IWAKI PUMPS IX-D Series Instruction Manual Download Page 27

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stal

lat

ion

Pipework

■ Piping layout

Flooded suction application

Suction lift application

NOTE

• The suction line I.D. should be equal to or wider than the I.D. of the pump.
• When handling liquids that generate gas bubbles (sodium hypochlorite or hydrazine solution), install the pump

in a cool and dark place. Flooded suction installation is strongly recommended.

Pipework

Accumulator/Chamber

Pump

Relief valve

Air vent/drain valve

Calibration

cylinder

Tank

Pressure gauge

Back pressure valve

Relief valve

Accumulator/Chamber

Pump

Calibration

cylinder

Air vent/

drain valve

Tank

Back pressure valve

Pressure gauge

Summary of Contents for IX-D Series

Page 1: ...K LTD TEL 44 1743 231363 FAX 44 1743 366507 China Guangzhou GFTZ IWAKI Engineering Trading Co Ltd TEL 86 20 84350603 FAX 86 20 84359181 Italy IWAKI Europe GmbH Italy Branch TEL 39 0444 371115 FAX 39...

Page 2: ...ency is found immediately contact your 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...

Page 3: ...trol 18 AUX function 18 Priming function 18 STOP functions 19 STOP function 19 Pre STOP function 19 Analogue output function 19 Protective functions 20 Interlock function 20 Diaphragm rupture detectio...

Page 4: ...ation 34 Before operation 34 Points to be checked 34 Retightening of pump head fixing bolts 34 Commissioning 35 Before a long period of stoppage One month or more 35 Perform a calibration 36 Calibrati...

Page 5: ...agm replacement 63 Exploded view 67 Pump head Drive unit Control unit 67 Pump head 68 IX D150 TC TE N 68 IX D300 TC TE N 69 IX D150 TC TE FA 70 IX D300 TC TE FA 71 IX D150 D300 S6 N 72 IX D150 D300 S6...

Page 6: ...Caution Prohibited actions and specific Requirement Indicates mishandling could lead to personal injury or prop erty damage CAUTION Caution marks Prohibition mark Requirement mark Safety instructions...

Page 7: ...t is not the manufacturer s responsibility for any failure or injury resulting from alterations to the pump Ne pas modifier la pompe Ne jamais modifier une pompe sous peine de causer un incident grave...

Page 8: ...as appliquer une autre tension que celle sp cifi e sur la plaque sig nal tique sinon il peut en r sulter une panne ou une incendie Assurez vous galement de la mise la terre de la pompe Keep electric p...

Page 9: ...et ez et installez un d tecteur de fuites la terre Preventative maintenance Follow instructions in this manual for replacement of wear parts Do not disassemble the pump beyond the extent of the instru...

Page 10: ...undation concrete and fasten anchor bolts securely to prevent vibration during operation Si plusieurs pompes sont install es ensemble elles interagissent et les vibrations peuvent devenir importantes...

Page 11: ...P65 quivalent mais n est pas compl tement tanche Ne pas laisser la pompe couverte de liquide pomp ou sous la pluie Il pour rait y avoir des rat s ou pr judices Si la pompe a t mouill e sechez la direc...

Page 12: ...s the flow rate Motor rotation is transmitted to an eccentric cam through a reduction gear and then converted to reciprocating motion Volumetric change occurs in the pump chamber as the diaphragm move...

Page 13: ...batch or interval batch operation programming Multivoltage operation The IX series can be used in all countries thanks to the universal power voltage 100 240VAC Safety design A diaphragm rupture dete...

Page 14: ...key To return to the flow rate display push the key The left graph shows the flow rate at each pattern a 4 20mA b 20 4mA c 0 20mA d 20 0mA The flow rate falls to 0mL H if the pump runs beneath the mi...

Page 15: ...SP 2 Ampere 17mA Flow rate 255L H BOX A stroke flow rate changes with a current value by a programmed line The rate does not exceed the Set Point 2 but then falls to 0 before the Set Point 1 Condition...

Page 16: ...educed to zero In this control mode the pump runs at the MAN speed the pump speed in the manual mode The pump behaviour can change depending on the setting of the buffer See below When the buffer is O...

Page 17: ...lation is cleared when the key is pushed once Pulse input by the key 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...

Page 18: ...a the AUX terminal See page 51 This function works only when the pump is running in either MAN or EXT mode see page 40 The pump returns to the MAN or EXT mode once the AUX signal stops Priming functio...

Page 19: ...signal from a level sensor The operation LED changes from green to orange colour when the pump is receiving the Pre STOP signal from a level sensor in operation See page 32 STOP IN for wiring diagram...

Page 20: ...ied the leak sensor is no longer usable In this case a leak from the drain port is the only valid indicator In either case replace the diaphragm immediately when a leak is found Pressure overload Fail...

Page 21: ...MAX OUT Pos through the Other Features menu in order to extend the pump shaft to the maximum Select MAX IN Pos to contract it to the minimum and mount the pump head See page 63 Diaphragm replacement f...

Page 22: ...icks once to close it Bolt cover Take out the cover to remove the pump head Drain port Vent hole Chemical liquid will be released from here Do not plumb this drain port to a supply tank with sodium hy...

Page 23: ...An operational status a selected mode and programmed values are shown here Start Stop key Used for starting stopping the pump operation or moving back to the MAN EXT selection ESC key Used for cancell...

Page 24: ...t state in manual mode A wait state in EXT mode ana logue control MAN EXT selec tion Menu screen or Pressure overload protection is ac tive Pressure overload protection is ac tive Diaphragm is bro ken...

Page 25: ...DM EPDM is not a wet end EPDM is not a wet end Material code PVDF Polyvinylidene difluoride PPS Poly Phenylene Sulfide CE Ceramics FKM Fluorine contained rubber PTFE Polytetrafluoroethylene EPDM Ethyl...

Page 26: ...ditions suspend operation immediately and inspect solve problems Do not place explosive or flammable material near the pump Use of a damaged pump could lead to an electric shock or death Pump mounting...

Page 27: ...rate gas bubbles sodium hypochlorite or hydrazine solution install the pump in a cool and dark place Flooded suction installation is strongly recommended Pipework Accumulator Chamber Pump Relief valve...

Page 28: ...the diaphragm back Liquid in the drain tank is the sign of the damaged diaphragm Immediate inspection or repair is necessary Do not leave this condition as it is Fumes or vapors from certain solutions...

Page 29: ...eplate 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 wirin...

Page 30: ...precautions for ON OFF control by a mechanical relay Apply power sharply Do not apply gradually Surge voltage The electronic circuit in the control unit may fail due to a surge voltage Do not place t...

Page 31: ...s for detail Signal wire connection Points to be checked 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 s...

Page 32: ...ptional cable The terminal 5 is an output and is not used Do not short circuit this terminal to COM 4 STOP IN To activate STOP function connect signal wires to the STOP terminal via the DIN 4 pin conn...

Page 33: ...ignal 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 interlock motor overload drive err...

Page 34: ...Power voltage range is correct Electrical wiring is correct and is free from the risk of short circuit and electrical leakage Retightening of pump head fixing bolts Important The pump head fixing bolt...

Page 35: ...ain line 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 pump...

Page 36: ...l flow rate Calibration is made to determine liquid volume per shot Arrange your piping system according to the guide below to ensure the calibration is made correctly Suggested piping layout Use a ca...

Page 37: ...in the manual mode See page 13 for detail NOTE The calibration accuracy won t change at any flow rate The higher the flow rate is the shorter time it takes and vice versa Select the calibration mode...

Page 38: ...he UP and DOWN keys to set the volume reduction Push the Enter key once The screen shows flow volume per shot The screen shows ERROR Volume Out Of Range if the reduction is too little or too large Ent...

Page 39: ...Pump OFF Leak detection Enable Disable Enable Alarm OUT 1 Batch Complete STOP Pre STOP Interlock Leak Detection Motor Overload Drive Error Leak Detection Enable Other alarms Disable OUT 2 Volume Prop...

Page 40: ...tting with the pump calibrated turn on power while pressing the ESC key Operation programming Wait state Operation MAN mode EXT mode Menu screen MAN EXT selection Power ON Use keys to scroll MAN mode...

Page 41: ...SP1 and 2 flow rates to configure the analog signal output behaviour See page 46 Alarm output setting OUT 1 Enable or disable the output of the batch completion STOP Pre STOP interlock diaphragm rupt...

Page 42: ...e 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 EX...

Page 43: ...rol 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 Analog...

Page 44: ...to confirm key to return to menu screen key to select key to change values Calibration See page 37 Calibration process for detail Interval batch control Set Day Set Hour Set Minute Set a flow rate Pro...

Page 45: ...STOP function key to confirm key to return to menu screen key to scroll key to change values Function setting screen Function selection screen Signal input setting Closed Pump OFF Operation LED lights...

Page 46: ...nge 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 return to menu scree...

Page 47: ...input of the completion signal Disable OUT1 is inactive Enable OUT1 is activated at input of STOP signal Output setting screen Output selection screen Alarm output setting OUT 1 Mechanical relay STOP...

Page 48: ...OP 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 detectio...

Page 49: ...in the same way as the OUT 1 Disable OUT2 is inactive Enable OUT2 is activated to make the pulse signal Alarm output setting OUT 2 PhotoMOS relay Output selection screen Output setting screen STOP fu...

Page 50: ...rmation Operation programming 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 m...

Page 51: ...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 Programming of other functions To ne...

Page 52: ...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 Either one of the above...

Page 53: ...Operation Operation programming 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 necessar...

Page 54: ...y to select MAN and the Enter key to enter that choice The pump enters a waiting state Use the UP and DOWN keys to set the flow rate Push the start stop key to start operation The operation LED lights...

Page 55: ...hen the key is pushed Push the key to return The operation LED turns green during operation AUX function Operation at an AUX speed starts while receiving the external signal via the AUX terminal when...

Page 56: ...operation This function is available at any time except when the menu screen is opened Keypad lock activation Press and hold both the right and left keys for 3 seconds 3 sec KEY LOCKED appears on the...

Page 57: ...n 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...

Page 58: ...Replace as necessary A ball valve is stuck on a valve seat Dismantle inspect and clean the valve Replace as necessary A vale seat has been pressed in the valve guide Do not push the valve seat into t...

Page 59: ...lowing points 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...

Page 60: ...u tion spray Rinse wet ends thoroughly with tap water Every time the pump head is dismantled replace the diaphragm and the valve sets with new ones Wear part list Pump head Parts of parts Estimated li...

Page 61: ...8 Inlet IX0097 7 IX0094 3 IX0088 2 IX0087 4 IX0090 7 IX0094 5 IX0091 Outlet Inlet 7 IX0094 6 IX0092 2 sets 8000 hours Valve set S6 type IX0103 10 IX0102 3 IX0100 2 IX0099 10 IX0102 4 IX0101 10 IX0102...

Page 62: ...aintains the higher pressure than the atmospheric pressure Valve set replacement Remove pipes from the pump NOTE Be careful not to get wet with residual chemicals in piping Rinse chemicals or crystals...

Page 63: ...must be held in the valve guide by the seat holder when assembling an IX D150 D300 TC TE valve set Do not push the valve seat down into the valve guide Otherwise a leak may result Connect pipes and th...

Page 64: ...age of LEAK DETECTED the diaphragm has been fully extended In this instance skip to the next step Select Diaphragm Pos through the menu screen and push the Enter key See page 51 for detail Select MAX...

Page 65: ...pump shaft and tighten it until bottoms out and will not turn further NOTE If it is fitted loose failure may result Retract the pump shaft by keypad operation Push the Enter key Select Diaphragm Pos...

Page 66: ...hten the nuts NOTE Check if the valve set mounting direction is correct Both the valve sets must be oriented to the same direction Go back to the waiting state Push the Enter key once to shift to the...

Page 67: ...Control unit Do not dismantle the pump beyond the extent shown in the diagram below Pump head material and size differ with models Exploded view Pump Pump head Nut Valve set Nut Valve set Retainer Dia...

Page 68: ...at holder 1 6 In seat holder 1 7 O ring 4 8 O ring 2 19 Hex socket head bolt 2 20 Hexagon head bolt 6 21 Spring washer 6 22 Plain washer 6 28 Bolt cover 1 29 Reinforcing plate 1 30 Diaphragm 1 31 Reta...

Page 69: ...Out seat holder 1 6 In seat holder 1 7 O ring 6 19 Hex socket head bolt 2 20 Hexagon head bolt 6 21 Spring washer 6 22 Plain washer 6 28 Bolt cover 1 29 Reinforcing plate 1 30 Diaphragm 1 31 Retainer...

Page 70: ...eat holder 1 6 In seat holder 1 7 O ring 4 8 O ring 2 19 Hex socket head bolt 2 20 Hexagon head bolt 6 21 Spring washer 6 22 Plain washer 6 28 Bolt cover 1 29 Reinforcing plate 1 30 Diaphragm 1 31 Ret...

Page 71: ...at 2 5 Out seat holder 1 6 In seat holder 1 7 O ring 6 19 Hex socket head bolt 2 20 Hexagon head bolt 6 21 Spring washer 6 22 Plain washer 6 28 Bolt cover 1 29 Reinforcing plate 1 30 Diaphragm 1 31 Re...

Page 72: ...Valve seat 2 10 Valve gasket 6 20 Hexagon head bolt 6 21 Spring washer 6 22 Plain washer 6 30 Diaphragm 1 31 Retainer plate 1 55 Setting flange 2 73 Fitting 2 83 Hexagon head bolt 8 84 Spring washer 8...

Page 73: ...3 Valve guide 2 4 Valve seat 2 10 Valve gasket 6 20 Hexagon head bolt 6 21 Spring washer 6 22 Plain washer 6 30 Diaphragm 1 31 Retainer plate 1 45 Flange unit 2 83 Hexagon head bolt 8 84 Spring washer...

Page 74: ...t rated voltage and ambient temperature Pressure overload protection will stop operation when a discharge pressure has risen 1 3 to 2 times higher than the maxi mum level Allowable room temperature 0...

Page 75: ...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 voltage contact or open collector...

Page 76: ...ter dimensions Outer dimensions IX D150 D300 TC TE N TB A B C D E F G IX D150 317 108 42 409 450 144 472 IX D300 384 74 52 415 467 151 489 A B 15 20 194 183 C G E 513 282 D 174 9 107 5 59 50 50 9 F Ce...

Page 77: ...ecifications Outer dimensions IX D150 D300 TC TE N RF A B C D E F G IX D150 317 108 42 409 450 144 465 IX D300 384 74 52 415 467 151 482 A B 15 20 194 140 247 C G E 282 D 174 9 107 5 59 50 50 9 F Cent...

Page 78: ...78 IX D150 D300 TC TE FA TB A B C D E F G IX D150 340 97 409 144 IX D300 383 74 415 151 Specifications Outer dimensions A B 15 20 194 183 513 282 D 174 9 107 5 59 50 50 9 F Centre of inlet outlet...

Page 79: ...ecification IX D150 D300 TC TE FA RF A B C D E F G IX D150 340 97 409 144 IX D300 383 74 415 151 Specifications Outer dimensions A B 15 20 194 140 247 282 D 174 9 107 5 59 50 50 9 F Centre of inlet ou...

Page 80: ...D300 S6 N TB A B C D E F G IX D150 315 108 30 401 431 136 460 IX D300 355 88 37 408 445 143 467 Specifications Outer dimensions A B 15 20 194 183 C G E 513 282 D 174 9 107 5 59 50 50 9 F Centre of in...

Page 81: ...IX D150 D300 S6 N RF A B C D E F G IX D150 315 108 30 401 431 136 453 IX D300 355 88 37 408 445 143 460 Specifications Outer dimensions A B 15 20 194 140 247 C G E 282 D 174 9 107 5 59 50 50 9 F Centr...

Page 82: ...82 IX D150 D300 S6 FA TB A B C D E F G IX D150 363 84 401 136 IX D300 405 63 408 143 Specifications Outer dimensions A B 15 20 194 183 513 282 D 174 9 107 5 59 50 50 9 F Centre of inlet outlet...

Page 83: ...Specification IX D150 D300 S6 FA RF A B C D E F G IX D150 363 84 401 136 IX D300 405 63 408 143 Specifications Outer dimensions A B 15 20 194 140 247 282 D 174 9 107 5 59 50 50 9 F Centre of inlet out...

Page 84: ...K LTD TEL 44 1743 231363 FAX 44 1743 366507 China Guangzhou GFTZ IWAKI Engineering Trading Co Ltd TEL 86 20 84350603 FAX 86 20 84359181 Italy IWAKI Europe GmbH Italy Branch TEL 39 0444 371115 FAX 39...

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