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Operating instructions

Peristaltic Pump ISI Series

6. Assemble the flanges.

7. Mount the front cover.

8. Turn the rotor with the help of the mo-

tor so that the remaining roller presses
against the pump hose.

9. Dismount the front cover.

10. Re-attach the second roller with shims

back onto the rotor.

11. Apply grease manually to the new hose,

as shown in the photo. Rollers will
spread grease evenly over hose when
rotor rotates.

6

8

10

11

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Summary of Contents for ISI 10

Page 1: ...Operating instructions ISI Series Peristaltic pump ALL THE HOSE PUMP YOU LL EVER NEED ...

Page 2: ...hoses and accessories reflect what hose pump customers really need and use after all best is what you want second best should never be an option We hope you ll find using your realax pump simple trouble free and that it makes a positive contribution to the success of your process If you have any questions you can t find answers to in these pages check our website or call your local representative ...

Page 3: ...Safety 6 3 Functional description 11 4 Description 12 5 Construction 13 6 Pump hose 14 7 Transport storage 14 8 Assembly commissioning installation 16 9 Maintenance 25 10 Troubleshooting 32 11 Spare parts 34 12 End of life 52 13 Declaration of Conformity 53 14 Warranty 54 15 Where to buy 55 ...

Page 4: ...y additional future standard 1 1 How to use this manual This manual is intended as a reference book by means of which qualified users are able to install commission and maintain the hose pumps mentioned on the front cover 1 2 Original instructions The original instructions for this manual have been written in English Other language versions of this manual are a translation of the original instruct...

Page 5: ...cific adjustments installation maintenance or repair jobs which fall beyond the scope of this manual contact your AxFlow representative Make sure you have the serial number hose pump at hand 1 5 Environment and disposal of waste Enquire within your local government about the possibilities for reuse or environment friendly processing of packaging materials contaminated lubricant ...

Page 6: ...ce with the intended use In case of doubt it is the use which appears to be its intended use judging from the construction execution and function of the product Observing the instructions in the user s documentation also belongs to intended use Only use the pump in conformance with the intended use described above The manufacturer cannot be held responsible for damage or harm result ing from use t...

Page 7: ... should therefore guarantee that the pump is transported installed put in service used maintained and repaired by qualified personnel who should possess Specific training and sufficient experience for the tasks Knowledge of the technical standards and applicable laws Knowledge of the national and local safety and installation standards Any work carried out on the electrical part of the pump should...

Page 8: ...e fatal or very serious injuries Risk mitigation ensure that there can be no unauthorized access to the pump or to the system Hazardous media contamination of persons and equipment Possible consequences fatal serious injuries Material damage Ensure that the pump hoses are chemically resistant against the media being handled Always observe the safety data sheets for the media to be handled The syst...

Page 9: ...switch the pump on if the front cover has been attached Do not carry out any maintenance operations or dismantle the pump without first making sure that the pipes are not under pressure and are empty or isolated In the case of the hose becoming stuck during extraction or fitting it is necessary to reverse the direction of the pump re lubricate and then repeat the operation As the peristaltic pump ...

Page 10: ...ommended maximum temperature Direction of rotation flow direction Possible consequence material damage destruction of the unit The pump s direction of rotation in relation to the desired flow direction must be checked prior to every start Disconnect the pump from the mains Possible consequence personal injury Work may only be carried out on the pump after it has previously been switched off and di...

Page 11: ...rox NB Maximum pressure on suction inlet side is 0 5 bar 7 25 psi approx for ISI 19 The ISI Series has been designed for safe and uncomplicated operation as well as straightforward maintenance The ISI Series can be used for many different media However this pump type is often the optimal solution for abrasive shear sensitive and viscous media Typical areas of use include processes where only a low...

Page 12: ... Max Capacity Continuous Duty m3 h 0 10 0 16 0 38 0 52 1 GPM 0 42 0 70 1 67 2 29 4 40 Max Capacity Intermittent Duty m3 h 0 13 0 19 0 44 0 78 1 15 GPM 0 55 0 82 1 94 3 43 5 06 Capacity per Revolution l rev 0 02 0 04 0 09 0 12 0 25 Gal rev 0 01 0 01 0 02 0 03 0 07 Max Permissable Working Pressure bar 8 2 8 Permissable Ambient Temperature ºC 40 to 40 40 40 to 40 Permissable Product Temperature ºC 10...

Page 13: ...s serves to suck the media and convey it into the metering line Fig 1 Diagram of functional principle 1 Pump housing 2 Rotor 3 Rollers 4 Hose 4 3 Identification of the gearbox B The gearbox has an identity plate with the model serial number and manufacturer s details as well as information relevant to its function such as reduction ratio 4 4 Identification of the electric motor C The motor has an ...

Page 14: ...er No one black NBR Nitrile rubber Red EPDM EPDM Blue CSM Hypalon Green NBR A Nitrile rubber food grade White NR A Available for ISI 10 and ISI 13 Natural rubber food grade Black TUBE TYPE TUBE MATERIAL COLOUR STRIPE NORPRENE Norprene food N A SILICONE Silicone N A TYGON only ISI 19 Tygon N A 7 TRANSPORT AND STORAGE 7 1 Transport The pump is protected by cardboard packaging or a wooden crate The p...

Page 15: ...orage periods of longer than 30 days protect the coupling surfaces clamps reducers motors with adequate anti rust protection For storage periods longer than 6 months rotate the rotor a few turns to prevent damage to bearings and oil seals and to prevent grease migration Spare hoses should be stored in a dry place away from direct light 7 4 Elevation ISI pumps sizes can be lifted manually ISI 22 pu...

Page 16: ...Temp C Feed chemical Min Temp C Environment Max Pressure bar NORPRENE SILICONE 10 90 20 2 TYGON only ISI 19 70 At max temperature the life of hose is drastically reduced Please contact authorized distributor for applications in temperature range higher than 60 o C 8 2 Commissioning 8 2 1 Testing prior to commissioning the pump The following tests are to be carried out Check that the rollers are co...

Page 17: ...ed rated values Ensure that the hose is suitable for the fluid to be conveyed and that it is not damaged Make sure that the temperature of the liquid does not exceed the recommended temperature range Ensure that there is enough space for free airflow around the motor Ensure that no nearby objects or direct sunshine radiate additional heat to the motor 8 3 1 Suction side Install a manometer in the ...

Page 18: ...mended to use flexible piping between the fixed pipes and the hydraulic connections of the pump in order to avoid the transmission of vibrations Maximum pressure on suction inlet side is 3 bar 45 psi approx 8 3 2 Maximum permissible loads on the pump flange Pump must be bolted to floor before applying loads to connections flanges F1 F2 F3 Maximum permissible loads on the pump flange FORCE UNIT ISI...

Page 19: ...is recommended in the event of viscous liquids It is recommended to use flexible piping between the fixed pipes and the hydraulic connections of the pump in order to avoid the transmission of vibrations Install a pressure relief valve or a pressure switch or similar device in the pressure line in order to protect the pump in the event that a valve is unintentionally closed off or the line is block...

Page 20: ...mpression force of the pump hose can be adjusted by placing a number of shims under the pressing rollers The shims 2 are fitted between the rotor 1 and the pressing roller 3 The number of shims will vary for each counter pressure situation Shims placement ISI 22 Hose compression 1 Hose without compression 2 Insufficient compression back flowing media in the cavity will destroy the hose within a sh...

Page 21: ...9 0 5 1 1 1 1 1 Number of shims 2 0 1 1 1 1 1 4 0 2 1 1 1 1 6 0 2 2 2 N A N A 8 0 3 2 N A N A N A Factory default setting if working pressure is not specified N A Outside standard opera ting range of pump Hose materials NORPRENE SILICONE One 2 5 mm shim can be used part number AX102 01 16 alternatively five 0 5 mm shims can be used part number AX102 01 49 for a total of 2 5 mm NOTE for fluid tempe...

Page 22: ... A 8 0 3 2 N A N A N A Factory default setting if working pressure is not specified N A Outside standard operating range of pump Hose materials NORPRENE SILICONE One 2 5 mm shim can be used part number AX102 01 16 alternatively five 0 5 mm shims can be used part number AX102 01 49 for a total of 2 5 mm NOTE for fluid temperatures 60 ºC reduce shim quantities by 1 Bar Revolutions minute 0 19 20 39 ...

Page 23: ...ONE One 2 5 mm shim can be used part number AX101 02 42 plus four 0 5 mm shims can be used part number AX101 02 35 for a total of 4 5 mm NOTE for fluid temperatures 60 ºC reduce shim quantities by 1 Bar Revolutions minute 0 19 20 39 40 59 60 79 80 99 0 5 1 4 1 4 1 4 1 4 1 4 Number of shims 2 0 1 4 1 4 1 4 1 4 1 4 Factory default setting if working pressure is not specified N A Outside standard ope...

Page 24: ...A N A 8 0 4 3 N A N A N A Factory default setting if working pressure is not specified N A Outside standard operating range of pump Hose materials NORPRENE SILICONE One 5 mm shim part number AX113 00 37 plus two 0 5 mm shims part number AX113 00 33 can be used for a total of 6 mm NOTE for fluid temperatures 60 ºC reduce shim quantities by 1 Bar Revolutions minute 0 19 20 39 40 59 60 79 80 99 0 5 1...

Page 25: ...bs Pump cover 0 11 kg 0 24 lbs 3 26 kg 7 19 lbs 3 58 kg 7 89 lbs Roller subassembly 0 30 kg 0 66 lbs 0 60 kg 1 32 lbs 1 06 kg 2 34 lbs Connection 0 08 kg 0 18 lbs 0 14 kg 0 31 lbs 0 20 kg 0 44 lbs Press flange 0 05 kg 0 11 lbs 0 07 kg 0 15 lbs 0 10 kg 0 22 lbs Hose 0 16 kg 0 35 lbs 0 33 kg 0 73 lbs 0 70 kg 1 54 lbs 9 2 Torque values ...

Page 26: ...r D Flange bracket bolts Nm 2 M6 Allen Key Size 5 4 M8 Allen Key Size 6 4 M8 Allen Key Size 6 E Drive shaft bolts Nm 33 M6 Allen Key Size 5 33 M6 Allen Key Size 5 43 M10 17 mm Spanner 9 3 Lubrication and cooling ISI Pumps only require a thin film of grease to reduce the friction between the roller and the outer surface of the Hose or Tube No other lubrication is necessary Lubricant quantity table ...

Page 27: ...contact the gearbox manufacturer or their authorised distributor in your country 9 4 Exchanging the pump hose 9 4 1 Dismantling Close off all valves in order to prevent leakage of the feed liquid 1 Dismantle the pipes from both discharge and suction sides 2 Remove the front cover Front covers of ISI Series can be removed manually 3 kg 3 Remove the roller incl roller support the roller that is not ...

Page 28: ...ic Pump ISI Series 4 Rotate the rotor 180 to liberate the hose Flange connection 5 Remove the press and connection and hydraulic connections from pump housing 6 Remove the pump hose to be exchanged 7 Dismount the connections of the hose ...

Page 29: ...ing insert the connections into the replaced tube 4 Lubricate with our original lubricant the hose and at the contact surfaces between the pump hose and the external part of the new hose 5 Lay the pump hose into the pump housing through the connection holes The hoses of the ISI pumps must be manually inserted through the lower opening up to the point where the hose begins to be compressed by the r...

Page 30: ...tor with the help of the mo tor so that the remaining roller presses against the pump hose 9 Dismount the front cover 10 Re attach the second roller with shims back onto the rotor 11 Apply grease manually to the new hose as shown in the photo Rollers will spread grease evenly over hose when rotor rotates 6 8 10 11 ...

Page 31: ...hey could be disas sembled from the pump housing The pump is stable on its baseplate and will not fall over when the electric motor and gear reducer are disassembled No support set is necessary 9 6 Addition of leak detection sensor Detection sensor must be requested in initial order so that an additional hole is drilled in the pump housing Standard ISI pump housing is not prepared for retrofitting...

Page 32: ...antity in storage container Fill storage container or exchange pump Insufficient diameter on the suction side Increase the diameter on the suction side as far as possible Suction line too long Shorten the suction line as far as possible High viscosity of medium Reduce viscosity as far as possible Air introduction in the suction connections Check connections and accessories for air tightness High p...

Page 33: ...Use realax lubricant Insufficient quantity of grease Reapply lubricant Pump hose pulled into the pump housing High inlet pressure 3 bar Reduce inlet pressure Pump hose filled with deposits Clean or replace the pump hose Holder press connection insufficiently tightened Re tighten holder press connection Insufficient grease Reapply lubricant The pump does not start up Insufficient motor performance ...

Page 34: ...34 Operating instructions Peristaltic Pump ISI Series 11 Spare parts 11 1 Spare parts exploded ISI 10 Model ...

Page 35: ...ISI 10 2 AX102 00 20 5 Peristaltic Hose NR ISI 10 1 AX102 00 27 Peristaltic Hose NR A ISI 10 1 AX102 00 32 Peristaltic Hose NBR ISI 10 1 AX102 00 28 Peristaltic Hose NBR A ISI 10 1 AX102 00 29 Peristaltic Hose EPDM ISI 10 1 AX102 00 30 Peristaltic Hose CSM ISI 10 1 AX102 00 33 6 Plastic Cover 1 AX102 02 08 7 Base plate 1 AX102 00 12 Base plate S S 1 AX102 00 24 8 Drive 1 9 Cover Gasket 1 AX102 01 ...

Page 36: ...36 Operating instructions Peristaltic Pump ISI Series 11 2 Spare parts exploded ISI 10 Model NORPRENE SILICONE ...

Page 37: ... S TRI CLAMP 1 2 ISI 10 2 AX102 00 22 Connection SS SMS25 ISI 10B 2 AX102 00 21 Connection DIN 11851 NW 10 ISI 10 2 AX102 00 20 5 Peristaltic Hose NORPRENE ISI 10 1 AX102 00 31 Peristaltic Hose SILICONE ISI 10 1 AX102 00 45 6 Plastic Cover 1 AX102 02 08 7 Base plate 1 AX102 00 12 Base plate S S 1 AX102 00 24 8 Drive 1 9 Cover Gasket 1 AX102 01 05 10 DIN 931 Hexagonal Head Partially threaded Cap Sc...

Page 38: ...38 Operating instructions Peristaltic Pump ISI Series 11 3 Spare parts exploded ISI 13 Model ...

Page 39: ...5 ISI 13 2 AX103 00 20 5 Peristaltic Hose NR ISI 13 1 AX103 00 27 Peristaltic Hose NR A ISI 13 1 AX103 00 33 Peristaltic Hose NBR ISI 13 1 AX103 00 28 Peristaltic Hose NBR A ISI 13 1 AX103 00 29 Peristaltic Hose EPDM ISI 13 1 AX103 00 30 Peristaltic Hose CSM ISI 13 1 AX103 00 32 6 Plastic cover 1 AX102 02 08 7 Base plate 1 AX102 00 12 Base plate S S 1 AX102 00 24 8 Drive 1 9 Cover Gasket 1 AX102 0...

Page 40: ...40 Operating instructions Peristaltic Pump ISI Series 11 4 Spare parts exploded ISI 13 Model NORPRENE SILICONE ...

Page 41: ...9 Connection S S TRI CLAMP 3 4 ISI 13 2 AX103 00 22 Connection S S DIN 11851 NW 15 ISI 13 2 AX103 00 20 5 Peristaltic Hose NORPRENE ISI 13 1 AX103 00 31 Peristaltic Hose SILICONE ISI 13 1 AX103 00 38 6 Plastic cover 1 AX102 02 08 7 Base plate 1 AX102 00 12 Base plate S S 1 AX102 00 24 8 Drive 1 9 Cover Gasket 1 AX102 01 05 10 DIN 931 Hexagonal Head Partially threaded Cap Screw M6x30 4 AXTORDIN931M...

Page 42: ...42 Operating instructions Peristaltic Pump ISI Series 11 5 Spare parts exploded ISI 16 Model ...

Page 43: ...S SMS 25 ISI 16 2 AX101 00 20 Connection S S DIN 11851 NW20 ISI 16 2 AX101 00 19 5 Peristaltic Hose NR ISI 16 1 AX101 00 26 Peristaltic Hose NBR ISI 16 1 AX101 00 27 Peristaltic Hose NBR A ISI 16 1 AX101 00 32 Peristaltic Hose EPDM ISI 16 1 AX101 00 28 Peristaltic Hose CSM ISI 16 1 AX101 00 33 6 Metallic cover 1 AX101 03 11 7 Plastic cover 1 AX101 00 12 8 Base plate 1 AX101 00 24 Base plate S S 1 ...

Page 44: ...44 Operating instructions Peristaltic Pump ISI Series 11 6 Spare parts exploded ISI 16 Model NORPRENE SILICONE ...

Page 45: ...18 Connection S S TRI CLAMP 1 ISI 16 2 AX101 00 21 Connection S S SMS 25 ISI 16 2 AX101 00 20 Connection S S DIN 11851 NW20 ISI 16 2 AX101 00 19 5 Peristaltic Hose NORPRENE ISI 16 1 AX101 00 30 Peristaltic Hose SILICONE ISI 16 1 AX101 00 54 6 Metallic cover 1 AX101 03 11 7 Plastic cover 1 AX101 00 12 8 Base plate 1 AX101 00 24 Base plate S S 1 AX101 00 25 9 Drive 1 10 Cover gasket 1 AX101 02 40 11...

Page 46: ...46 Operating instructions Peristaltic Pump ISI Series 11 7 Spare parts exploded ISI 19 Model NORPRENE TYGON ...

Page 47: ...0 18 Connection PVC NPT 1 ISI 19 2 AX105 00 22 Connection S S TRI CLAMP 1 ISI 19 2 AX105 00 21 Connection S S DIN 11851 NW25 ISI 19 2 AX105 00 19 5 Peristaltic Tube NORPRENE ISI 19 1 AX105 00 27 Peristaltic Tube TYGON ISI 19 1 AX105 00 26 6 Metallic cover 1 AX101 03 11 7 Plastic cover 1 AX101 00 12 8 Base plate 1 AX101 00 24 Base plate S S 1 AX101 00 25 9 Drive 1 10 Cover gasket 1 AX101 02 40 11 D...

Page 48: ...48 Operating instructions Peristaltic Pump ISI Series 11 8 Spare parts exploded ISI 22 Model ...

Page 49: ...nnection S S DIN 11851 NW 25 ISI 22 2 AX113 00 16 5 Peristaltic Hose NR ISI 22 1 AX113 00 24 Peristaltic Hose NBR ISI 22 1 AX113 00 25 Peristaltic Hose NBR A ISI 22 1 AX113 00 26 Peristaltic Hose EPDM ISI 22 1 AX113 00 27 Peristaltic Hose CSM ISI 22 1 AX113 00 30 6 Metallic Cover 1 AX113 01 08 7 Plastic Cover 1 AX113 00 09 8 Base plate 1 AX113 00 21 Base plate S S 1 AX113 00 22 9 Cover Gasket 1 AX...

Page 50: ...50 Operating instructions Peristaltic Pump ISI Series 11 9 Spare parts exploded ISI 22 Model NORPRENE SILICONE ...

Page 51: ...ISI 22 2 AX113 00 18 Connection S S SMS 25 ISI 22 2 AX113 00 17 Connection S S DIN 11851 NW 25 ISI 22 2 AX113 00 16 5 Peristaltic Hose NORPRENE ISI 22 1 AX113 00 28 Peristaltic Hose SILICONE ISI 22 1 AX113 00 42 6 Metallic Cover 1 AX113 01 08 7 Plastic Cover 1 AX113 00 09 8 Base plate 1 AX113 00 21 Base plate S S 1 AX113 00 22 9 Cover Gasket 1 AX113 00 36 10 Drive 1 11 DIN 912 Socket Cap Screw M8x...

Page 52: ... recycled Pump housing Rotor and rollers Baseplate Drive Some specialist disassembly may be required 12 2 Recycling and or Repurposing The following components even when cleaned must still be prepared for special waste disposal Customer is responsible to follow local legislation for reuse or environ mentally friendly processing of packaging materials contaminated lubricant oil and the following co...

Page 53: ...53 13 Declaration of Conformity ...

Page 54: ...deliv ery This guarantee does not cover the hose or the lubricant as these are elements that have a normal function wear irrespective of their duration This guarantee is valid as long as the equipment is operated in accord ance with this document This guarantee includes materials and work but not the cost for transpor tation of the equipment to the authorized repair shop or its return to the custo...

Page 55: ...k 30e 2241 Spodnji Duplek Tel 386 2 684 00 60 Fax 386 2 681 01 62 E Mail vip tehnika siol net www vip tehnika si Für weitere Informationen und umfassenden Service wenden Sie sich bitte an Beratung Verkauf und Service AxFlow GmbH Theodorstrasse 105 40472 Düsseldorf Deutschland Tel 49 211 23806 0 E mail info axflow de Service Stützpunkt und Werkstatt AxFlow Service Süd Kiryat Shmona Straße 11 87700 ...

Page 56: ...fo axflow it www axflow it Aby uzyskać więcej informacji na temat pomp realax węża prosimy o kontakt AxFlow Sp z o o ul Floriana 3 5 04 664 Warszawa Telefon centrala 48 613 00 12 Wsparcie techniczne Pompy wewn 223 lub kom 48 691 978 211 wewn 254 lub kom 48 667 856 565 Wsparcie techniczne części zamienne wewn 218 lub kom 48 667 808 878 Pompy rejon Północ 48 601 816 003 Pompy rejon Centrum 48 601 35...

Page 57: ...ww axflow rs For service and support to your realax hose pumps please contact AxFlow Services Phone 44 1484 543649 Fax 44 1484 512608 E mail service axflow co uk For more information about realax hose pumps please contact AxFlow London head office Orion Park Northfield Ave Ealing London W13 9SJ Phone 44 20 85792111 AxFlow Scotland Unit 3 Harlaw Centre Howe Moss Crescent Kirkhill Industrial Estate ...

Page 58: ...e tick if one of the above is applicable include MSDS and if necessary special handling instructions DESCRIPTION OF FAILURE PHOTOS AVAILABLE Yes No The pump s should be emptied and cleaned of any contamination before it is sent In case of a corrosive flammable or toxic product the pumps must be accompanied by a certificate of decontamination Make sure the cleaning product you use is compatible wit...

Page 59: ......

Page 60: ...AHQ IOM EN 0849 1120 www realaxpumps com ALL THE HOSE PUMP YOU LL EVER NEED ...

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