposits or
because of less severe damage to the environment, like smell).
Leakages will be transported away by the quenching liquid. In vacuum operation dry running of the
seals is avoided.
(continued)
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.4
Transfer Pump P5 (continued)
E-2.4.3
Shaft Sealing through Single Mechanical Seal (continued)
I/I
E-2
103
MAY 20
No pressure higher than that of the pumped medium in front of the mechanical seal is allowed to
build up in the quenching area (1) behind the mechanical seal. Otherwise the counter ring will be
pushed out of the housing. Free discharge from (2) is necessary!
Closing off the quenching area from the atmosphere:
1.
In the case that high emission levels can be tolerated: Through a throttle bush (4). Cooling
liquid not permanently used, only released from time to time.
In the case that medium emission levels can be tolerated: By a radial shaft seal ring (3).
Permanent radial shaft seal lubrication through quenching liquid is necessary.
2.
The supply of the Quench liquid can be done in two ways:
1.
From a line via a throttle and shut-off valve with free outlet from the Quench space of the
mechanical seal as shown in the illustraion.
from a reservoir, which is located max. one meter above the seal with a drain valve on the
quenching of the mechanical seal. The level in the reservoir has to be always visible from full
and almost empty. Follow-up intervals are set on the operating experience of the operator.
2.
b) Top lubrication
Attention: For vertically installed pumps with overhead drive as type BT:
On initial start-up the mechanical seal has not come in contact with the medium. It runs therefore
dry for a short period of time until the air is displaced from the pump housing.
-
On first start–up and if stood idle for longer periods lubricate the mechanical seal before
switching on the pump.
-
Apply water, glycerin or oil depending on their compatibility with the pumping medium and
the elastomer of the mechanical seal.
-
Fill the quench cup of the mechanical seal housing.
(continued)
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.4
Transfer Pump P5 (continued)
E-2.4.4
Trouble-Shooting and Remedying
I/I
E-2
104
MAY 20
E-2.4.4.1 Trouble Chart
The following chart lists possible problems as
-
the type
-
the likely reason / cause
-
the remedy
A problem may have various causes:
➔ several boxes in the vertical column are marked with a cross
A reason / cause may result in various problems:
➔ several boxes in the horizontal column are marked with a cross
E-2.4.4.2 How do you trace the kind of problem to find the possible cause?
-
the column describing a possible problem shows one or several boxes marked with a cross
on the corresponding lines you will find the possible reasons / cause and some hints how to
handle the problem
Thus the actual cause of the problem can be narrowed down and eventually detected.
-
if you find further cross-marked boxes on one of the lines and should there appear
corresponding problems as well, then the likely cause of the problem has been detected
The table helps in finding the root of the problem and will give you the remedy if it is straight
forward.
(continued)
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Operating Manual
JZR-„BIOMASTER®“
Part E: Maintenance
Maintenance of Pumps and Blowers
x
x
The shaft seal is leaking
The rotor life time is too short
The stator life time is too short
The drive is overloaded
The pump is stuck
The pump is running loudly
Trouble-Shooting and Remedying (continued)
Possible Problems
The pumped medium is
E-2.4.4
The pressure is too low
Transfer Pump P5 (continued)
The pumped medium is too little
E-2.4
The pump is no longer sucking
Maintenance of pumps and fans (continued)
The pump is no longer starting
E-2
x
Possible Causes
x x
x
In new pumps or
stators: the static
friction is too great.
The pump electrical equipment is not
compatible with the electrical supply..
x
x x x
The pressure is too high.
x
x x
x
x x x x
x
x x x
x
x x x
x
x x x x x
x x x
x x x x
The shaft seal is leaking.
x x
The rpm is too low.
x x x
With reduced diameter rotors: operating
temperature has not been reached.
x x x x
x x x
The stator has swollen, the elastomer
is not compatible with the medium.
The solids content of the medium is too
high and leads to blockages.
The liquid medium sediments or hardens
when left to stand.
There is air in the suction pipe.
The suction pipe is leaking.
x x x x
x x
There are foreign bodies in the pump.
The temperature of the liquid medium is
too high, the stator is too ductile.
x x
x x x x
x
The suction is too great or pressure too
low (cavitation).
The pump is running dry.
The stator is worn out.
I/I
E-2
105
MAY 20
Behebung der Remedy
Fill the pump up, then pump through
manually using a suitable appliance; if
necessary use glycerin as lubricant in the
stator.
Check order information. Examine
electrical installation (possibly 2 phase
operation).
Measure the pressure with a
manometer and check against order
details. Reduce the pressure or
change the drive.
Remove foreign bodies and eliminate
possible damage.
If the liquid medium temperature cannot
be lowered, use a reduced diameter rotor.
Check whether the liquid medium
agrees with the order requirements.
Possibly change stator material.
Increase the liquid part of the medium.
Clean the pump and rinse through after
each run.
Increase the suction liquid level, prevent
turbulence and air bubbles at the inlet.
Check seals and tighten pipe connections.
Stuffing box: tighten or renew.
Mechanical seal: renew seals, eliminate
solid deposits.
In the case of adjustable drives:
increase the rpm. If necessary change
the drive.
Warm up the pump (stator) to
operating temperature first of all.
Decrease suction resistance, lower
the temperature of the liquid medium,
install the pump at a lower location.
Fill up the pump, provide for dry
running protection, move the
pipes.
Replace with a new stator.
(continued)
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Part E: Maintenance
Maintenance of Pumps and Blowers
The shaft seal is leaking
The rotor life time is too short
The stator life time is too short
The drive is overloaded
The pump is stuck
The pump is running loudly
Trouble-Shooting and Remedying (continued)
Possible Problems
The pumped medium is
E-2.4.4
The pressure is too low
Transfer Pump P5 (continued)
The pumped medium is too little
E-2.4
The pump is no longer sucking
Maintenance of pumps and fans (continued)
The pump is no longer starting
E-2
Possible Causes
x x x
x
x x
The stator material is brittle.
x x x
x
x
The rotor is worn out.
x
The joints are worn out.
The pump and drive are not axially aligned.
x
x
x
x
x The roller bearings are destroyed.
The elastic element of the coupling is worn out.
x
The rpm is too high.
x
The viscosity is too high.
x
The specific weight of the medium is too
high.
x
x The stuffing box is incorrectly tightened.
x The packing is not suited to the liquid medium.
x Mechanical seal: rotation is incorrect.
seal: mechanical seal and mating
x Mechanical
ring have failed.
x
x Mechanical seal: elastomers damaged,
swollen or brittle.
E-2.4.5
I/I
Operating Manual
JZR-„BIOMASTER®“
E-2
106
MAY 20
Behebung der Remedy
Fit a new stator. Check the liquid medium
agrees with order details; if necessary
change the stator material.
Change rotor, establish the cause. Wear and
tear, corrosion, cavitation; if necessary
change to a different material or coating.
Replace relevant parts, carefully reseal
and lubricate.
Re-align the unit.
Use a new connection and re-align the pump.
Replace roller bearings, lubricate, reseal. At
higher temperatures observe the lubricant and
the bearings.
In the case of adjustable drives : lower the rpm.
If necessary change the drive.
Measure the viscosity and compare with order
details. If necessary adjust viscosity or change
the drive.
Measure specific weight and compare with
order details. If necessary adjust specific
weight or change the drive.
Service stuffing box according to page 7.4, if
necessary renew worn shaft.
Replace fitted packing with another packing
type.
Change electrical connection.
Replace relevant rings with new ones.
Replace elastomers. Check whether the liquid
medium agrees with order details, if
necessary change material.
Dismantling and Assembly of the Pump Housing
Removal and Fitting of End Connection, Stator and Pump Housing
The pump with attached pipework should be empty and must have cooled off. Disconnect the
pipework on the suction side and pressure side of the pump.
(continued)
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.4
Transfer Pump P5 (continued)
E-2.4.5
Dismantling and Assembly of the Pump Housing (continued)
I/I
E-2
107
MAY 20
E-2.4.5.1 Dismantling
-
Remove securing screws (S) from support feet (2035) to baseplate (G).
-
Unscrew hex nuts (3020) and remove with spring washers (3015).
Withdraw end connection (2005) and first support foot (2035/1) with washers (3070).
-
Support pump housing (2010) and stator (3005) with wooden blocks.
Loosen hex nuts (3020), where fitted, and remove thru bolts (3010).
Where fitted, remove second support foot (2035/2) and washers (3070).
(continued)
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.4
Transfer Pump P5 (continued)
E-2.4.5
Dismantling and Assembly of the Pump Housing (continued)
I/I
E-2
108
MAY 20
E-2.4.5.1 Dismantling (continued)
Caution for pumps with tubular rotors:
Where the walls of tubular rotors are worn in the wear zones, pumping medium may occur inside the
rotor and may come out when pulling off the stator. Ensure that protective measures have been
taken when pumping dangerous media!
-
Pull the stator (3005) out forward.
-
Remove the hex nuts (2030) with spring washers (2025).
Pull the pump housing (2010) off forward.
Pressure reduced execution:
-
Remove screws (2164) and spring washers (2167).
Pull the pump housing (2010) completely forward, off the mechanical seal housing of the shaft
sealing (W).
(continued)
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.4
Transfer Pump P5 (continued)
E-2.4.5
Dismantling and Assembly of the Pump Housing (continued)
I/I
E-2
109
MAY 20
E-2.4.5.1 Dismantling (continued)
E-2.4.5.2 Assembly
Refit in reverse order.
When refitting the stator (3005) check direction of stator (3005) is correct! The funnel-shaped inflow
side (E) of the stator (3005) must show to
-
the pump housing (2010) when rotation is anti- clockwise
the end connection (2005) when rotation is clockwise
when viewed on pump shaft end.
(continued)
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.4
Transfer Pump P5 (continued)
E-2.4.5
Dismantling and Assembly of the Pump Housing (continued)
I/I
E-2
110
MAY 20
E-2.4.5.2 Assembly (continued)
-
Elastomer stators (A) have integrated front side sealing profiles (D). They don't need additional
gaskets for sealing off the end connection (2005) and the pump housing (2010).
Solid stators (B) have no integrated front side sealing profiles. Therefore additional gaskets
(8005) should be installed to seal off the end connection (2005) as well as the pump housing
(2010).
Be careful when engaging the stator (3005) and rotor (1999). Do not trap your fingers. Do not reach
inside the stator.
-
Push stator (3005) with a rotating movement on to rotor (1999).
Apply an assembly device and some glycerine to ease engaging stator (3005) and rotor (1999).
When tightening the hex nuts (2030), a gap remains between the lantern (0085) and the pump
housing (2010) or the mechanical seal housing of the shaft sealing (W).
Do not try to close this gap by over-tightening the hex nuts (2030)!
Lantern (0085) can break!
(continued)
OM_2020051900_DVZ-JZR-BIOMASTER-JZRY01001_EN - Subject to technical modification without notice DVZ-SERVICES GmbH | Boschstraße 9 | D-28857 Syke | Germany | FON +49 (0) 4242 16 93 8 0 | FAX +49 (0) 4242 16 93 8 99 | WEB www.dvz-services.de | MAIL info@dvz-services.de
JZR-„BIOMASTER®“
I/I
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.4
Transfer Pump P5 (continued)
E-2.4.5
Dismantling and Assembly of the Pump Housing (continued)
E-2
111
MAY 20
E-2.4.5.2 Assembly (continued)
Torque values for hex nuts (2030):
Size
M6
M8
M10
M12
M16
M20
M24
M30
Required torque [Nm]
8
15
30
45
75
20
100
120
Fastening the end connection (2005):
-
Screw hex nuts (3020/C) down into thru bolts (3010) as far as possible.
Slip on the first washers (3070), the support foot (2035/1), the second washers (3070), the end
stud (2005) and tighten with spring washers (3015) and hex nuts (3020/A).
Fasten support foot (2035/1) from behind with hex nuts (3020/C).
Ensure during refitting that the O-ring (8015) or, where a heating jacket (3025) is installed, the Orings (8030) are in perfect condition and will sit correctly.
Ensure that the drain plug (2015) is not screwed too tightly into the pump housing (2010), since
otherwise its conical thread may break the pump housing (2010).
The torque should be about 40 - 50 Nm.
(continued)
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.4
Transfer Pump P5 (continued)
E-2.4.5
Dismantling and Assembly of the Pump Housing (continued)
I/I
E-2
112
MAY 20
E-2.4.5.2 Assembly (continued)
E-2.4.6 Dismantling and Assembly of the Rotating Parts
E-2.4.6.1 Removal of Rotor and Coupling Rod
For removal of the rotor (1999) and coupling rod (1998) the pin joints should be dismantled as
follows:
-
Place the dismantled unit - consisting of bearing housing (0005) with drive shaft (1005) or drive
stool (0085) with drive (A) and connecting shaft (1050), coupling rod (1998) and rotor (1999) - on
the workbench with a wooden block supporting the
-
Push circlip (5065) out of its groove and slip off over the head of rotor (1999), connecting shaft
(1050) or adapter (5055, 5056).
(continued)
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.4
Transfer Pump P5 (continued)
E-2.4.6
Dismantling and Assembly of the Rotating Parts (continued)
I/I
E-2
113
MAY 20
E-2.4.6.1 Removal of Rotor and Coupling Rod (continued)
Pumps fitted with a metallic rotor (1999):
-
If necessary hit the edge of sleeve (5110, 5115) at an angle with the help of a wooden block and
a plastic hammer. Taking care not to damage the O-rings (8060)!
-
Press the pin (5075) out of the head of rotor (1999), connecting shaft (1050) or adapter (5055,
5056). If necessary use a hammer and a thin cylindrical pin (DIN 6450 C).
Drain the oil into a receptacle.
-
(continued)
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.4
Transfer Pump P5 (continued)
E-2.4.6
Dismantling and Assembly of the Rotating Parts (continued)
I/I
E-2
114
MAY 20
E-2.4.6.1 Removal of Rotor and Coupling Rod (continued)
-
Using a screwdriver, carefully lever the SM-pin joint seal (8235) out of the head of rotor (1999),
connecting shaft (1050) or adapter (5055, 5056).
Taking care not to damage the SM-pin joint seal (8235).
-
Pull apart the rotor (1999)/ coupling rod (1998)/ drive shaft (1005) or connecting shaft (1050)
with adapter (5055, 5056) assembly.
Remove the O-rings (8060).
-
-
Push the SM-pin joint seal (8235) towards the head of coupling rod (1998). In the narrow
coupling rod section press the clamp ring (5425) out of the groove of the seal.
Slip the SM-pin joint seal (8235) and clamp ring (5425) off over the head of the coupling rod
(1998).
Where an adapter (5055, 5056) is fitted: See Page 10.3, Section 10.3: Removal and Fitting of
Adapters.
(continued)
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JZR-„BIOMASTER®“
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Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.4
Transfer Pump P5 (continued)
E-2.4.6
Dismantling and Assembly of the Rotating Parts (continued)
I/I
E-2
115
MAY 20
E-2.4.6.1 Removal of Rotor and Coupling Rod (continued)
E-2.4.6.2 Fitting the Rotor and Coupling Rod
For fitting the rotor (1999) with coupling rod (1998), the two pin joints should be assembled as
follows:
-
Slip the clamp ring (5425) over the head of coupling rod (1998).
-
Push the SM-pin joint seal (8235) over the head of coupling rod (1998) towards its narrow
section, there squeezing the clamp ring (5425) into the groove of the SM-pin joint seal (8235).
(continued)
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.4
Transfer Pump P5 (continued)
E-2.4.6
Dismantling and Assembly of the Rotating Parts (continued)
I/I
E-2
116
MAY 20
E-2.4.6.2 Fitting the Rotor and Coupling Rod (Continued)
-
Push the SM-pin joint seal (8235) with the correctly placed clamp ring (5425) up to the shoulder
of coupling rod (1998).
-
Slip the circlip (5065) on to the coupling rod (1998).
Slide the sleeve (5110) or (5115) on to coupling rod (1998) so the inside diameter of chamfering
(A) is being placed towards the coupling rod (1998) extension.
Chamfering (A) will later on ease the installation over the O-rings (8060).
Orient the head of coupling rod (1998) until it is in vertical position for the bore (B) for the pin
(5075).
-
-
-
Slide the coupling rod (1998) with SM-pin joint seal (8235) into the bore of rotor (1999),
connecting shaft (1050) or adapter (5055, 5056) and insert the pin (5075) from below and push
up to the upper edge of coupling rod (1998).
Support the pin (5075) against dropping out.
Slide the SM-pin joint seal (8235) into the rotor (1999), connecting shaft (1050)/ or adapter
(5055, 5056) only from below, and in a slightly slanted
(continued)
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.4
Transfer Pump P5 (continued)
E-2.4.6
Dismantling and Assembly of the Rotating Parts (continued)
I/I
E-2
117
MAY 20
E-2.4.6.2 Fitting the Rotor and Coupling Rod (Continued)
-
-
-
-
For lubrication, use an oil can which should be fitted with a thin plastic hose having an outside
diameter of not more than 4 mm.
Insert this hose into the upper oil port opening in the rotor (1999), connecting shaft (1050) or
adapter (5055, 5056). Then slide the hose end past the coupling rod (1998) all the way down to
the bottom section of the rotor head (1999) or connecting shaft (1050) or adapter (5055, 5056).
Slowly fill with lubricating oil up to the filling port.
Pull the hose out. Then insert the hose end through the small gap on the topside of SM-pin joint
seal (8235) and guide it down to the bottom of the hollow space between coupling rod (1998)
and SM-pin joint seal (8235).
Slowly fill with lubricating oil up to the gap.
(continued)
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.4
Transfer Pump P5 (continued)
E-2.4.6
Dismantling and Assembly of the Rotating Parts (continued)
I/I
E-2
118
MAY 20
E-2.4.6.2 Fitting the Rotor and Coupling Rod (Continued)
-
Pull the hose out.
Push the pin (5075) entirely into the bore of head of rotor (1999), connecting shaft (1050) or
adapter (5055, 5056) and retain in place.
Only now, press the SM-pin joint seal (8235) into the bore of head of rotor (1999), connecting
shaft (1050) or adapter (5055, 5056) and push up to the shoulder. In doing so the SM-pin joint
seal (8235) should be slightly bulbous around the outer surface.
-
Wipe off overflow oil. Use this oil for lubricating the O-rings (8060).
Slip the sleeve (5110) or (5115), with its chamfering (A) forward, on to the head of rotor (1999),
connecting shaft (1050) or adapter (5055, 5056) and push up to the shoulder.
-
Place the circlip (5065) into its groove on the rotor head (1999), connecting shaft (1050) or
adapter (5055, 5056) and carefully snap in place all around.
(continued)
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.4
Transfer Pump P5 (continued)
E-2.4.6
Dismantling and Assembly of the Rotating Parts (continued)
I/I
E-2
119
MAY 20
E-2.4.6.2 Fitting the Rotor and Coupling Rod (Continued)
-
Drive shaft (1005) or connecting shaft (1050) with adapter (5055, 5056), coupling rod (1998)
and rotor (1999) are now joined by means of the two pin joints.
Pump housing (2010), stator (3005) and end connection (2005) may now be fitted.
E-2.4.7 Removal and Fitting of the Connecting Shaft with Shaft Seal
E-2.4.7.1 Removal:
-
Push the circlip (1035) in the direction to the mechanical seal.
Remove pin (1030).
Remove the shaft seal housing (7005) and mechanical seal (7010) together with connecting shaft
(1050) and set ring (1035) from drive stool (0085) and the drive shaft.
The thread of cylindrical head screw (1040) can be used as forcing screw.
E-2.4.7.2 Fitting:
Apply grease into the bore of the connecting shaft (1050) to avoid rust (e.g. TCE-Metallic 600).
Assemble the shaft seal housing (7005) and mechanical seal (7010) together with connecting
shaft (1050) and set ring (1035) with drive stool (0085) and push connecting shaft (1050) on to
the drive shaft.
- At this please observe the installation direction of set ring (1035) (please see mark).
- Connect the connecting shaft (1050) and the drive shaft by pin (1030).
- Push set ring (1035) on pin (1030).
(continued)
-
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.4
Transfer Pump P5 (continued)
E-2.4.7
Removal and Fitting of the Single Mechanical Seal
-
-
-
I/I
E-2
120
MAY 20
Carefully slide out mechanical seal housing (7005) together with the parts of the mechanical seal
contained in it from connecting shaft (1050).
Carefully push mechanical seal (7010) stationary seat out of mechanical seal housing (7005).
Refitting is a simple reversal of the above procedure.
To reduce frictional forces during seal assembly, apply some glycerine to the shaft and the seal
housing in the area of the gaskets.
Special care must be taken when fitting double PTFE-coated gaskets: the joint of the outer
coating must point away from the seal assembly direction, otherwise the coating may open or be
pulled off!
Ensure that the distribution of pressure is uniform when inserting the pressure sensitive counter
rings. When inserting larger rings, use a suitable mandrel.
Do not allow any foreign bodies to get between the sliding surfaces.
Exactly keep to the seal installation dimensions and ensure that the sealing faces are correctly
pressed together (see table on sectional drawing W ... ).
Insert mechanical seal (7010) stationary seat into mechanical seal housing (7005).
Insert mechanical seal housing (7005) together with the stationary seat into the drive stool
without the installed connecting shaft (1050).
If necessary take the installation dimension from the table and add the thickness S of the set
ring (7086) when existing.
Mark this installation dimension on the connecting shaft (1050).
Fix the rotating unit of the mechanical seal (7010) on the connceting shaft (1050) depending on
the installation dimension so that the rotating unit of the mechanical seal (7010) or the set ring
(7086) is at the mark.
Insert connecting shaft (1050) with the rotating unit of the mechanical seal (7010) into drive
stool (0085) and install lip seal (7091, if existing.
Push the set ring (1035) on to connecting shaft (1050) and observe at this the installation
direction (see mark).
Push connecting shaft (1050) on to the drive shaft and connect with pin (1030). Push the set ring
(1035) on pin (1030).
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.5
Discharge Pump P3/6
I/I
E-2
121
MAY 20
E-2.5.1 Maintenance
a) During operation, the pump must be checked for normal operation and abnormal noises in
following intervals as a minimum: 10 min. / 1 hour / 10 hours / 1 day / 1 week / 1 month. After
that, the inspection may be performed in monthly intervals if the operating conditions do not
change.
When the pump is at a standstill, never fill the casing with water during the cold season of the year!
The water may freeze and destroy the casing!
b) Once every three months lubricate the mechanical seal if necessary.
c) Once every six months open the inspection cover or the casing and look inside. Remove possible
foreign bodies. Clean pump and motor. Check more frequently if necessary.
d) General overhaul once every 5-10 years
E-2.5.2
Lubrication of the mechanical seal
Models with lubricating nipples do not require maintenance for the first 200 operating hours.
After that, one stroke of grease must be applied once every three months. Use a commercially
available grease with viscosity degree of 1 to 3.
Do not apply an excessive amount of grease, otherwise the adjacent ball bearing can be damaged!
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.6
Blower G1
I/I
E-2
122
MAY 20
E-2.6.1 Servicing indications
Wear parts are included in the recommended maintenance intervals are a part of the applicable
warranty. The lifetime of wear parts (ball bearings and filters) depends on operating hours, load and
other influences as e. g. temperature etc.
Maintenance and servicing may only be performed by persons with the necessary expertise and
regular training. In addition to the appliance’s operating instructions and the regulations and
recommendations for the system as a whole, the following points should be observed:
Inspection and maintenance intervals:
The operator must set the cleaning, inspection and maintenance intervals himself according to
operating hours, load and operating conditions.
Immediate inspection and maintenance
The blower must be inspected immediately if vibrations or reduced air fl ow are observed.
E-2.6.1.1 Ball bearings
The side channel is equipped with enclosed deep groove ball bearings, which do not have be to regreased and have a minimum service life of approx. 22,000 hours. We recommend exchanging the
ball bearings before the end of their service life (at least 22,000 hours).
A service period of 30 months must not be exceeded if the blower runs continuously for 24 hours a
day.
E-2.6.1.2 Seals and radial shaft sealing rings
Sealing elements and shaft sealing rings must, for safety reasons, always be replaced after
maintenance work involving opening, removing or otherwise modifying sealing elements.
E-2.6.1.3 Micro-filters
The degree of clogging of the filter elements should be checked at regular intervals, depending on
the ambient conditions / conditions of use. This means that the user is responsible for ensuring that
the filters are permeable. The micro-filter must be positioned horizontally to prevent contamination
entering the side channel blower during maintenance work. With vertical micro-filter installation, the
complete filter must be removed from the unit before starting cleaning/maintenance.
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JZR-„BIOMASTER®“
Operating Manual
Part E: Maintenance
Maintenance of Pumps and Blowers
E-2
Maintenance of pumps and fans (continued)
E-2.6
Blower G1 (continued)
I/I
E-2
123
MAY 20
E-2.6.1.4 Cleaning
Cleaning or maintenance must not damage or alter the appliance and its component parts to the
detriment of health and safety protection, and must not, for instance, affect the balancing of the
impeller. Cleaning or maintenance works must not lead to any damages or changes at the device
and its components which might impair safety or health protection, and may not e. g. impair the
balance condition of the impeller.
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