Instruction Manual - Industry Surplus Australia
Contents
1. 14 5 1 Unpacking After unpacking the goods check the following Model Capaciy Max pressure points to ascertain that the product is exactly as you ordered x If you find anything wrong please get in touch with Metering Pump your dealer Stroke Rage spm Hub frequenz Thermally Uberhitzungsschutz MFG No Ser Nr jum 1 Do the model voltage etc shown on the name IWAKI CO LTD plate represent what you ordered 2 Has the goods been damaged in transit Are Manufacturing number Voltage Curent the bolts and nuts loose 2 Operation Principle The EH Series electronic metering pump consists of a pump unit a drive unit and a control unit Drive unit The drive unit is an electromagnetic solenoid Stroke length When the solenoid coil is energized by the control adjusting dial unit the armature shaft moves forward due to the magnetic force of the solenoid The shaft is NA attached to a PTFE faced diaphragm which is part Control unit L Pump the pump unit The diaphragm is forced into the head pump head cavity decreasing volume and increas ing pressure which forces liquid in the pump head out though discharge check valves When solenoid coil is de energized a spring returns the armature to its starting position This action pulls the diaphragm out of the head cavity increasing volume and de2. handled The value in the above table is obtained from a continuous run of the pump using clean water at ambient temperature Take the value as a guideline for replacement The valve set illustrated above represents VC V6 PC and types of E30 amp E35 For composition of valve set of all other types refer to next item Names of parts and Structures on pages 47 and 48 6 Names of Part and Structure 1 Pump Head Unit Material symbol VC V6 PC P6 VM FO EH E30 35 EH E45 EH E55 EM 28 28 z Sie 4 3 REL 14 S 14 h st 13 14 11 9 Parts name for types VC V6 PC VM FC Parts name for types VC V6 PC VM FC Pump head O ring Gasket for type FC Fitting Diaphragm spacer Note 4 Fitting nut Hex sock cap bolt Note 2 Diaphragm Plain washer Note 2 Retainer Spring washer Note 2 Back up retainer Note 1 Hose stopper Valve guide Note 2 4 Fitting spacer Valve seat Note 2 1 O ring Gasket for type FC Valve Note 2 1 Spacer Valve gasket Note 3 Note 1 For type E55 only 2 is for E45 E55 3 Valve gasket maked 14 15 FC type 4 Two or more spacers may be put depending on
3. A IWAKI PUMPS Electromagnetic Metering Pump _ Type _ Instruction Manual Read this manual before use of product E Thank you for choosing an Iwaki s EH E Series metering pump This instruction manual deals with the correct installation operation maintenance and trou bleshooting procedures for the EH E model metering pump Please read through it carefully to ensure the optimum performance safety and service of your pump Contents IMPORTANT INSTRUCTION 1 Safety Section bined eI d DOE 2 1 INTRODUCTION eee ee eee eee eee eee eee eee eee ee rer ee ree ee ree ee eee rere eee eee eee eee ee ee eee 5 1 Unpacking a S hama sassa hpa E 6 2 Operation Principle aa masa Sag payaa sta 6 9 Specifications ew G N Sa Dare 7 4 Operation Function d 10 5 Controller Display sues emat A sam EN 12 6 Dimensions _ _____ ___ ____ __________ pistas 14 2 INSTALLATION eee eee eee eee eee eee eee eee ee eee eer ee eee ee eee ee eer ee eer ee eee eee ee eee ee ee reer 18 1 Notes on Installation eee A aaa a aa yas 19 2 Location RATE EEN AT I
4. For the wiring connect the wires to the terminals 5 and 8 and fix them by screws Tightening torque is 0 4 N m or less 6 is plus and 8 is minus Inside resistance 250 Ohm NOOO ON ICLOSE External contact OPEN e Wiring for stop function Stop function means the method to provisionally stop the pump operation by external potential free contact signal or open collector signal For the wiring connect the wires to and 8 of the connector When used with open collector Pay attention to the polarity is plus and is minus Max chargeable voltage is 5 V cur rent 1 1 mA When used with mechanical contact such as relay or so Use the electronic purpose one of which the minimum applicable load of 1 mA or below e Wiring for pulse input function Pulse input function means the pulse multiply or dividing operation by external potential free con tact signal or open collector input For the wiring connect the wires to 7 and with screw driver Tightening torque is approx 0 4 Nem When used with open collector Pay attention to the polarity is plus and is minus Max chargeable voltage is 5 V cur rent 1 1 mA When mechanical contact such as relay or so 15 used use the one designed for electronic pur pose of which the minimum applicable load of 1 mA or below 3 OPERATION
5. Starting and stopping pump operation 1 Switch on the power and ON lamp green Lights and goes to WAIT mode after the word V3 0E was displayed When the pump is switched on for the first time The word WAIT is lit during WAIT mode WAIT EXT STOP OVER SET ON lamp START STOP key 2 Push START STOP key one time The word WAIT disappears and pump starts operation Every time START STOP key is pushed opera tion and stopping is repeated EXT STOP OVER SET Bleeding for types VC V6 PC and FC 1 Return the discharge side hose to the tank and start the pump Remove the check valve if it is Fitting nut Remove mounted check valve 2 Run the pump for 10 minutes for bleeding 3 When the air is removed and pump head is com pletely filled with liquid return the discharge tube to the normal piping Return to tank 4 Check if no liquid leaks from any part y Adjusting screw Bleeding for SH stainless steel head type Before the bleeding is done tighten the nut and discharge fitting Tightening torque E30 3558 5 N m E45 555 7 Nem 1 Connect hose to bleeding hose connection part return the hose to the suction tank Bleeding hose should be open without any load Pay attention that the air and liquid come out Nut Discharge fitting together when bleeding is done 2 Tu
6. ference between the two levels is 5 meters or less Fig C 4 In case the pressure loaded to the pump due to pipe resistance discharge head etc is less than 0 13 MPa 5 Other precautions for tubing Use the specified size of tube Otherwise required pump performance and flow rate may not be obtained 2 Suction side tube should be as shorter as pos sible Max length is 1 meter 3 Self priming ability of this pump is 1 meter or less when the valves are dry Install the pump of which the pump head to be meter or less than the liquid level 4 In case are handled gaseous liquids such as sodium hypochlorite or hydrogen peroxide etc flooded suction is recommended for suc tion side Flooded suction is effective to avoid gas generation or air pocket in the piping 6 Precautions when mounting check valve 1 Install the check valve at the end of discharge tubing It should be separated the pump by 1 meter or more CA type check valve 2 CA type check valve can be connected to either tube or threaded pipe of R1 2 and R3 8 3 Stainless steel check valve CS type has the T connection of RC1 4 or NPT1 4 for pump _ models EH E30 and 35SH and RC3 8 NPT3 8 for pump models EH E45 and 55SH r For the connect
7. TEL TEL TEL TEL TEL TEE TEL TEL 49 2154 9254 0 39 02 990 3931 45 48 24 2345 46 8 511 72900 358 9 2742714 47 66 81 16 60 43 2236 33469 31 297 241121 34 943 630030 321430 7007 FAX FAX FAX FAX FAX FAX 33 1 69 63 33 70 FAX 44 1743 231363 FAX 1 41 32 3235024 11430 7008 2154 1028 02 990 42888 48 24 2346 8511 72922 92742715 66 81 16 61 164 49 92 73 1743 366507 32 3226084 2236 33469 297 273902 943 628799 1308 3 02 06
8. 1 Precaution for Operation econ 29 71 7 Bleeding AN 29 1 2 Adjustment of Discharge Capacity 31 2 Operation s SPSS ss 33 2 1 Overview Operating Scheme 33 2 2 Setting and Operation of Controller 35 1 Preparation for Operation Do not operate the pump with discharge side valve completely closed Operating the pump with discharge side valve fully closed may lead to liquid leakage or pipe rupture Do not run pump dry Dry operation of the pump over a long time longer than 30 minutes causes the pump to overheat and the pump unit pump head valve guide etc to become deformed or the pump head attachment to become loose which may result in liquid leakage trouble Keep the pump head firmly assembled If mounting bolts on the pump head are loosened liquid leakage may result Fasten the 4 or 6 hex socket bolts tightly before starting the initial pump operation The bolts may be loosened during storage or transportation of the pump depending upon the condition Fastening torque 2 6 N m Tighten all the bolts fully by applying an equal amount of torque in a diagonal order among the bolts 1 1 Bleeding Bleeding 15 process to eliminate the air which residues in the suction tube or pump head Make sure to carry the bleeding prior to the initial operation of the pump or when the liquid in the tank was replaced or the pump rested for long time
9. and comes to WAIT mode In case the pump is powered on for the first time If it does not come to WAIT mode push once START STOP key to come to WAIT mode 2 Stroke rate can be changed by pushing A or Y key at wait 1 mode or during operation Push key to increase stroke WAIT EXT STOP OVER SET time the spm figures changes slowly by one spm and if you I rate and W key to decrease If you push the key in a short continue to push over three seconds they change quickly The pump is shipped set at 360 spm When the spm value is changed the value is not put in mem ory unless you push START STOP key or EXT key or until three or more seconds have passed 3 Push START STOP key to start the pump WAIT word disappears and ON lamp blinks Blink 4 Stop the pump i 1 When START STOP key is pushed once the pump stops and 550 WAIT word appears to to WAIT mode WAIT EXT STOP OVER SET Automatic operation 1 Analog signal operation 1 Power ON s 1 When the power is on a green lamp lights up and the l L 2 wording V3 0E appears then stroke for manual 1 operation is displayed and comes to WAIT mode In case EXT STOP OVER SET the pump is powered on for the first time If it does not come to WAIT mode push once START STOP key to come to WAIT mode 2 Change over at EXT operation mode Push EX
10. and situations related with the use of the pump system e The symbols relate to the following meanings described below Nonobservance or misapplication of the contents of A Warning the Warning section could lead to a serious acci dent including death or injury Nonobservance or misapplication of the contents of A Caution the Caution section could lead to serious physical injury to the user or serious damage to the product Types of Symbols Indicates that Warning or Caution must be exercised Inside this triangle a concrete and practical image provided as a warning or caution message is depicted Indicates a prohibited action or procedure Inside or near this cir cle a concrete and practical image of the activity to be avoided is depicted Indicates an important action or procedure which must be per formed or carried out without fail Failure to follow the instructions herein can lead to malfunction or damage to the pump 0 gt Safety Section Turn off the power supply Working without disconnecting the power supply cause an electrical shock Before engaging upon working procedures involving the pump make sure to turn the 2 Electrical Shock power supply switch off and to stop the pump and other related devices Terminate operation When you detect or become aware of a dangerous sign or abnormal condition dur ing operation terminate the operation immediately and start from th
11. be Remove check valve sucked in 4 3 Tubing for bleeding When you do bleeding return the discharge side Return to tank tube to the suction side tank Remove the check valve if it is mounted Refer to 1 1 Bleeding on page 29 Check valve H gt Caution The EH E pump is not equipped with built in Three way joint air vent valve Mount the air vent valve refer Air vent ring to the illustration on left valve Discharge hose Built in type air vent valve is available as an option for types VC V6 and PC Pump J i D t LI EE Suction side Discharge side Fig Q EHE Fig B 4 Mounting check valve In case the pump is installed as mentioned below make sure to install the check valve to avoid over feeding 1 In case the suction side liquid level is higher than that of discharge side Fig A 2 In case the suction side pressure is higher than the discharge side one Fig B 3 In case the discharge side liquid level is high er than the suction side one but the height dif
12. electrical shock may result Make sure the grounding wire is connected with grounding terminal Install an earth leakage breaker The operation of a pump without using an earth leakage breaker may cause an electrical shock Please install a leakage breaker in the system Electrical Shock Handling of power cable Use of a defective or damaged power cable may result in a fire or electrical shock Handle the power cable carefully Electrical Shock Grounding Follow the instruction manual Replace the consumable part by following the descriptions in the instruction manual Do not disassemble any part of the pump if the disassembling procedure for the part in question is not included in the instruction manual Limited operating site and storage Places where a flammable gas or material is used or stored Places where the ambient temperature is extremely high 40 C or higher or Prohibited extremely low 0 C or lower Do not install or store the pump in the following places S Disposal of used pump Disposal of used or damaged pumps must be done in accordance with the relevant local law and regulations Consult a licensed industrial waste products disposing company 1 INTRODUCTION L Unpacking 6 2 Operation Principle 6 3 Specifications 7 4 Operation Function MA 10 5 Controller Display 12 6 Dimensions
13. from outside Indication Display 4digit l4segment LCD Stroke Green LED Input Stop signal No voltage contact pulse signal Pulse No voltage contact pulse signal Output Power source for sensor 12VDC 10 mA or less Power AC 100 90 127 V AC 110 AC 115 AC 90 127 V source AC 200 AC 180 242 V AC 230 AC 198 264 V 4 Operation Function e Manual operation Stroke rate can set from 0 to 360 spm with keys and Y and pump start and stop can be done with keys START STOP Both setting can be done while the pump stops or operates Operation chart ON ON ON START STOP key Analog input operation 0 20 mA 0 360 spm operation in proportion to 0 20 mA current input Pump is fixed at 360 spm when came input signal exceeding 360 spm Straight line is automatically made by setting two points So the pump may not come to 0 spm even if 0 mA current comes Condition 1 Ai 20 mA 360 spm 2 lt 360 spm 3 Ai 4 Pi P gt point 2 point 1 0 Ai A2 20 mA SET point 1 SET point 2 Current Current e Digital input pulse multiply operation Pump makes strokes from 1 to 999 responding to external pulse signal Stroke rate is the spm set for man ual operation The pulses which came while operation are put in memory up to 255 pulses It is possible to make the pulses not to be
14. push START STOP key at WAIT mode To stop the pump push START STOP key again 3 EXT operation starts by pushing EXT key at WAIT mode and stops by pushing START STOP key 4 For the switching over between analog and digital operation push EXT and A keys simultaneously Parameter is changed by A and Y keys and the set value is fixed by START STOP key 5 To move to pulse memory switching mode push EXT key while DIG is selected at analog digital switching mode If ANA is selected you can not come to this mode Figures are changed by A and Y keys and switching between multiply and dividing is done by EXT key Push START STOP key to return to WAIT mode Initial parameter value When the pump is shipped from our factory each parameter value is set as shown on table below Mode Parameter Initial value Setting range Manual spm 360 1 360 A D switching Digital Analog dIG DIG ANA Pulse memory Dividing OF ON OF switching Multiply x ON ON OF Dividing 1 1 999 Multiply x1 1 999 Set point 1 Amp 4 0 0 0 20 0 Set point 1 spm 0 0 360 Set point 2 20 0 0 0 20 0 Set point 2 spm 360 0 360 EXT operation Analog 2 2 Setting and Operation of Controller Manual operation 1 Power ON r When the power is on green lamp lights up and the word 2 C 4 ing V3 0E appears then the stroke rate for manual opera WAIT EXT STOP OVER SET tion is displayed
15. put in memory Digital input multiplying example X 5 Ext pulse Pump stroke 3 45 12345 e Digital input pulse dividing operation Pulse dividing operation by external pulse signals for 999 1 to 1 1 Stroke rate is the one set for manual operation When the signals exceeding the set stroke rate came excessive signals can be put in memory up to 255 pulses Digital input Dividing example 5 Ext pulse Pump stroke 2 L JL 5 Controller Display e Controller display and panel START STOP key Manually starts or stops the pump This key is used in Alpha numeric display Indicates stroke frequency or external mode or external settings setting external modes EXT indicator Visible when pump is operating via external input WAIT indicator Visible when pump is in WAIT mode EXT key Push to set pump START STOP WAIT EXT STOP OVER SET for external input operation STOP indicator Visible when the pump is stopped via external signal The ON light Indicates power to the pump and blinks with each stroke Over indicator Visible when signal exceeds the 360 spm capability pump stops when visible e Basic display SET point indicator Visible when SET point 1 and 2 are
16. 0 42 2 08 0 3 1 5 mm 0 69 3 47 Note 1 The performance data is based on clean water at 25 C under rated voltage Note 2 Capacity is that at the max pressure at max stroke length and max stroke frequency Capacity exceeds the value at max pressure when pump operates under low pressure Note 3 Operating ambient temperature 0 40 C Relative humidity 30 to 90 non condensing Note 4 Liquid temperature PVC PVDF 0 C 40 C PC SH 0 C 60 C Note 5 Permissible voltage fluctuation Within 10 of rating Please note that for the purpose of improvement parts which have no effect on specifications and fitting sizes are subject to change without prior notice For SH type install air chamber of approx 500 ml volume at the location as close to pump discharge port Adjustment Range Recommended stroke length adjustment range 20 96 to 100 96 Recommended frequency adjustment range 0 to 360 stroke per minute e Control unit specifications MAN Manual Mode EXT External Changeover Entering by keys EXT START STOP Function Parameters EXT Digital input pulse multiply 1 1 999 Digital input pulse dividing nil n 999 1 Analog input SET point1 Current 0 20 mA Stroke rate 0 360 spm SET point2 Current 0 20 mA Stroke rate 0 360 spm MAN Stroke rate 0 360 spm Keys 4 keys START STOP EXT A V Upper limited spm 360 spm Stop By receiving stop signal
17. AE EAT TEA AN 21 3 Tubing eee ame 22 4 Electrical Wiring _ _ __ ___ __ ____________ __________________ 25 3 OPERATION eee 28 1 Precaution for Operation iine ike QI e tul e n RESULT 29 1 1 Bleeding 29 1 2 Adjustment of Discharge Capacity sawa a etin 31 2 Operation 33 2 1 Overview Operating Scheme aa Qha 32 2 2 Setting and Operation of Controller 00000068 35 4 MAINTENANCE 45 1 Maintenance sese ARNE ae aioe RAE CREE Ee 46 2 Diaphragm Replacement mmt tns 46 3 Valve Replacement 46 4 Tubing aa 46 5 Consumable parts ee ee ee ee 46 6 Names of Part and Structure Sesia nion Eid 47 7 Troubleshooting So GS ______ __ 49 Important Instruction For the Safe and Correct Handling of the Pump e Read the Safety Instructions sections carefully to prevent accidents involving your customers or other person and to avoid damage or loss of other assets Always follow the instructions and advice found in these sections e Observe and abide by the instructions described in this manual These instructions are very important for protecting pump users from dangerous conditions
18. T EXT STOP OVER SET Display for excess spm at EXT operation Pulse multiply operation lt In multiply operation visible if next pulse comes when the pump is making N N the strokes While visible max 255 pulses be put in storage You 1 AN set not to put them in storage lt WAIT EXT STOP OVER SET Display for excess spm at EXT operation Pulse dividing operation In dividing operation visible if signal which exceeds max preset number of strokes comes While visible the pump runs at fixed max number of strokes You can set so that excessive input pulses can be put in storage up to 255 pulses WAIT EXT STOP OVER SET 6 Dimensions Material symbol VC V6 PC VM FC e EH E30 e EH E35 NZ JA lili VC V6 PC VM FC 6 Dimensions Material symbol e EH E45 114 3 e EH E55 6 Dimensions Material symbol SH e EH E30 Rc 1 4 e EH E35 249 Rc 1 4 6 Dimensions Material symbol SH 45 Rc 3 8 55 114 3 2 INSTALLATION 1 Notes on Installation 19 cotta 21 3 22 4 Electrical Wing us 25 1 Notes on Installation Operators and maintenance service staff must read the instruction manual thoroughly before using the prod ucts Do not operate the pump system unless all of the contents in the ma
19. T key and A key simultaneously Display shows dIG and SET lights If ANA is displayed go to next item 3 WAIT EXT STOP OVER SET The display changes to ANA if Y key is pushed Every time W key is pushed the display changes ANA to N 2 416 When the pump is shipped from the factory it is set at dIG WAIT EXT STOP OVER SET 3 Push START STOP key to confirm the analog mode and c move to WAIT mode 2 WAIT EXT STOP OVER SET 4 Value input at analog mode Push EXT key and V key simultaneously Display shows the initial set value A04 0 and SET and 1 light 5 Setting of input amperage at SET point 1 Set the input amperage at SET point 1 by and Y keys mmr The value increases with A key pushed and decreases I l with W key pushed Amperage changes slowly by 0 1 mA WAIT EXT STOP OVER SET when the key is pushed briefly and changes quickly if pushed 3 seconds or more Setting range is 0 0 20 0 mA When the pump is shipped it is set at 4 0 mA WAIT EXT STOP OVER SET WAIT EXT STOP OVER SET M ic ME WAIT EXT i OVER SET MAE C JOLI WAIT EXT STOP OVER SET r1 2 WAIT EXT STOP OVER SET 6 Push EXT key to confirm the value at SET point 1 and move to the setting of stroke rate for the current value of SET point 1 The words PO
20. WAIT EXT STOP OVER SET 4 Setting of pulse memory ON OFF 1 Push key Y key to set ON and OFF of pulse memo oo ry Display X ON shows the pulse memory ON and X OF shows memory OFF status When the pump is shipped from the factory it is set at OF WAIT EXT STOP OVER SET 5 Push EXT key to confirm ON OFF of pulse memory The display shows dIG and SET lights dit WAIT EXT STOP OVER SET 6 Push START STOP key to confirm the digital mode and move to wait mode WAIT EXT STOP OVER SET 7 Switching of operation mode Push EXT key and Y key simultaneously and 1 Pulse dividing operation mode is displayed and SET lights WAIT EXT STOP OVER SET If X1 multiplying mode is displayed push EXT key to change to 1 Every time EXT key is pushed the display changes from X1to 1 WAIT EXT STOP OVER SET 8 Setting of dividing ratio Set the dividing ratio with A key and Y key A key increases the number and W key decreases the number The number changes slowly one by one if key is pushed in a short time and changes rapidly if pushed more than 3 seconds Set range is 1 to 999 The pump is set at 1 when it is shipped from the factory lt WAIT EXT STOP OVER SET 9 Push START STOP key to confirm the operation mode a and dividing ratio 2 WAIT EXT STOP OVER SET 10 Setti
21. apacity to confirm the wanted capacity is discharged 100 Stroke rate fixed 360spm 270spm a 180spm e o Disch capacity a O 2025 50 75 10 Stroke length is adjusted 2 Adjustment of stroke rate Stroke rate is adjusted by keys operation on the control unit Stroke rate is adjusted from 1 to 360 spm Stroke length fixed gt a Disch capacity a a 0 180 360 Stroke rate spm 3 Adjustment of stroke length 1 Power on the pump to start and adjust the discharge capacity by turning the stroke length adjustment knob 2 Figure below shows the relation between the stroke length and discharge capacity Stroke length can be adjusted from 0 to 100 but actually set the length between 50 and 100 Fixed stroke rate 75 Disch capacity 25 0 25 50 75 100 Stroke length A Caution Do not turn the stroke length adjusting knob while pump stops When the pump is stopped for a long period more than 1 month When the pump is stopped for a long period clean the wet end of pump and tubing by operating the pump with clean water for 30 minutes before stopping the pump When the pump is started after stopping if it does not suck up and discharge the liquid clean the valve set and remove foreign matters adhered Do bleeding and adjust the discharge capacity 2 O
22. creasing pressure Atmospheric Plunger Spring Diaphragm pressure then pushes liquid from the supply tank through the suction check valves to refill the pump head 3 Specifications e Pump identification EH E 30 230 PE8 1 2 3 4 5 6 7 e 2 1 2 Drive component E 48 W 3 Diaphragm effective diameter 30 30 mm 35 35 45 45mm 55 55 4 4 Material of liquid Pump head Valve Balls Valve seat amp Diaphragm amp Fittings O ring Gasket PVC CE FKM PVC SUS316 EPDM GFRPP CE FKM PTFE M PVC CE FKM bonded to EPDM PVDF CE PCTFE PTFE SUS316 SUS316 PTFE PVC Polyvinyl chloride Transparent GFRPP Glass fiber reinforced polypropylene M PVC Polyvinyl chloride Machined CE Alumina ceramic SUS316 316 Stainless steel FKM Fluoroelastomer EPDM Ethylene propylene diene methylene PTFE Polytetrafluoroethylene PVDF Polyvinylidenefluoride HC276 Hastelloy C276 5 Voltage symbol Symbol Voltage Input voltage Frequency 100 AC 100 V 90 110 V 50 60 Hz 11U AC 110 V 115 V AC 90 126 V 50 60 Hz 20J AC 200 V AC 180 220 V 50 60 Hz AC 230 V AC 207 253 V 50 60 Hz AC 220 230 240 V AC 198 264 V 50 60 Hz 6 Power code P with plug Nosymbol without plug 7 Controller type 8 Connec
23. ds qO 13S H3AO 4015 1X3 i 096 4018 1 15 nw easing 138 3015 1X3 X v 146 H3AO 4015 1X3 140 X bui jdnnw asind Je 0 esnid 13S H3AO 4015 t dO 13S H3AO 3015 1X3 NO J NO slnq 440 asing dO 1X3 1X3 fe dsip 19A 13S H3AO 4015 1X3 NO 13S H3AO 3015 6G enuey dO dO LX3 135 H3AO 4015 1X3 i Oel Indu Boyeuy 13S H3AO 4015 1X3 L X Ajdyjnw sinq 13S 3015 i ok qO 1X3 Notes to Overview Operating Scheme 1 gt means automatic movement After the program Ver is displayed it automatically moves to the sta tus at which the power was off last time When the pump is powered for the first time it comes to WAIT mode 2 For the pump start by manual operation
24. e beginning again The use of a pump in any application other than those clearly specified may result in injury or damage to the pump Use the pump strictly in accordance with the pump specifications and application range For specified application only S Prohibited No remodeling Never remodel a pump Otherwise a serious accident may result Iwaki will not be responsible for accident damage of kind which is caused the user remodeling the pump without first obtaining permission or instructions from Iwaki Wear protectors If you touch or come in contact with any type of hazardous chemical liquid including s but not limited to chemicals you may experience a serious injury Wear protective Weir protective gear protective mask gloves etc during the pump operation gear Operating site must be free of water and humidity The pump is not designed to be water proof or dust proof The use of the pump in S places where water splashes or humidity is high may result in an electrical shock or k Prohibited short circuit Safety Section Qualified operators only The pump operator and pump operation supervisor must not allow any operators S who have little or no knowledge of the pump to run and operate the pump Pump operators must have a sound knowledge of the pump and its operation Specified power only Do not operate the pump on voltage which is not specified on the nameplate S Fail
25. ecially when pumping liquids that readily generate gas bubbles Sodium hypochlorite and hydrogen peroxide are common examples of such liquids See Figure 1 Figure 1 Figure 2 Figure 3 Flooded Suction Shelf Mount Tank Mount If flooded suction mounting is not possible a shelf adjacent to but not directly above the supply tank often works well See Figure 2 The supply tank or cover can also be used if it has provisions for mounting a pump See Figure 3 In any care the total suction lift should not exceed 1 0 m 3 Tubing 1 Tubing for types VC V6 PC VM FC Mount securely the tube with fitting nut hose stopper and fitting spacer referring to the illus tration on left Hose 777 attention not to tighten fitting nut exces C Fitting nut sively E Hose stopper Z Caution h Use specified size of tube Oren wise tube may come off Refer to pump connection table on O ring page 8 for the size of tube Insert the fitting spacer into tube as deep as possible Otherwise liquid may leaks or tube may come off attention not to lose O ring If O ring is not mounted it may cause liquid leakage or failed self priming 2 Tubing for SH type Connections are Rc1 4 or NPT1 4 EH E30 35SH and 3 8 NPT3 8 EH E45 55SH Apply seal tape to connected pipe and securely tighten it so that liquid can not leak nor air
26. eplace control unit Pump does not prime Pump stroke length is too short Operate pump with stroke length set at 100 until primed Then set stroke length as needed to obtain desired output Air in suction tubing Reroute suction tubing to eliminate air trap Valve gasket is missing Install valve gasket Valve set assembly direction is wrong Reassemble valve set Pump is air locked Prime pump per instructions Suction or discharge valve is clogged with foreign matter Disassemble inspect clean Ball stuck to valve seat Disassemble inspect clean Output fluctuates Suction or discharge valve is clogged with foreign matter Disassemble inspect clean Air is trapped in pump Prime pump per instructions Overfeeding Install injection valve or back pressure valve Diaphragm is damaged Replace diaphragm Worn check valves Replace valve cartridges Liquid leaks Fitting or coupling nut is loose Tighten Pump head is loose Tighten pump head bolts Torque 2 6 Diaphragm is damaged Replace diaphragm O ring or valve gasket missing Install o ring or valve gasket A IWAKI PUMPS Country codes IWAKI CO LTD 6 6 Kanda Sudacho 2 chome Chiyoda ku Tokyo 101 8558 Japan TEL 81 3 3254 2935 FAX 3 3252 8892 http www iwakipumps jp U S A Australia Singapore Indonesia Malaysia Taiwan Thailand Hong Kon
27. equipment of 220 V or above that gener ates high surge voltage Under unavoidable circumstances take either of the following measures 1 Use a surge absorbing element such as a varistor with surge resistance of 2000A or Noise cut transformer more at the pump power supply connection 2 Use a noise cut transformer 2 Wiring Power cord and external signal cord are connected according to the procedure as bellow Never do the wiring when pump is operating Otherwise you will get an electric shock or the pump will be failed due to the short circuit Wait one minute or more after the power is switched off to start the wiring works because the internal cir cuit will be electrified just after it is switched off Use the cord of which outer diameter is 7 or 8 mm If smaller cord is used enough tightness can not be obtained Control unit Cord nut Cord gasket Cord Fig 5 i 2 4 5 6 7 8 Green L Digital Input Stop Input Power Ground Analog Input Sensor Power DC 12V 10 mA max e Wiring for analog input operation Analog input operation means the pump opera tion by input current signal of 0 to 20 mA to change the stroke rate in proportion to 0 to 360 spm
28. f next pulse comes during the multiplying operation OVER lights If the pulse memory is set to ON max 255 times pulse is put in memory and the pump continues operation WAIT EXT STOP OVER SET 3 Pulse dividing operation 1 Power ON Power and green lamp lights display shows l L 2 and then shows stroke rate of manual operation and goes l 1 lt to WAIT mode EXT STOP OVER SET In case the pump is powered for the first time The word WAIT is lit at WAIT mode If it does not show WAIT push START STOP key once to change to WAIT mode 2 Move to EXT operation mode Push key and EXT key simultaneously 4 2 The word 410 is displayed and SET lights If the word 15 displayed push Y key to change to WAIT EXT STOP OVER dIG Every time you push W key the words ANA and dIG switch over When the pump is shipped from the factory it is set at dIG 8 Move to pulse memory The function to memorize the pulses max 255 pulses which come while the pump does the multiply operation Push EXT key and OF or ON is displayed and SET WAIT EXT STOP OVER lights If X ON or X OF is displayed push EXT key and the display changes to ON or OF Every time you push EXT key OF or ON X ON or X OF switches When the pump is shipped from the factory it is set at X OF
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30. ghts Stroke rate changes corre sponding to input current To stop the pump push START STOP key and WAIT word lights To start the pump next time push EXT key WAIT EXT STOP OVER SET Blink Alarm indication At the analog input operation if the current exceeding 360 spm comes the word OVER lights While the OVER is lighting the pump operates at 360 spm When analog input being set if the same value current or 7 stroke rate is put for SET point 1 2 1 is dis Vt 2 played for three seconds then returns to set display LAW WAIT EXT STOP OVER SET 2 Pulse multiply operation 1 Power ON Power on and green lamp lights display shows V3 0E 2 and then shows stroke rate of manual operation and goes lt ow to WAIT mode WAIT EXT STOP OVER SET In case the pump is powered for the first time The word WAIT is lit at WAIT mode If it does not show WAIT push START STOP key once to change to WAIT mode 2 Move to EXT operation mode j Push key and EXT key simultaneously 1 2 The word 410 is displayed and SET lights am If the word ANA 15 displayed push Y key to change to dIG Every time you push W key the words ANA and dIG switch over When the pump is shipped from the factory it is set at dIG WAIT EXT STOP OVER SET 3 Move to pulse memory The function
31. gt 3 Install the pump at the place convenient for the maintenance inspection works in the future Securely fix the pump so that the pump can not vibrate horizontally 4 Use the tube corresponding to the pump suction and discharge port sizes Securely connect the tube so that liquid can not leak or air can not be sucked in 5 Make bleeding when you use the pump for the first time or when you replaced the chemical tank Refer to item Bleeding procedure on page 6 When you disassemble the pump head replace diaphragm O ring valve gasket and valve unit by new ones 7 Do not wipe the pump body with the cloth in which is soaked by solvent such as benzene kerosene or thinner Otherwise the body may be discolored To clean pump body use dry cloth or the cloth in which are soaked by water or neutral detergent Caution Liquid splash on driving unit and control unit may cause failure or accident Pay attention the liquid not to be splashed 2 Location Choose a location for the pump which is clean dry close to an electrical outlet and allows convenient access to stroke length control frequency control and tubing connections Avoid areas where ambient temperature exceeds 40 C or falls below 0 C or where the pump or tubing would be exposed to direct sunlight Flooded suction mounting the pump below the level of liquid in the supply tank is strongly recommended esp
32. ion of pipe apply seal tape to CS type check valve avoid liquid leakage 7 Install of accumulator or air chamber Air chamber To avoid the vibration caused by the pulsation of pump discharge side install an accumulator or m 2 air chamber in piping Vibration of pipe causes the rupture of pipe Ar gt I Discharge 9 2 5 4 Electrical Wiring 1 Precautions on wiring Only qualified operator service staff should be in charge of the related electrical arrangement and control of the power source Failure to observe this instruction may result in injury to person or damage to assets 1 The control unit can be detached but do not detach it when unnecessary Never combine the control unit with the driving unit which are different power voltages Otherwise the electronic circuit or driving unit may be failed or damaged A 2 Never use in common power source of the pump and that of high power electrical equip ment which generates surge voltage The surge voltage may cause the damage and failure of controller Surge voltage Surge absorbing blement The electronic of me control unit may be affected by excessively high surge voltage So do not operate the pump near high power elec P trical
33. is displayed and SET and 1 light 7 Setting of stroke rate for the current value at SET point 1 Set the stroke rate for the current value at SET point 1 by A and W keys Setting range is 0 360 spm The pump is set at 0 spm when it is shipped from the factory 8 Push EXT key to confirm the set current value at SET point 1 and move to the setting of the input current value at SET point 2 Display shows A20 0 and SET and 2 light 9 Setting of current value at SET point 2 Push A and Y keys to set the current value at SET point 2 Do not set the value which is set at SET point 1 Set range is 0 00 20 00 mA The pump is set at 20 00 mA when it is shipped from fac tory 10 Push EXT key to confirm the set current value at point 2 and move to the setting of stroke rate vs current value of SET point 2 Display shows P360 and SET and 2 light 11 Setting of stroke rate for the current value of SET point 2 Push A and V keys to set the stroke rate for the current value at SET point 2 Do not set the value which is set for SET point 1 Set range is 0 360 spm The pump is set at 360 spm when it is shipped 12 Push START STOP key to confirm the set value and lt move to WAIT mode 2 WAIT EXT STOP OVER SET 13 Push EXT key to start the pump Pump operates according to the set current value WAIT disappears and ON lamp blinks Display shows the stroke rate at which the pump oper ates and EXT word li
34. ng of upper stroke rate Stroke rate at pulse dividing operation is the one which is m z set for manual operation mode At WAIT mode push key and V key to set the stroke rate Refer to the item of WAIT EXT STOP OVER SET Manual Operation for details The pump is set at 360 spm when it is shipped from the factory 11 Push EXT key to start the pump WAIT disappears and ON lamp blinks Dividing ratio 15 displayed and EXT lights Stop the pump push START STOP key to come to WAIT mode When the pump 15 started next time push EXT key lt WAIT EXT STOP OVER SET Alarm indication If pulses which exceeds upper stroke rate come OVER lights If the pulse memory is set at ON max 255 pulses input are put in momory and the pump continue to run 1 2 WAIT EXT STOP OVER SET 4 Maintenance N S Maintenance 46 Diaphragm Replacement 46 Valve Replacement 46 TUBING eee 46 Consumable parts 46 Names of Part and Structure 47 Troubleshooting 49 1 Maintenance Caution Before working on the pump disconnect the power cord depressurize the discharge tubing and drain or flush any residual liquid from the pump head and valves 2 Diaphragm Replacement Disconnect AC power to the pump and disconnect the suction tubing and discharge tubing Remove the four head bolts with a 5 mm hex
35. nual are completely understood Turn off the power supply Working without disconnecting the power supply may cause an electrical shock Before engaging upon any working procedures involving the pump make sure to turn the power supply switch off and to stop the pump and other related devices Terminate operation When you detect or become aware of a dangerous sign or abnormal condition during operation termi nate the operation immediately and start it from the beginning again Specified power only Do not operate the pump on voltage which is not specified on the name plate Failure to do so may result in damage or fire Only the specified power level is to be applied Keep from heat or flame Do not place any dangerous materials or flammable objects near the pump for the prevention of fire or accident Damaged pump Never operate a damaged pump A damaged pump may cause leakage or electrical shock 1 Dropping the pump or subjecting it to strong impacts may result in faulty performance Handle the pump with care 2 When installing the pump avoid places exposed 4 to direct sunlight or direct rain with an ambient u tin temperature of above 40 C or with a relative humidity or above 90 Though the pump has a x simple waterproof and dust proof structure a sheltered location is recommended 2
36. peration 2 1 Overview Operating Scheme 13S H3AO 3015 1X3 LY 138 H3AO 3015 09 A 138 4018 Y 13S H3AO 3015 t 661V t 138 H3AO 3015 13S 3015 LOL d 0 d 13S 3015 185 3015 i 0 0 jas 1 9 do asing 138 H3AO 3015 1X3 i L X 1X3 1 9 146 H3AO 4015 1X3 L asind 195 je Boyeuy 195 13S 4015 1X3 k lt 195 145 H3AO 4015 1X3 X 138 3015 1X3 1 195 Bunjes 13S H3AO 4015 195 3015 096 4015 1 18 enuey 4015 1 16 eDueuo u
37. rn an adjusting screw counter clockwise by half to one turn To tank 3 Run the pump for ten minutes for bleeding 4 Close the adjusting screw by turning it clock wise 5 Check if no liquid leaks from any part 1 2 Adjustment of Discharge Capacity Adjustment of the discharge capacity can be done by adjusting the stroke length and by adjusting the stroke rate but basically it is done by adjusting the stroke rate Stroke length adjustment is an auxiliary way when the stroke rate adjustment is not enough Pay attention to the followings for the correct adjustment 1 For the gaseous liquid such as sodium hypochlorite and hydragine solution set the stroke length at 100 or near Discharge flow may be reduced if the stroke length is short 2 When the back pressure is high at discharge side set the stroke length at 100 or near 1 Procedure to adjust the discharge capacity Appropriate stroke length and stroke rate are decided considering the pump operating condition and liq uid characteristics or so Following ways are recommended for proper calibration 1 Set the stroke length at 100 to roughly adjust the discharge capacity by adjusting the stroke rate 2 Measure the discharge capacity 3 If the measured capacity is below the wanted value increase the stroke rate and measure again the dis charge capacity 4 Adjust the stroke length to do the fine adjustment of the capacity 5 Measure again the discharge c
38. set at EXT mode and analog input 0 20mA operation UP key Increases numeric values Used with EXT key to select external modes DOWN key Decreases numeric values Used with EXT key to select external setting mode SET indicator Visible when pump external mode and or settings are being selected Display examples Meanings Running at manual operation mode WAIT EXT STOP OVER SET Value shows set spm 1 2 Waiting at WAIT mode WAIT EXT STOP OVER SET 1 2 Displayed value is set value at manual operation mode V c N WAIT EXT STOP OVER SET Display shows running at 1 5 multiply 1 2 Running at EXT operation mode Pulse multiply Display examples Meanings Running at EXT operation mode Dividing Display shows running at 5 1 dividing EXT STOP OVER SET Running at EXT operation mode Analog input 0 20 mA 1 Display shows running at 120 spm speed responding to input current EXT STOP OVER SET In setting mode LIN IU FINI EXT STOP OVER SET EXT STOP OVER SET e Alarm display Display examples Meanings Display for excess spm at EXT operation analog input operation n In analog input operation visible if external signal exceeding 360 spm opera Ac tion comes While visible pump runs at fixed speed of 360 spm WAI
39. shipped pumps 5 2 5 for types VC V6 PC VM and 6 pos type FC 2 Pump Head Unit Material symbol SH E30 E35 E45 E55 37 S pum 42 44 9 S4 S n 18 w 11 13 4 60 1 G 3 Parts name for type SH Parts name for type SH Pump head Spring washer Suction fitting Gasket Discharge fitting Nut Diaphragm Fitting Retainer Fitting gasket Back up retainer Note 1 Air vent gasket Valve guide Note 2 Air vent body Valve seat Adjusting screw Valve Note 2 Seal nut Valve gasket Note 2 Seal ring Diaphragm spacer Hex sock cap bolt Note 2 Note 3 Seat Seat ring 2 Plain washer Note 1 For type E55 only 2 is for E45 E55 3 Two or more spacers may be put depending on shipped pumps Tube connector 7 Troubleshooting Caution A Problem Before working on the pump disconnect the power cord depressurize the discharge tubing and drain or flush any residual liquid from the pump head and valves Possible Cause Corrective Action Pump does not start Faulty wiring Correct wiring Improper voltage Connect to proper voltage source Electronic control unit is damaged R
40. tion Symbol Applicable hose dia ID x OD Type 4 8 x 13 mm VC V6 PC VM 99 912 VC V6 PC VM 10 x 0 12 mm FC 9 1 2 x 93 8 inch VC V6 PC VM FC Rc 1 4 SH NPT 1 4 SH 10 x 16 mm VC V6 PC VM Rc 3 8 SH NPT 3 8 SH 9 Special configuration 01 99 Special material special connection port diameter etc e Controller identification EHC 100 P E 1 2 3 4 5 Controller Voltage symbol AC 100 V AC 90 126 V 110 V AC 115 V AC 90 126 V AC 200 V AC 180 220 V AC 220 AC 230 AC240V AC 198 264 V AC 230 V AC 207 253 V Lead wire P with plug No symbol without plug Controller E Special configuration 0 99 Points to be noted in handling 1 Do not detach the control unit unless unavoidable 2 Never use the control unit with pumps having different symbols for driving unit and power source voltage specified on the control unit Check the nameplate Caution Operation with a pump having different symbols for driving unit and power source voltage other than those specified may cause failure or trouble in the electronic circuit of the control unit or the driving unit of the pump e Pump specifications Output Output per Maximum Stroke Stroke capacity Stroke Pressure frequency length ml min ml stroke MPa spm mm 0 19 0 94 0 29 1 44 a
41. tion mode Push EXT key and W key simultaneously and 1 Dividing operation mode is displayed and SET lights If X 1 is displayed go to next 8 If you push EXT key the display changes to X 1 Multiplying operation Every time EXT key is pushed X land 1 are switched over 8 Setting of stroke number to be counted Set the stroke number with A key and W key A key increases the number and W key decreases the number The number changes slowly one by one if key is pushed in a short time and changes rapidly if pushed more than 3 seconds Set range is 1 to 999 The pump is set at 1 when it is shipped from the factory 9 Push START STOP key to confirm the operation mode and stroke number 10 Setting of stroke rate Stroke rate at multiply operation is the one which is set for manual operation mode At WAIT mode push A key and Y key to set the stroke rate Refer to the item of Manual Operation for details The pump is set at 360 spm when it is shipped from the factory 11 Push EXT key to operate the pump Pump starts to operate WAIT goes out and ON lamp blinks when a pulse comes The pump automatically stops after it operated for the stroke number which is set at above item 8 During the operation the display shows pre set stroke number and EXT lights Push START STOP key to stop the pump and go to WAIT mode To start the pump again push EXT key WAIT EXT STOP OVER SET Blink Alarm indication I
42. to put in memory ur 1 the pulses max 255 pulses which come while the pump 2 does the multiply operation Push EXT key and OF or ON is displayed and SET lights If X ON or X OF is displayed go to next 4 When the pump is shipped from the factory it is set at OF WAIT EXT STOP OVER SET Push EXT key and the display changes to X ON or X WE OF Every time you push EXT key OF or ON X V y 2 ON or X OF switches When the pump is shipped from the factory it is set at X ON WAIT EXT STOP OVER SET 4 Setting of pulse memory ON OFF Push A key and W key to set ON and OFF of pulse memo i ry Display X ON is memory ON and X OF is memo m ry OFF status WAIT EXT STOP OVER BEN When the pump is shipped from the factory it is set at X ON 5 Push EXT key to confirm ON OFF of pulse memory and return to EXT operation mode The display shows dIG and SET lights WAIT EXT STOP OVER SET 6 Push START STOP key to confirm the digital mode and m move to wait mode 2 WAIT EXT STOP OVER SET WAIT EXT STOP OVER SET WAIT EXT STOP OVER SET lt WAIT EXT STOP OVER SET lt _ 2 a LIL WAIT EXT STOP OVER SET 350 WAIT EXT STOP OVER SET 7 Switching of opera
43. ure to do so may result in damage or fire Only the specified power level is to be applied Prohibited Prohibited Do not run the pump dry Do not run the pump dry without liquid inside the pump Heat generated as a D result of abrasion between elements inside the pump during operation without liquid may damage the inside of the pump Do not wet or dampen If an electric part or wiring gets wet with the liquid spilled over accidentally a fire or N Prohibited electrical shock may be caused Install the system in a place free from liquid Poa Aa spillage or leakage dampen Ventilate Poisoning may result during an operation which involves toxic or odorous liquid Ventilate the operating site sufficiently Caution Spill out accident Protective measures should be taken against any accidental spill out or leakage of A the operating liquid as a result of unexpected damage on the pump or the related piping Caution Damaged pump Never operate a damaged pump A damaged pump may cause leakage or electri cal shock Prohibited Do not damage or change power cable Do not scratch damage process or pull the power cable forcibly An extra load A onto the cable such as heating the cable or placing something heavy on the cable Caution may damage the cable and finally cause a fire or an electrical shock Safety Section Arrange grounding Do not operate the pump without connecting the grounding wire Otherwise an
44. wrench Turn the stroke length knob fully counter clockwise Unscrew the diaphragm and remove its retainer small disk behind the diaphragm Install the new retainer and diaphragm on the shaft Turn the diaphragm clockwise until it bottoms on the shaft Replace the pump head and tighten the head bolts to a torque of 2 6 N m 3 Valve Replacement Remove the suction and discharge tubing Remove the suction fit GASKET ting two valve cartridges o ring and gasket s Install the new o ALVE GUDE ring gasket s and valve cartridges J ALL Be sure both valve seats are in the same orientation Refer to Figure 6 below Tighten the suction fitting Similarly remove and replace RON the discharge valve cartridges o ring and gasket s Figure 6 Valve Cartridge Orientation 4 Tubing Check ends of tubing for splits cracks or thin spots Examine the full length of tubing for damage due to chafing abrasion stress cracks excessive temperature or exposure to ultraviolet light direct sunlight or mercury vapor lamps If any signs of deterioration exist replace the entire length of tubing It is a good idea to replace discharge tubing on a regular preventive maintenance schedule every 12 months 5 Consumable parts Replacement Timing Valve set 90 e00 Refor to pages 47 and 48 Diaphragm O The durability of expendable parts depends on the pressure temperature and properties of the liquid
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