IWAKI PUMPS Hi-Techno IX-B Series Instruction Manual Download Page 12

Page: 12 / 92

Overview

Introduction

Pump characteristics, features and part names are described in this

section.

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Pump structure & Operating principle

The IX series are diaphragm pumps with a brushless DC (BLDC) motor and feature a high turndown ratio &
automatic controls.

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Motor rotation is transmitted to an eccentric cam through a reduction gear and then converted to reciprocating

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Pump head

Pump head valve

(discharge side)

Pump head valve

(suction side)

Eccentric cam

Diaphragm

Brushless motor

Keypads

OUT

Summary of Contents for Hi-Techno IX-B Series

Page 1: ...IWAKI CO LTD Thank you for choosing our product Please read through this instruction manual before use This instruction manual describes important precautions and instruc tions for the product Always...

Page 2: ...distributor a Check if the delivery is correct Check the nameplate to see if the information such as model codes discharge capacity and discharge pressure are as ordered b Check accessories are comple...

Page 3: ...ion 18 STOP functions 19 STOP function 19 Pre STOP function 19 Analog output function 19 Protective functions 20 Interlock function 20 Diaphragm rupture detection 20 Pressure overload Failed rotation...

Page 4: ...nnection 35 EXT IN 36 STOP IN 36 AUX IN Analog OUT 37 Alarm OUT DIN connector 37 Operation 38 HIRUH RSHUDWLRQ 38 Points to be checked 38 5HWLJKWHQLQJ RI SXPS KHDG LQJ EROWV 38 Commissioning 39 Before...

Page 5: ...Drive unit Control unit 71 Pump head 72 IX B007 B015 B030 B045 TC TE R N 72 IX B007 B015 B030 B045 TC TE G 73 IX B007 B015 B030 B045 TC TE F 74 IX B007 B015 B030 B045 TC TE T 75 IX B007 B015 B030 B04...

Page 6: ...of Caution Prohibited actions DQG VSHFL F 5HTXLUHPHQW QGLFDWHV PLVKDQGOLQJ FRXOG OHDG WR SHUVRQDO LQMXU RU SURS HUW GDPDJH CAUTION DXWLRQ PDUNV 3URKLELWLRQ PDUN 5HTXLUHPHQW PDUN Safety instructions S...

Page 7: ...It is not the manufacturer s responsibility for any failure or injury resulting from alterations to the pump 1H SDV PRGL HU OD SRPSH 1H MDPDLV PRGL HU XQH SRPSH VRXV SHLQH GH FDXVHU XQ LQFLGHQW JUDYH...

Page 8: ...1H SDV DSSOLTXHU XQH DXWUH WHQVLRQ TXH FHOOH VSpFL pH VXU OD SODTXH VLJ QDOpWLTXH VLQRQ LO SHXW HQ UpVXOWHU XQH SDQQH RX XQH LQFHQGLH VVXUH YRXV pJDOHPHQW GH OD PLVH j OD WHUUH GH OD SRPSH HHS HOHFWUL...

Page 9: ...OH GLVSRVLWLI FKHW H HW LQVWDOOH XQ GpWHFWHXU GH IXLWHV j OD WHUUH 3UHYHQWDWLYH PDLQWHQDQFH Follow instructions in this manual for replacement of wear parts Do not disassemble the pump beyond the exte...

Page 10: ...d foundation concrete and fasten anchor bolts securely to prevent vibration during operation Si plusieurs pompes sont install es ensemble elles interagissent et les YLEUDWLRQV SHXYHQW GHYHQLU LPSRUWDQ...

Page 11: ...OD SRPSH FRXYHUWH GH OLTXLGH SRPSp RX VRXV OD SOXLH O SRXU UDLW DYRLU GHV UDWpV RX SUpMXGLFHV 6L OD SRPSH D pWp PRXLOOpH VHFKH OD directement Do not close discharge line during operation Solution may...

Page 12: ...V WKH RZ UDWH Motor rotation is transmitted to an eccentric cam through a reduction gear and then converted to reciprocating PRWLRQ 9ROXPHWULF FKDQJH RFFXUV LQ WKH SXPS FKDPEHU DV WKH GLDSKUDJP PRYHV...

Page 13: ...ge 100 240VAC 6DIHW GHVLJQ A diaphragm rupture detection ensures user safety and a pressure overload detection protects the pump and pipework from an accidental discharge line pressure rise QJUHVV SUR...

Page 14: ...pera WLRQ WKH GLVSOD VKRZV WKH FXUUHQW RZ UDWH 7R VKRZ WKH FXUUHQW YDOXH SXVK WKH NH 7R UHWXUQ WR WKH RZ rate display push the key The left graph shows the flow rate at each pattern a 4 20mA b 20 4mA...

Page 15: ...17mA Flow rate 12 7L H BOX VWURNH RZ UDWH FKDQJHV ZLWK D FXUUHQW YDOXH E D VHW OLQH 7KH UDWH GRHV QRW H FHHG WKH 6HW 3RLQW EXW WKHQ falls to 0 before the Set Point 1 Condition Set Point 1 SP 1 Ampere...

Page 16: ...U UHPDLQLQJ RZ YROXPH LV VKRZQ RQ WKH FRQWUROOHU XQWLO LW KDV UHGXFHG WR HUR Q WKLV FRQWURO PRGH WKH SXPS UXQV DW WKH 0 1 speed the pump speed in the manual mode The pump behaviour can change dependin...

Page 17: ...s cleared when the key is pushed once 3XOVH LQSXW E WKH NH Instead of the pulse signal input pushing the key can start or stop the batch control In this case the pump behaves as the control with the b...

Page 18: ...when the pump is running in either MAN or EXT mode see page 44 The pump returns to the MAN or EXT mode once the AUX signal stops Priming function 7KH SXPS UXQV DW WKH SUHVHW PD LPXP RZ UDWH RU WKH PD...

Page 19: ...VHH SDJH 7KH OLTXLG OHYHO LQ WKH VXSSO WDQN FDQ EH PRQLWRUHG E WKH VLJQDO IURP D OHYHO VHQVRU 7KH EDU FKDQJHV from green to orange colour when the pump is receiving the Pre STOP signal from a level s...

Page 20: ...stop the pump even when no leak has occured Reduce the temperature difference between the OLTXLG WHPSHUDWXUH DQG WKH URRP WHPSHUDWXUH RU GLVDEOH WKH HDN HWHFWLRQ RSWLRQ WR UHPRYH WKLV LVVXH 3UHVVXUH...

Page 21: ...and drive error detection turn disabled in that Alarm OUT The other outputs STOP Pre STOP interlock diaphragm rupture detection pressure overload detection and drive error detection can be enabled to...

Page 22: ...minimum and mount the pump head See the Diaphragm replacement sec tion on page 67 for detail QWL FKDWWHULQJ VHWWLQJ VHH SDJH Set a pulse recognition time for the IX not to be adversely affected by ch...

Page 23: ...h sodium hypochlorite or any other strong acid Make sure this port breathes in a clean atmosphere DVH Always anchor it with bolts 2XWOHW RQWURO XQLW Used for the start stop of the pump and operation c...

Page 24: ...us a selected mode and set values are shown here 6WDUW 6WRS NH Used for starting stopping the pump or moving back to the MAN EXT selection in setting 6 NH Used for cancelling the current setting and m...

Page 25: ...when Pre STOP func tion is active Stop A white lights pump waits in the MAN mode A white lights pump waits in the EXT mode A white lights pump waits in the MAN EXT selection A white lights pump waits...

Page 26: ...EPDM SUS316 O ring FKM EPDM Valve gasket PTFE Diaphragm PTFE PFA 0DWHULDO FRGH 39 3RO YLQ OLGHQH GL XRULGH OXPLQD FHUDPLFV 0 OXRULQH FRQWDLQHG UXEEHU 37 3RO WHWUD XRURHWK OHQH 3 0 WK OHQH SURS OHQH UX...

Page 27: ...erous conditions suspend operation immediately and inspect solve problems R QRW SODFH H SORVLYH RU DPPDEOH PDWHULDO QHDU WKH SXPS Use of a damaged pump could lead to an electric shock or death 3XPS PR...

Page 28: ...pump base 8VH IRXU 0 DQFKRU EROWV DQG WKH SXPS EDVH RQWR the vertical wall The pump base have a mounting direction the push mark upward Hang the pump onto the pump base The inverted triangles on the b...

Page 29: ...29 Installation Pump mounting HPRXQWLQJ Press the push mark and remove the mounting adapter from the base Push the pump toward to the wall to unhook demount the pump from the base 2 1...

Page 30: ...or counter clockwise at the 9 and 6 o clock positions 5HDU FDVH Remove the cap and loosen the screw a few turns Adjust the rear case to the best direction It can turn clockwise counter clockwise and s...

Page 31: ...W IXUWKHU GH grees with an adjustable wrench or spanner crush tube mount Do not use excessive force to the plastic fitting nut In your try to remove the connection the adapter may be stuck in the crus...

Page 32: ...S LQWR WKH FRPSDUW ment behind the diaphragm back LTXLG LQ WKH GUDLQ WDQN LV WKH VLJQ RI WKH GDPDJHG GLDSKUDJP PPHGLDWH LQVSHFWLRQ RU UHSDLU LV QHFHVVDU Do not leave this condition as it is Fumes or v...

Page 33: ...late Otherwise failure or fire may result Do not perform wiring work while electric power is on Otherwise an electrical shock or a short circuit may result Be sure to turn off the power before wiring...

Page 34: ...precautions for ON OFF control by a mechanical relay SSO SRZHU VKDUSO R QRW DSSO JUDGXDOO 6XUJH YROWDJH The electronic circuit in the control unit may fail due to a surge voltage Do not place the pum...

Page 35: ...ction 3RLQWV WR EH FKHFNHG Check that power voltage is turned off Use our optional connector cables below or purchase DIN 4 and 5 pin female connector cables when using signal input and output Optiona...

Page 36: ...loured as above The terminal pin 5 is an output and is not used Do not short circuit the pin 5 and pin 4 COM STOP IN To activate STOP function connect signal wires to the STOP terminal via the DIN 4 p...

Page 37: ...external device connect signal wires to the OUT terminal via the DIN 4 pin connection Alarm OUT 1 OUT 1 Mechanical relay Enable or disable the alarm outputs of batch completion STOP Pre STOP interloc...

Page 38: ...Power voltage range is correct Electrical wiring is correct and is free from the risk of short circuit and electrical leakage 5HWLJKWHQLQJ RI SXPS KHDG LQJ EROWV PSRUWDQW 7KH SXPS KHDG LQJ EROWV PD OR...

Page 39: ...D PDLQ OLQH Before a long period of stoppage One month or more Clean wet ends and the inside of piping Run the pump with clean water for about 30 minutes to rinse chemicals off Before unplugging the...

Page 40: ...Q DFWXDO RZ UDWH DOLEUDWLRQ LV PDGH WR GHWHUPLQH OLTXLG YROXPH SHU VKRW UUDQJH RXU SLSLQJ V VWHP DFFRUGLQJ WR WKH JXLGH below to ensure the calibration is made correctly 6XJJHVWHG SLSLQJ OD RXW Use a...

Page 41: ...6XSSO WKH UDWHG SRZHU YROWDJH WR WKH SXPS DQG VHW D RZ UDWH LQ WKH PDQXDO PRGH See page 13 for detail NOTE 7KH FDOLEUDWLRQ DFFXUDF ZRQ W FKDQJH DW DQ RZ UDWH 7KH KLJKHU WKH RZ UDWH LV WKH VKRUWHU WLPH...

Page 42: ...the UP and DOWN keys to set the volume reduction 3XVK WKH HQWHU NH RQFH 7KH VFUHHQ VKRZV RZ YROXPH per shot The screen shows ERROR Volume Out Of Range if WKH UHGXFWLRQ LV WRR OLWWOH RU WRR ODUJH QWHU...

Page 43: ...sed Pump ON Closed Pump OFF Interlock Closed Pump OFF Closed Pump ON Closed Pump OFF Leak detection Enable Disable Enable Alarm OUT1 Batch Complete Stop Pre Stop Interlock Leak Detection Motor Overloa...

Page 44: ...ult setting with the pump calibrated turn on power while pressing the ESC key Operation setting Wait state Operation MAN mode EXT mode Menu screen MAN EXT selection Power ON Use keys to scroll MAN mod...

Page 45: ...6HW WKH RXWSXW FXUUHQW DW 63 DQG RZ UDWHV WR FRQ JXUH WKH analog signal output behaviour See page 21 and 50 ODUP RXWSXW VHWWLQJ 287 Enable or disable the output of the batch completion STOP Pre STOP i...

Page 46: ...setting screen key to confirm key to return to menu screen key to scroll key to change values To next page Analogue preset Pulse control Batch control Interval batch control Mode selection screen 7 P...

Page 47: ...l Set flow volume per pulse to change the value to change the value to change the value to change the value SP1 current setting SP1 flow rate setting SP2 current setting SP2 flow rate setting Analogue...

Page 48: ...m key to return to menu screen key to select key to change values DOLEUDWLRQ See the Calibration process section on page 41 for detail Interval batch control Set Day Set Hour Set Minute Set a flow rat...

Page 49: ...OP function key to confirm key to return to menu screen key to scroll key to change values Function setting screen Function selection screen 6LJQDO LQSXW VHWWLQJ Closed Pump OFF Operation LED lights i...

Page 50: ...ation setting to change the value to change the value to change the value to change the value SP1 current setting SP1 flow rate setting SP2 current setting SP2 flow rate setting key to confirm key to...

Page 51: ...input of the completion signal Disable OUT1 is inactive Enable OUT1 is activated at input of STOP signal Output setting screen Output selection screen ODUP RXWSXW VHWWLQJ 287 0HFKDQLFDO UHOD STOP fun...

Page 52: ...signal Pre STOP function Interlock function Disable OUT1 is inactive Enable OUT1 is activated at input of interlock signal Disable OUT1 is inactive Enable OUT1 is activated at input of the detection...

Page 53: ...in the same way as the OUT 1 Disable OUT2 is inactive Enable OUT2 is activated to make the pulse signal ODUP RXWSXW VHWWLQJ 287 3KRWR026 UHOD Output selection screen Output setting screen STOP functi...

Page 54: ...nformation Operation setting 3 sec Return to a previous screen Software version Operating time Total flow volume Powered on time Number of ON OFF Data logging screen key to confirm key to return to me...

Page 55: ...ion Anti chattering Max flow rate Buffer Other setting screen Other selection screen key to confirm key to return to menu screen key to scroll key to change values 6HWWLQJ RI RWKHU IXQFWLRQV To next p...

Page 56: ...os The diaphragm comes to the bottom dead point Anti chattering AUX speed Set a flow rate To next page Buffer Max flow rate Disable Buffer OFF Enable Buffer ON Set a flow rate LWKHU RQH RI WKH DERYH L...

Page 57: ...57 Operation Operation setting Language selection Flow rate unit Pin number entry key to confirm key to move through each digit key to change values Output 1 logic Set the output 2 logic as necessary...

Page 58: ...VHOHFW WKH 0 1 RSWLRQ DQG WKH HQWHU NH IRU FRQ UPDWLRQ The pump enters a ZDLWLQJ VWDWH 8VH WKH 83 DQG 2 1 NH V WR VHW WKH RZ UDWH Push the start stop key to run the pump in the MAN mode The green LED...

Page 59: ...up when the key is pushed Push the key to return The green LED lights runs during operation AUX function Operation at an AUX speed starts while receiving the external signal via the AUX terminal when...

Page 60: ...uming operation Keypads can be locked at any time except when the menu screen is opened H SDG ORFN DFWLYDWLRQ Press and hold both the right and left keys for 3 seconds 3 sec KEY LOCKED appears on the...

Page 61: ...to SDS 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 HIRUH XQSOXJJLQJ WKH SXPS Always stop...

Page 62: ...necessary A ball valve is stuck on a valve seat Disassemble inspect and clean the valves Replace as necessary A vale seat has been pressed in the valve guide Do not push the valve seat into the valve...

Page 63: ...ints If you notice any abnormal or dangerous conditions suspend operation immediately and inspect solve problems See the Troubleshooting section as necessary When wear parts come to the life limit rep...

Page 64: ...B007 B015 Valve set TC type IX0283 7 IX0254 14 IX0258 2 IX0249 3 IX0250 6 IX0252 15 IX0259 2 IX0249 6 IX0252 16 IX0260 3 IX0250 7 IX0254 2 sets inlet outlet 8000 hours or 1 year Valve set TE type IX02...

Page 65: ...301 16 IX0306 3 IX0050 7 IX0303 2 sets inlet outlet 8000 hours or 1 year Valve set S6 type IX0371 9 IX0354 13 IX0369 9 IX0354 4 IX0367 2 IX0072 9 IX0354 2 IX0072 13 IX0369 5 IX0368 9 IX0354 9 IX0354 2...

Page 66: ...replacement Remove pipes from the pump NOTE Be careful not to get wet with residual chemicals in piping Rinse chemicals or crystals off the parts as necessary Use care handling the valve set Do not d...

Page 67: ...ll NOTE Observe the mounting direction of the valve set For the pumps with the TC TE wet end code Do not push the valve seat down into the valve guide A leak may result Connect pipes and the pump For...

Page 68: ...he pump head Extend the pump shaft by keypad operation With the diaphragm rupture detection ON and the error message of LEAK DETECTED the diaphragm has been fully extended In this instance skip to the...

Page 69: ...r NOTE I LW LV WWHG ORRVH IDLOXUH PD UHVXOW Retract the pump shaft by keypad operation Push the enter key Select the Diaphragm Pos option and push the enter key Select the MAX IN Pos option by the rig...

Page 70: ...pump head or a leak or damage may result Remount the bolt cover pumps with TC TE wet ends RQQHFW SLSHV WR WKH WWLQJV DQG WKHQ WLJKWHQ WKH QXWV NOTE 0DNH VXUH 2 ULQJV DQG JDVNHWV DUH WWHG SURSHUO Go b...

Page 71: ...t Control unit Do not disassemble the pump beyond the extent shown in the diagram below Valve set materials differ with models Exploded view Pump Nut Valve set Nut Valve set Gasket Diaphragm unit Diap...

Page 72: ...Valve guide A 2 15 Valve guide B 2 16 Seat holder 2 17 IN adapter 1 18 OUT adapter 1 19 Hex socket head bolt 4 20 Spring washer 4 21 Plain washer 4 28 Bolt cover 1 30 Diaphragm unit 1 34 Gasket 1 35 B...

Page 73: ...4 8 O ring 2 14 Valve guide A 2 15 Valve guide B 2 16 Seat holder 2 17 IN adapter 1 18 OUT adapter 1 19 Hex socket head bolt 4 20 Spring washer 4 21 Plain washer 4 28 Bolt cover 1 30 Diaphragm unit 1...

Page 74: ...alve guide A 2 15 Valve guide B 2 16 Seat holder 2 17 IN adapter 1 18 OUT adapter 1 19 Hex socket head bolt 4 20 Spring washer 4 21 Plain washer 4 28 Bolt cover 1 30 Diaphragm unit 1 34 Gasket 1 35 Br...

Page 75: ...ide B 2 16 Seat holder 2 17 IN adapter 1 18 OUT adapter 1 19 Hex socket head bolt 4 20 Spring washer 4 21 Plain washer 4 28 Bolt cover 1 30 Diaphragm unit 1 34 Gasket 1 35 Bracket spacer 1 50 Nut 2 74...

Page 76: ...mes of parts 1 Pump head 1 2 Valve 4 4 Valve seat A 2 5 Valve seat B 2 9 Valve gasket 10 10 Gasket 2 13 Valve guide 4 19 Hex socket head bolt 4 20 Spring washer 4 30 Diaphragm unit 1 31 Retainer 1 32...

Page 77: ...t names of parts 1 Pump head 1 2 Valve 4 4 Valve seat A 2 5 Valve seat B 2 9 Valve gasket 10 10 Gasket 2 13 Valve guide 4 19 Hex socket head bolt 4 20 Spring washer 4 30 Diaphragm unit 1 31 Retainer 1...

Page 78: ...5 R1 2 3 7 N 1 2 NPT G G3 4 T 0 4 1 Tube 2 F 0 4 Flange 3 3 9 IX B045 S6 R 0 045 45 4 0 4 19 0 5 Rc3 8 5 0 N 3 8 FNPT FJ JIS 10K 15A 6 5 FD DIN PN10 DN15 FA ANSI 150 lb 1 2 The above information is ba...

Page 79: ...ed external pulse signal with buffer ON Current value indication An input current is displayed during operation in the ANA V mode Input Stop Pre STOP No voltage contact or open collector 3 AUX No volt...

Page 80: ...DWLRQV 2XWHU GLPHQVLRQV 3RZHU FDEOH Conduction section area 18AWG Triplex cable L N PE Length 1950 mm Standard U type SJT W A U2 type SJT W Terminal treatment Plug RG FRORXU Blue Munsell colour system...

Page 81: ...B C D E F G H IX B007 240 45 24 3 267 291 98 284 29 IX B015 249 41 24 3 267 291 98 284 29 IX B030 B045 273 30 26 4 270 296 101 289 28 6SHFL FDWLRQV 2XWHU GLPHQVLRQV B A 165 D H 132 G 362 376 175 C E 7...

Page 82: ...HQVLRQV 7 7 A B C D E F G H IX B007 146 92 24 3 267 291 98 284 29 IX B015 155 88 24 3 267 291 98 284 29 IX B030 B045 179 77 26 4 270 296 101 289 28 B A 165 D H 132 G 362 376 175 C E 7 20 20 7 120 42 8...

Page 83: ...DWLRQ 6SHFL FDWLRQV 2XWHU GLPHQVLRQV 7 7 A B C D E F G H IX B007 250 40 267 98 29 IX B015 259 36 267 98 29 IX B030 B045 283 25 270 101 28 B A 165 D H 132 362 376 175 7 20 20 7 42 81 F 6 120 Inlet outl...

Page 84: ...QVLRQV 7 7 7 A B C D E F G H IX B007 168 81 24 3 267 291 98 284 29 IX B015 177 77 24 3 267 291 98 284 29 IX B030 B045 201 66 26 4 270 296 101 289 28 B A 165 D H 132 G 362 376 175 C E 7 20 20 7 42 81 F...

Page 85: ...HFL FDWLRQV 2XWHU GLPHQVLRQV 6 5 1 A B C D E F G H IX B007 B015 161 82 18 267 285 94 5 277 6 29 IX B030 B045 177 72 19 269 5 288 5 97 281 28 B A 165 D G 362 C E 7 7 42 81 F 120 132 376 175 6 20 20 H I...

Page 86: ...86 6SHFL FDWLRQV 2XWHU GLPHQVLRQV 6 A B C D E F G H IX B007 B015 247 39 267 94 5 29 IX B030 B045 263 29 269 5 97 28 B A 165 D 362 7 20 20 7 42 81 F 120 H 132 376 175 6 Inlet outlet center...

Page 87: ...L H IRU WKH ZDOO WR KDYH 0 DQFKRU QXW OZD V VHOHFW WKH ULJLG ZDOO IRU ZDOO PRXQWLQJ RI WKH SXPS R QRW GURS W V QRW the manufacturer s responsibility for any failure or damage resulting from a dropped...

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Page 92: ...EL 39 0444 371115 FAX 39 0444 335350 U S A IWAKI America Inc TEL 1 508 429 1440 FAX 1 508 429 1386 China IWAKI Pumps Shanghai Co Ltd TEL 86 21 6272 7502 FAX 86 21 6272 6929 Spain IWAKI Europe GmbH Spa...

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IWAKI PUMPS Hi-Techno IX-B Series, Instruction Manual

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Summary of Contents for Hi-Techno IX-B Series

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