Realax IP Series Manuel utilisateur
Operating instructions
IP Series
Peristaltic pump
ALL THE HOSE PUMP YOU’LL EVER NEED
Congratulations!
And welcome to the world of realax
hose pumps.
Drawing on extensive interaction with real users of peristaltic
pumping technology and examining applications as diverse as
food, water and wastewater, chemicals and pharmaceuticals,
construction and mining, we have tried to tailor our range of
pumps more precisely to your needs.
Our range of hoses and accessories reect 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 nd 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 nd answers to
in these pages, check our website or call your local representative
on the number on the contact page of this guide.
Of course this manual is available in your language.
Please download it from the attached USB ash drive.
Operating instructions Peristaltic Pump IP Series
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TABLE OF CONTENTS
1 Introduction ............................................... 2
2 Safety and Responsibility................................. 4
3 Functional description.................................... 7
4 Transport and Storage .................................... 8
5 Assembly and Installation ................................ 9
6 Commissioning...........................................14
7 Maintenance, repair, malfunctions
disposal and spare parts.................................15
8 Spare parts................................................21
9 Declaration of Conformity...............................33
10 Warranty ..................................................34
Operating instructions Peristaltic Pump IP Series
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1 INTRODUCTION
This manual forms an integral part of the pump and must accompany it
until its demolition. The series IP peristaltic pump is a machine destined
to work in industrial areas and as such the instruction manual must
form part of the legislative dispositions and the applicable technical
standards and does not substitute any installation standard or eventual
additional standard.
Operating instructions Peristaltic Pump IP Series
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1.1 Explanation of the safety information
The instructions of this manual, whose inobservance
is determined as a failure to meet safety standards, are
identied by this symbol .
The instructions of this manual, whose inobservance
compromises electrical safety.
The instructions of this manual, whose inobservance
compromises the correct working of the pump, are
identied with this symbol.
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CAUTION
1.2 Users’ qualifications
Pumps are machines that due to their functioning under pressure and
moving parts can present dangers.
- Improper use.
- Removing the protections and/or disconnecting the protec-
tion device.
- The lack of inspections and maintenance.
They can cause serious damage or injury.
The person in charge of safety should therefore guarantee that the
pump is transported, installed, put in service, used, maintained and
repaired by qualied personnel who should therefore possess:
- Specic training and sufcient experience.
- Knowledge of the technical standards and applicable laws.
- Knowledge of the general national and local safety standards
and also of installation.
Any work carried out on the electrical part of the pump should be
authorized by the person responsible for safety. Given that the pump is
destined to form part of an installation, it is the responsibility of who-
ever supervises the installation to guarantee absolute safety, adopting
the necessary measures of additional protection.
Operating instructions Peristaltic Pump IP Series
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2 SAFETY AND RESPONSIBILITY
2.1 General safety information
Live parts
Possible consequence: Fatal or very serious injuries.
- Measure: The device must be disconnected from
the power supply before it is opened.
- Isolate damaged faulty or manipulated devices
from the mains in order to de-energise.
Emergency stop switch
Possible consequence: Fatal or very serious injuries.
An emergency stop switch is to be connected for the en-
tire plant. This should enable the entire plant to be shut
down in the event of an emergency in such a way that
the overall plant can be brought into a safe condition.
Unauthorized access
Possible consequence: Fatal or very serious injuries.
- Measure: Ensure that there can be no unauthor-
ized access to the unit.
Hazardous media/contamination of persons and
equipment
Possible consequence: Fatal or very serious injuries
material damage.
- Ensure that the pump hoses are resistant against
the media being conveyed.
- Always observe the safety data sheets for the
media to be conveyed. The system operator must
ensure that these safety data sheets are available
and that they are kept up-to-date.
- The safety data sheets for the media being con-
veyed are always decisive for initiating counter-
measures in the event of leakage to the media
being conveyed.
- Observe the general restrictions in relation to
viscosity limits, chemical resistance and density.
- Always switch the pump off before exchanging
the pump hose.
Operating instructions Peristaltic Pump IP Series
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Correct and proper use
Possible consequence: Fatal or very serious injuries.
- The unit is not intended to convey or regulate
gases or solid media.
- Do not exceed the rated pressure, speed or tem-
perature for the pump.
- The unit may only be used in accordance with
the technical data and specications provided in
these operating instructions and in the operating
instructions for the individual components.
- The system is not designed for use in areas of risk
from explosion.
- Only switch the pump on if it has been properly
fastened to the oor.
- Only switch the pump on if it the front cover has
been attached.
- Do not carry out any maintenance operations or
dismantle the pump without rst 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 tting it is necessary to reverse the
direction of the pump, relubricate, and then
repeat the operation.
- As the peristaltic pump is volumetric and its func-
tioning is positive displacement, it is necessary
to prevent a possible overload of pressure, due
to for example, the accidental closure of a valve.
For this reason it is advisable to t a safety device
such as: a safety valve, pressure limiter, etc.
Operational lifetime of the pump hoses
Possible consequence: Fatal or very serious injuries.
The operational lifetime of the pump hoses cannot be
precisely specied. For this reason, the possibility of
fracture and consequential leakage of liquids must be
accounted for. If the hose rupture alarm (optional) is
tted, then the pump can be stopped and / or an elec-
trical valve can be actuated.
CAUTION
CAUTION
Operating instructions Peristaltic Pump IP Series
In addition, as the hose has an indeterminate life and
due to the possibility of its breakage or deterioration,
the user is responsible for the prevention of a possible
(although most unlikely) incorporation of particles
from the hose into the product being pumped. This can
be achieved e.g. by means of ltration, a hose rupture
alarmorothermeans suitablefor therespective process.
CIP cleaning
In the event of CIP cleaning, it is necessary to obtain in-
formation from the manufacturer about correct instal-
lation of the pump (a special installation is required)
as well as regarding the compatibility of the cleaning
agents with the pump hoses and the hydraulic connec-
tions.
Cleaning should be undertaken at the recommended
maximum temperature.
Direction of rotation/flow direction
Possible consequence: Material damage right through
to destruction of the unit.
- The pump’s direction of rotation in relation to the
desired ow direction must be checked prior to
every start.
Disconnect the pump from the mains
Possible consequence: Personal injury.
You may only carry out work on the pump after it has
previously been switched off and disconnected from
the mains.
Environmental influences
Possible consequence: Material damage right through
to destruction of the unit.
- The device is not suitable for outdoor operation
- Take suitable measures to protect the device from
environmental inuences such as:
– UV rays.
– Moisture.
– Frost, etc.
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Operating instructions Peristaltic Pump IP Series
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3 FUNCTIONAL DESCRIPTION
The IP Series is a positive displacement pump. The process uid is con-
veyed by the rotor squeezing the hose in the direction of ow. No valves
are needed for this. This ensures gentle handling of the process uid.
The IP Series has been designed for safe and uncomplicated operation,
as well as straightforward maintenance.
The IP Series can be used for many different media. However, this
pump type is often the optimal solution for abrasive, shear-sensitive and
viscose media.
Typical areas of use include processes where only a low discharge
pressure is required (max. 8 bar).
3.1 Construction
Main modules: – Drive Unit, – Housing, – Base frame
The pump housing is closed off with a screwed front cover in order to
avoid the risk of injury.
The motor serves to drive the rotor. Two rollers at the ends of the rotor
serve to press the pump hose against the pump housing.
The rotary movement of the rotors alternately press and relax the
rollers in relation to the pump hose. This serves to suck the media and
convey it into the process line.
Fig. 1: Diagram of functional principle.
1 Casing 2 Rotor 3 Rollers 4 Hose
Operating instructions Peristaltic Pump IP Series
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4 TRANSPORT AND STORAGE
4.1 Transport
- The pump is protected by a cardboard packaging.
- The packaging materials are recyclable.
4.2 Storage
- The pump should be in a resting position. (The hose should
not be compressed).
- Avoid areas open to harsh weather or excessive humidity.
- For storage periods of longer than 60 days, protect the
coupling surfaces (clamps, reducers, motors) with adequate
anti-oxidant products.
- Spare hoses should be stored in a dry place away from direct
light.
4.3 Lifting
Models IP-30, IP-40, IP-50
- To lift the pump use the
eye bolt.
Models IP-60, IP-70, IP-70D
- To lift the pump, it’s
necessary to use lifting
slings.
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