IWAKI PUMPS EJ-B Series Instruction Manual Download Page 1

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2013 IWAKI CO., LTD.

Iwaki
Electromagnetic Metering Pump

EJ-B(R) (Europe)

Instruction manual

Thank you for choosing our product.

Please read through this instruction manual before use.

This instruction manual describes important precautions and
instructions for the product. Always keep it on hand for quick
reference.

Summary of Contents for EJ-B Series

Page 1: ... EJ B R Europe Instruction manual Thank you for choosing our product Please read through this instruction manual before use This instruction manual describes important precautions and instructions for the product Always keep it on hand for quick reference ...

Page 2: ...roblem or inconsistency is found immediately contact your distribu tor a Check if the delivery is correct Check the nameplate to see if the information such as model codes dis charge capacity and discharge pressure are as ordered b Check if the delivery is damaged or deformed Check for transit damage and loose bolts ...

Page 3: ...g principle 12 Features 13 Operational functions 13 Manual mode 13 EXT mode 14 STOP function 14 Part names 15 Pump 15 Operational panel 16 Basic displays Pump states 17 Identification codes 18 Installation 19 Pump mounting 19 Pipework 20 Tube connection 20 Check valve mounting 22 Wiring 24 Power voltage Earthing 24 Signal wire connection 26 Input signal 27 ...

Page 4: ...eration programming 35 Programming flow 35 Manual operation 36 EXT operation 38 STOP function 39 Keypad lock 40 Keypad lock activation 40 Keypad lock release 40 Maintenance 41 Troubleshooting 42 Inspection 43 Daily inspection 43 Periodic inspection 43 Wear part replacement 44 Wear part list 44 Before replacement 45 Valve set replacement 46 Discharge valve set dismantlement assembly 46 Suction valv...

Page 5: ...p head 53 Specifications Outer dimensions 54 Specifications 54 Pump unit 54 Control unit 55 European power cable 55 Australian power cable 55 Pump colour 55 Outer dimensions 56 EJ B09 B11 B16 B21 VC VH 56 EJ B11 B16 B21 TC 57 EC Declaration of Conformity 58 ...

Page 6: ...ting the use of Caution Pro hibited actions or specific Requirements Indicates mishandling could lead to personal injury or property damage CAUTION Caution marks Prohibited mark Requirement mark Electrical shock Caution Requirement Export Restrictions Technical information contained in this instruction manual might be treated as controlled technology in your countries due to agreements in internat...

Page 7: ...e of risk It is not the manufacturer s responsibility for any failure or injury resulting from alterations to the pump Wear protective clothing Always wear protective clothing such as an eye protection chemi cal resistant gloves a mask and a face shield during disassembly assembly or maintenance work The specific solution will dictate the degree of protection Refer to MSDS precautions from the sol...

Page 8: ... fixing screws may loosen and liquid may leak Optimise your system If the pump runs dry for a long period for more than 30 minutes the pump head and the valve cases may deform by friction heat and conse quently leakage results Keep electric parts and wiring dry Risk of fire or electric shock Install the pump where it can be kept dry Observe an applicable MSDS Take account of installation environme...

Page 9: ...damaged pump Use of a damaged pump could lead to an electric shock or death Disposal of a used pump Dispose of any used or damaged pump in accordance with local rules and regulations If necessary consult a licensed industrial waste disposal company Check pump head bolts Liquid may leak if any of the pump head bolts become loose Tighten the bolts diagonally and evenly by 2 16N m before initial oper...

Page 10: ...oesn t vibrate If the pump is not installed level output may be affected When two or more pumps are installed together vibration may be significant resulting in poor performance or failure Select a solid foundation concrete and fasten anchor bolts securely to prevent vibration during operation Allow sufficient space around the pump for easy access and maintenance Install the pump as close to the s...

Page 11: ...d prevent damaged plumbing Solution in the discharge line may be under pressure Release the pressure from the discharge line before dis connecting plumbing or disassembly of the pump to avoid solution spray Wear protective clothing when handling or working with pumps Consult solution MSDS for appropriate precautions Do not come into contact with residual solution Do not clean the pump or nameplate...

Page 12: ...m is directly driven by elec tromagnetic force Principle of operation The pulse signal via the PCB generates the electromagnetic force to make reciprocating motion with the assistance of the spring force The reciprocating motion is transferred to a diaphragm through a plunger and then volumetric change occurs in the pump head This action transfers liquid along with pump head valve action Control u...

Page 13: ...f 65 equivalent This pump is not waterproof Protect the pump with a cover when installing it out of doors Operational functions Manual mode Run stop the pump by the start stop key A stroke rate MAN speed can be changed in the range of 1 360spm by the up key at any time during operation or stop See page 36 for detail The pump can also be turned ON OFF by switching the main power Run Run Stop Stop K...

Page 14: ...l See page 38 for detail Example The pump makes one shot per signal STOP function The start stop of the pump can be controlled by the external STOP signal See page 39 for detail The pump resumes operation when the STOP signal is released The pump stops running while the STOP signal is inputted Pulse signal input Pump operation Run Run Stop STOP signal input Pump operation ...

Page 15: ...end to a supply tank or a container A circumferential direction of the port can be changed up to 90 degrees counterclockwise from the original position Adjusting screw Used for opening the air vent port Nameplate Describes the pump specifications Base Always fix with bolts Pump head Inlet Outlet Air vent body EXT terminal 5 pin DIN connector Remove the protective cap before use Power cable ...

Page 16: ...ve the DOWN key so if you want a lower spm first get to the max 360 spm and then push this key once The spm will return to 1 Display Stroke rate and operational status are shown here START STOP key Used for starting stopping the pump If pushed while the UP key is depressed the pump enters EXT mode ON LED Lights as turning on power and flashes at each stroke ...

Page 17: ...signal is turned OFF STOP signal is entered in EXT mode If the spm flashes it means the pump is just suspend ed and will restart as the signal is turned OFF Keypads are locked and any key operation is cancelled Keypads are locked in a sus pended MAN EXT mode with the STOP signal The pump is in maintenance mode When extending the dia phragm the display flashes Part names Represents the pump is rece...

Page 18: ...M EPDM TC PVDF Alumina ceramic FKM FKM Material code PVC Transparent polyvinyl chloride PVDF Polyvinylidene difluoride HC276 HASTELLOY C276 FKM Fluorine contained rubber EPDM Ethylene propylene rubber PTFE Polytetrafluoroethylene e Tube I D Area Europe Australia Material VC VH TC VC VH TC No code ø4 ø6 ø4 ø6 ø4 ø6 ø6 ø8 ø6 ø8 ø6 ø8 1 ø4 ø9 ø4 ø9 ø4 ø9 ø4 ø9 2 ø4 ø6 ø4 ø6 ø4 ø6 ø4 ø6 ø4 ø6 ø4 ø6 3 ...

Page 19: ...r flammable material near the pump Do not use a damaged pump Use of a damaged pump could lead to an electric shock or death Pump mounting Select an installation location and mount the pump Necessary tools Four M5 bolts pump mounting Adjustable wrench or spanner Select a suitable place Select a level location free from vibration that won t hold liquid See page 10 for detail Flooded suction is recom...

Page 20: ...g nut and hoes stopper and then slide it down to the hose adapter as far as it will go b Fit the tube end hose adapter to the fitting Then hand tighten the fitting nut c Retighten the fitting nut by turning it 180 degrees with an adjustable wrench or spanner The plastic fitting nut may be broken if it is tightened too much Tube end Side view Tube Fitting nut Fitting Hose stopper Hose adapter a b O...

Page 21: ...e an air vent port direction The air vent port can rotate 90 de grees a Turn the lock nut anticlockwise b Adjust the direction of the air vent port c Hand tighten the lock nut holding the air vent body A d Turn the lock nut 90 degrees clockwise further with an adjustable wrench or spanner 1 2 3 Tube Tube Outlet Inlet Air bleed tube Air vent port Air vent port Air vent body A Lock nut ...

Page 22: ... side liquid level is higher than a discharge side or an injection point at atmospheric pressure A discharge side liquid level is higher than a suction side but the distance is 5m or below A suction line pressure is higher than a discharge line pressure A discharge pressure including pipe resistance and discharge head is below 0 13MPa Suction side Discharge side Suction side Discharge side 5morbel...

Page 23: ...t us or your nearest distributor CBN check valve NOTE Periodically clean or replace a check valve with new one for the prevention of crystal clogging especially when using sodium hypochlorite Tubing layout Flooded suction application Suction lift application NOTE Flooded suction is recommended when handling a gaseous liquid such as sodium hypochlorite 1 Check valve Accumulator Chamber Pump Pump Ac...

Page 24: ...c power is ON Otherwise an electrical shock or a short circuit may result Be sure to turn off the power before wiring work Be careful for the power not to be turned on during work The power cable is not replaceable The DIN 5 pin male connector is protected with a protective cap Do not remove the cap unless the connector is used or failure may result Necessary tools Adjustable wrench or spanner Phi...

Page 25: ...lay Apply power sharply Do not apply gradually Surge voltage The electronic circuit in this pump may fail due to surge voltage Do not place the pump close to a high power device of 200V or more which may generate large surge voltage Otherwise take any of the following meas ures Install a surge absorption element ex a varister with capacity of 2000A or more via power cable Recommended varisters SUN...

Page 26: ...wable ON OFF operation is about 150 000 times The contact capacity should be 10A or more when making ON OFF operation over 150 000 times or sharing a power source with a large capacity equip ment Otherwise a contact point may fail by surge voltage Use a solid state relay SSR as necessary such as the OMRON G3F See manufacturer s catalogues for detail Signal wire connection Points to be checked Chec...

Page 27: ...therwise noise is generated through the cables due to induction effect and it results in malfunction or failure The following products are the recommended SSRs Solid State Relays for signal input Any other SSRs may cause malfunction See manufacturer s information for details on these SSRs OMRON G3FD 102S or G3FD 102SN OMRON G3TA IDZR02S or G3TA IDZR02SM When using a mechanical relay for signal inp...

Page 28: ... connected and is free from leakage and clogging Discharge suction valves are opened A power voltage is in the allowable range Electrical wiring is correct and is free from the risk of short circuit and electri cal leakage Retightening of pump head fixing bolts Important The pump head fixing bolts may loosen when plastic parts creep due to tem perature change in storage or in transit and this can ...

Page 29: ...tained with gas in the pump Conduct degassing in the following cases When the pump starts to run for the first time When a flow rate is too low After liquid is replaced in a supply tank After a long period of stoppage After maintenance and inspection NOTE Both gas and chemical come out together through an air bleed tube Place the end of the tube in a supply tank or a container Some chemicals may c...

Page 30: ...with other settings Use the UP key to set a stroke rate to 360spm This programming is not necessary when the display already shows 360 Move to the next step If the key is pressed and held the spm will quickly increases to the max rate Rotate the adjusting screw two revolutions anticlockwise to open the air vent port Do not rotate it three revolutions Otherwise liquid may come out from the adjustin...

Page 31: ...op key and stop the pump Rotate the adjusting screw clockwise to close the air vent port Check liquid is discharged Degassing is required again if the pump does not discharge liquid Check connections for leakage Degassing has now been completed Before operation 4 7 5 6 8 ON START STOP ON START STOP ...

Page 32: ...oke rate is shown as below Turn on power and call up manual mode Enter manual mode to indicate a stroke rate on the screen Push the start stop key when the pump is in the EXT mode When STOP appears on the screen suspend the STOP signal Determine a stroke rate that will meet a required flow See the above table The discharge capacity described on the nameplate is the value at 100 2 1 ON START STOP 1...

Page 33: ...e key for three seconds for quick increment Quick increment stops at 360spm 360spm skips to 1spm when the key is released and pushed once Measure a flow rate If a flow rate is lower than a specified level increase a stroke rate Measure the flow again to see the specified level is obtained ON START STOP ON START STOP 5 3 4 6 ...

Page 34: ...ump by key operation and wait for three seconds before unplugging the pump Otherwise the last key operation may not be put in memory In this case the pump unintentionally starts to run as powered on discharging liquid When the pump does not transfer liquid at resuming operation Clean the valve sets and remove foreign matters If gas is in the pump head expel gas and readjust a flow rate See Degas s...

Page 35: ... operation Programming flow The maintenance mode is used for the replacement of a diaphragm Power ON while the UP key is pressed The maintenance mode will come up after 3 seconds Display flashes and diaphragm is extended to the full 3 sec 3 sec 3 sec and Power ON spm setting WAIT mode EXT mode Keypad lock Ex MAN mode operation Keypads are locked Maintenance mode MAN mode ...

Page 36: ...power is turned ON with a default set ting or calls up the last selected mode when powered on with other settings Enter WAIT mode Move to the next step when spm 1 360 is shown on the screen When EXT is shown on the screen Push the start stop key once to return to the WAIT mode When STOP is shown on the screen Release the STOP signal 2 1 ON START STOP ON START STOP ON START STOP ...

Page 37: ...ey for three seconds for quick increment Quick increment stops at 360spm 360spm skips to 1spm when the key is released and pushed once Push the start stop key The LED and spm indication blink as the pump starts to run Only the LED blinks in sync with the pump operation 4 3 ON START STOP ON START STOP ON START STOP ON START STOP ...

Page 38: ...WAIT mode When EXT is shown on the screen The pump is already in the EXT mode and waiting for the input of the external signal When STOP is shown on the screen Release the STOP signal Push the UP key while pressing the start stop key The mode changes to the EXT mode and starts running as receiving the external signal The displayed spm shows an actual pump speed in the EXT mode 2 1 ON START STOP ON...

Page 39: ...ion The start stop of the pump operation can be controlled by the external stop signal The display changes as below when the STOP signal is inputted MAN mode EXT mode STOP signal STOP signal ON START STOP ON START STOP ON START STOP ON START STOP ...

Page 40: ...t acceptable when the keypads are locked In an emergency unplug the pump to stop operation Plugging in the pump keypads are locked again Keypad lock activation Press and hold the start stop key for three seconds Keypad lock release Press and hold the start stop key for three seconds Keypad lock is released and key operation becomes acceptable 1 1 ON START STOP ON START STOP ON START STOP 3 sec ON ...

Page 41: ...sk and a face shield during disassembly assembly or maintenance work The specific solution will dictate the degree of protec tion Refer to MSDS precautions from the solution supplier Risk of electrical shock Be sure to turn off power to stop the pump and related devices before service is performed Before unplugging the pump Always stop the pump by key operation And wait for three seconds before un...

Page 42: ... Dismantle inspect and clean the valves Replace as necessary A ball valve is stuck on a valve seat Dismantle inspect and clean the valve Replace as necessary A flow rate fluctuates Air stays in the pump head Expel air See page 29 Overfeeding occurs Mount a check valve See page 22 Foreign matters are stuck in the pump head valves Dismantle inspect and clean the valves Replace as necessary Diaphragm...

Page 43: ...are normal Check specifica tions If liquid has deteriorated crystallized or precipitated Visual or audio inspection 2 Noise and vibration If abnormal noise or vibration occurs They are signs of abnormal opera tion Visual or audio inspection 3 Air ingress from pump head joints and a suction line If leakage occurs If pumped liquid includes air bubbles check lines for leakage and retighten as necessa...

Page 44: ...rge line before disconnecting plumbing or disassem bly of the pump to avoid solution spray Rinse wet ends thoroughly with tap water Each time the pump head is dismantled replace the diaphragm O rings and valve sets with new ones Wear part list Parts of parts Estimated life Pump Valve set 2 sets 8000 hours Diaphragm 1 O ring See page 52 Wear part duration varies with the pressure temperature and ch...

Page 45: ... the air vent port NOTE Do not rotate it three revolutions or more Otherwise the adjusting screw may come off with solution spray Check the discharge line and the pump head are depressurized Liquid pressure is released from the air vent port in the form of solution spray NOTE If pressurized liquid is not expelled run the pump with an opened air vent port until pressure is removed 1 2 3 ...

Page 46: ...x wrench A pair of tweezers Unfix the pump base before disassembly Loosen the fitting nut to remove a dis charge tube and an air bleed tube NOTE Wash out residual liquid or substances Turn the lock nut anticlockwise by an adjustable wrench and remove the air vent body A 1 2 Fitting nut Air bleed tube Discharge tube Lock nut Air vent body A ...

Page 47: ... the air vent body B through the lock nut Be careful not to misarrange the valve set or place upside down Otherwise leakage or flow rate reduc tion may result Do not forget to fit O rings and gaskets Keep the valve set free from dust or foreign matters Remount the air vent body A and connect tubes Air vent body B 3 4 5 6 5 12 9 11 10 9 11 10 13 4 Air vent body B Valve set Lock nut ...

Page 48: ...eezers Place a new valve set into the fitting Hand tighten the fitting into the pump head as far as it will go Retighten it by a further 1 4 turn with an adjustable wrench or a spanner Be careful not to misarrange the valve set or place upside down Otherwise leakage or flow rate reduction may result Do not forget to fit O rings and gaskets Keep the valve set free from dust or foreign mat ters Reco...

Page 49: ...aphragm location Note that the number of diaphragm spacers varies with pump model Do not access the pump in or right after operation Wait until the drive unit of the pump cools down Loosen the fitting nuts and remove a suction tube a discharge tube and an air bleed tube Remove the pump head with a hexa gon wrench Enter the pump into maintenance mode Press and hold the UP key and then turn ON the p...

Page 50: ...ended for 10 minutes or more Push the UP key again to retract the shaft once the time has passed Rotate and remove the diaphragm from the plunger pump shaft Slide a retainer and diaphragm spacer s onto the screw of a new diaphragm Screw the new diaphragm into the plunger as far as it will go Be careful not to loose the retainer and diaphragm spacer ON START STOP ON START STOP Diaphragm Diaphragm s...

Page 51: ...ract the pump shaft to the minimum Push the start stop key to enter the WAIT mode Mount the pump head Tighten the pump head fixing bolts evenly to 2 16N m in diagonal order A hexagon wrench can be used for a torque wrench See page 29 ON START STOP ON START STOP 8 9 10 ...

Page 52: ...d view Pump head Drive unit The pump in the diagram below is completely dismantled Do not dismantle the pump beyond the extent shown in this instruction manual Valve set Pump body Retainer Diaphragm spacer Diaphragm Valve set ...

Page 53: ...lve seat 4 11 Valve 4 12 Valve gasket 2 13 O ring 2 14 Diaphragm spacer 15 Hex socket head bolt PW SW 4 16 Adjusting screw 1 18 O ring P4 1 19 O ring P10A 1 20 O ring P10 1 24 Hose stopper 3 25 Hose adaptor 3 26 O ring P9 3 28 Bolt cover 4 26 26 24 24 25 25 26 25 24 15 28 1 3 2 10 11 9 10 11 9 12 13 12 9 11 10 9 11 10 13 16 19 18 8 20 4 3 5 3 6 7 14 The number of diaphragm spacers varies with pump...

Page 54: ... 8 30 1 0 EJ B16 3 0 50 0 6 EJ B21 4 8 80 0 3 The above information is based on pumping clean water at rated voltage and ambient temperature Flow rates were collected at the maximum discharge pressure and 360spm A flow rate increases as a discharge pressure decreases Allowable ambient temperature 0 40 C Allowable liquid temperature 0 40 C VC VH or 0 60 C TC Allowable power voltage deviation 10 of ...

Page 55: ...the EJ to an external contact is 15V at 3mA When using a mechanical relay the minimum application load should be 3mA or below 2 When the external pulse signal is entered to run the pump over the max spm the signal is cancelled 3 Observe the allowable voltage range of 90 264VAC Otherwise failure may result European power cable Conduction section area 0 75 mm2 triplex cable L N PE Length 2000 mm Sta...

Page 56: ...56 Specifications Outer dimensions Outer dimensions EJ B09 B11 B16 B21 VC VH LOCK IN AIR OUT 96 195 219 18 160 47 24 76 5 36 5 194 6 2 88 9 16 5 10 32 5 100 ...

Page 57: ...57 Specification Specifications Outer dimensions EJ B11 B16 B21 TC LOCK IN AIR OUT 96 194 2 220 19 159 48 24 76 5 36 5 195 6 2 88 9 16 5 10 32 5 100 ...

Page 58: ...6 95 EC EMC DIRECTIVE 2004 108 EC STANDARDS EN809 1998 A1 2009 EN60335 1 2002 A14 2010 ENISO12100 2 2003 EN61000 6 2 2005 EN61000 6 3 2007 A1 2011 A PERSON WHO AUTHORISED TO COMPILE THE TECHNICAL FILE IN THE COMMUNITY AKIRA AIYAMA IWAKI EUROPE GMBH SIEMENSRING 115 D 47877 WILLICH GERMANY NOTE THIS DECLARATION BECOMES INVALID IF TECHNICAL OR OPERA TIONAL MODIFICATIONS ARE INTRODUCED WITHOUT THE MAN...

Page 59: ... Country codes IWAKI CO LTD 6 6 Kanda Sudacho 2 chome Chiyoda kuTokyo 101 8558 Japan SensysLtd01438759595 ...

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