IWAKI PUMPS AMP Series, AMP 50, AMP 40 Instruction Manual

IWAKI Magnetic Drive Pump

AMP Series

(Asia Edition: English)

Instruction Manual

Read this manual before use of product

Thank you for selecting an Iwaki AMP Series Magnetic Drive Pump. This instruction manual
deals with "Safety instructions", "Outline", "Installation ", "Operation", and "Maintenance"
sections. Please read through this manual carefully to ensure the optimum performance, safety
and service of your pump.

Contents

Important instructions ···································································· 1

Safety instructions ·········································································· 2

Outline 1. Unpacking & Inspection

2. Model code

3. Operating conditions

4. Part names

Installation 1. Before installation

2. Piping

3. Wiring

4. Protection equipment

Operation 1. Before operation

2. Operation

3. Shutdown

Maintenance 1. Troubleshooting

2. Maintenance & Inspection

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5
6
7

8
10
11
14
14
16
17
17
19
21

3. Disassembly & Assembly

4. Spare & Wear parts

This instruction manual should be kept on hand by the end user for

quick reference.

Contact us or your nearest dealer if you have any questions.

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23
29

Important instructions

For the Safe and

Correc t Handl ing of the Pump

●

"Safety Instr uct ion" section deals with important det ails about handling of the product. Before

use, read this section carefully for the prevention of personnel injury or property damage.

●

Observe the instructions accompanied with "WARNING" or "CAUTION" in this manual. These

instructions are very important for protecting users from dangerous situations.

●

Th e symb ol s o n t his ins truc t i on m anu a l h ave the fol lowi ng m e a ni ng s:

Nonobservance or misapplication of “Warning” sec-

WARNING

tions could lead to a serious accident which may
result in death.

Nonobservance or misapplication of “Caution” sec-

CAUTION

tions could lead to a personal injury or property
damage.

Types of Symbols

Indicates that “Warning” or “Caution” must be exercised. Inside this triangle, a con­crete and practical im age provided as a war ni ng or caution message is depicted.

Indicates a prohibited action or procedure. Inside or near this circle, a concrete and
practical image of the activity to be avoided is depicted.

Indicates a n i mp or t a nt ac tion or pro ced u re wh ich must be pe r forme d or ca rried out
without fail. Failure to follow t he inst ructions herein can lead to malfunct ion or
damage to the pump.

For exportation

Technology related to the use of goods in this instruction manual falls in the category of

technology contained in the Foreign Exchange Order Attachment, which includes com-

plementary export control of technology. Please be reminded that export license, which

is issued by the Ministry of Economy, Trade, and Industry could be required, when this is

exported or provided to someone even in Japan.

- 1 -

Safety instructions

WARNING

●

Pay attention to the magnet field

The magnet drive pump has a pair of strong magnets. The strong magnet

field could adversely affect the persons who are assisted by electronic

devices such as the pacemaker.

●

Power OFF

Be sure to turn off the power before starting a maintenance/repair work.

Make sure no one turns on the power while working on the pump, other-

wise it may result in a serious accident. If your work field is noisy or dark,

let other people know about the situation by displaying a notice such as

"POWER OFF (Maintenance)" near the power switch.

●

Wear protective clothing

Always wear protective clothing such as eye protection and protective

gloves during pipework or dismantlement of the pump.

●

When lifting the pump

Chain the pump via eye bolts to lift it up.

●

Do not remodel the pump

Prohibited

Tur ning of f pow er

Wear protective

gear

Do not remodel the pump. We are not responsible for a personal injury or

pump damage due to any modification.

●

When handling dangerous liquid

For the transfer of the harmful liquid as mentioned below, be sure to con-

duct daily inspection and maintenance for the prevention of liquid/gas leak-

age or other failure.

1. Explosive or flammable liquid

2. Corrosive or stimulus toxic liquid

3. Health hazardous liquid

●

Ventilation

Poisoning may result when handling a toxic or odorous liquid. Keep good

ventilation in your operating site.

No Remodeling

- 2 -

Safety instructions

CAUTION

●

Attention to magnetic force

A pair of strong magnets is mounted in the pump and may cause personal
injury. Follow "Disassembly & Assembly" section when dismantling and/or
assembling the pump.

●

Do not run pump dry

Do not run pump dry (Operation without liquid). Friction heart in the dry run­ning causes the pump damage. If the pump is operated with a suction side
valve closed, the pump runs dry.
Note that the CF type of high density carbon bearing can run dry within one hour.

●

Restriction on pump operator

The pump must be handled or operated by a qualified person with a full
understanding of the pump.

●

For a specified application only

Use of the pump in any application other than those clearly specified may
result in pump failure or damage.

●

Static electricity

Take countermeasures to remove the static electricity when low electric
conductivity liquids such as ultra-pure water and fluor inactive liquid (e.g.
Fluorinert
the pump and may cause static discharge.

TM

) are handled. Otherwise, the static electricity may generate in

Prohibited

Prohibited

●

Static electricity

Always run the pump for air elimination before full operation. Note that
hydrogen peroxide and sodium hypochlorite easily generate gas. If the
pump runs without full air elimination, the pump is damaged by friction heat.

●

Countermeasure against efflux

Take a protective measurement against accidental chemical efflux and
splash at pump or piping breakage. Also, take an appropriate measure­ment to prevent accidental outflow from directly soaking into the ground.
Otherwise, It leads to personal injury or environmental damage.

●

Pump disposal

Any used or damaged pump must be disposed of in accordance with local
laws and regulations as an incombustible (Consult a licensed industrial
waste products disposing company.). Neutralize and flush out chemicals
before disposal. Do not incinerate fluororesin parts. Fluororesin emits harm­ful gas when it is burnt and affects human health and environment.

- 3 -

Outline

1. Unpacking & Inspection

2. Model code

3. Operating conditions

4. Part names

- 4 -

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5
6
7
8

Outline

1. Unpacking & Inspection

Pump unit (Liquid feeding section)

Not capable of self-priming:
Before operating the pump, feed liquid
through the suction or discharge port.

On unpacking the product, check the following

points. If you find any problems, contac t your
nearest dealer.

1. Check the information on nameplate and con-

firm the product is delivered as per order.

2. Check for transit damage, deformation, and

loose bolts.

Tighten the rear casing support mounting bolts

to the specified tightening torque. See "13.

Disassembling & Assembling" section for the

specified tightening torque.

3. Check if accessories are included.

Bolt for back pull-out:

M12×100mm (2pcs)

Optional accessories (if ordered):

Spare parts and the dry run protector, etc.

Discharge port

Suction port

Drain port

Drain a liquid into a suitable container.
Follow an applicable local regulation
at disposal of liquid. Never allow the
discharged liquid to flow directly onto
the ground.

Eye bolt

Motor nameplate

Use only the power
voltage specified on the
nameplate. Follow an
applicable local power
regulation.

Nameplate

Foot support

Base plate

CAUTION

When cleaning the pump, do not wipe the nameplates, labels or the pump body with
any solvent.

- 5 -

Outline

2. Model code

AMP40 - 150 1 KK F 075 J - D 2

Pump discharge bore:

Suction Discharge

40: 50 × 40

50: 65 × 50

Nominal impeller diameter: 110 - 165 (mm)

Impeller code: 1

Bearing/Spindle material: KK: SiC/SiC CF: High density carbon/High purity ceramic

Motor type: F: Flanged motor

Motor output: 037: 3.7 kW, 055: 5.5 kW, 075: 7.5 kW

Flange/Motor standards J: JIS pump flange + JIS motor A: ANSI pump flange + JIS motor

Drain/Custom product

Drain

A

Without drain

S
D

With drain

X Custom product
B

Without drain

Y
E

With drain

Z

Number of motor poles: 2: Two pole motor

Base plate Standard or Custom product

Standard

With base plate

Without base plate

Custom product
Standard

Standard
Custom product
Standard
Custom product

NOTE: In this manual, model code is simplified by using pump discharge bore code and

impeller range code .

- 6 -

Outline

3. Operating conditions

1. Permissible pressure

Pump permissible pressure is 1.0MPa. Do not allow the pump discharge pressure to exceed the limit.

2. Slurry liquid

Slurry liquid can not be used except for the KK type of SiC bearing. The KK type can handle slurry in the fol-

lowing conditions:

• Slurry concentration up to 5 wt%

• Slurry hardness up to 80 Hs

• Slurry size up to 50 μm

Contact us for detail before slurry transfer.

NOTE: Not only friction parts but also plastic parts are worn when handling slurry liquid.

Note that periodic pump change is needed.

3. Performance change along with specific gravity and viscosity

Shaft power, discharge capacity and discharge head vary with specific gravity and viscosity. The pump has

been made in accordance with the specified operating condition at order phase. If the operating condition

has been changed since then, contact us before use of the pump.

4. Influence by liquid temperature

Viscosity, vapour pressure and corrosiveness vary with the temperature change. Pay attention to the change

of liquid characteristics.

•

Liquid temperature range: 0-80˚C

•

Ambient temperature range: 0-40˚C

•

Ambient humidity range: 35-85% RH

- 7 -

4. Part names

Outline



  









  









































 









NO. Parts name Q'ty NO. Parts name Q'ty

100.1 Front casing 1 554.2 Spring washer 2

100.2 Cover 1 554.4 Spring washer 8

122.1 Drain plate 1 554.5 Spring washer 4
158 Rear casing 1 554.6 Spring washer 4
159 Rear casing cover 1 554.7 Spring washer 2
161 Rear casing support 1 801 Motor 1
210 Spindle 1 858 Drive magnet unit 1
230 Impeller 1 859 Magnet capsule unit 1
310 Bearing 1 890 Base plate 1

314.1 Liner ling 1 900 Eye bolt 1

314.2 Mouth ring 1 901.1 Hex. head bolt 2

314.3 Rear thrust ring 1 901.2 Hex. head bolt 2

314.4 Rear ring 1 901.4 Hex. head bolt 8
330 Bracket 1 901.5 Hex. head bolt 4

400.1 Gasket 1 901.6 Hex. head bolt 4

400.2 Drain gasket 1 901.7 Hex. head bolt 2

500.1 Plain washer 2 903.1 Hex. head bolt 5

500.2 Plain washer 2 908.1 Hex. socket set screw 2

554.1 Spring washer 2 942 Pin 2

See the construction drawing for details.

- 8 -

Installation

1. Before installation

2. Piping

3. Wiring

4. Protection equipment

- 9 -

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10
11
14
14

1. Before installation

Example of recommended piping

Installation

12

1

12

Discharge pipe

Discharge valve

Check valve

Pressure gauge

Motor

11

2

3

Pump

Flexible joint

Vacuum gauge

Suction pipe

11

10

8

7

Within

4

1m

6

Suction valve

Gate valve

Air vent piping

5

Pipe support

10

13

9

7

1. Installation location

• The pump should be installed on a flat foundation where is free from vibration or torsional force.

• Spacing for the motor removal (for back pull out) and maintenance (assembly and dismantlement) are

needed.

• Installation surface should be larger than the pump base.

2. Positioning

• Install the pump as close to the suction tank in flooded suction system.

• If the flooded suction system can not be realized, install the auxiliary piping for priming and a foot valve at

the suction pipe end.

3. Pump mounting

• See the diagram below for mounting the pump in the foundation.

• For the pump without the base plate, note that the pump can not be dismantled with the foot supports of

the cover and bracket fixed in the foundation.

Foundation bolt

Baseplate

Liner

Liner

Concrete foundation

- 10 -

Installation

2. Piping

■

Tightening torque between discharge/ suction ports and pipes

Connections between the pipes and the pump ports should be tightened according to the table below.

Tightening torque (RV)

Bolt size

M16

■

Piping load and momentum

The permissible piping weight and moment to the pump are as below.

Tightening torque

78.4 N•m

Y

Z

Y

Z

X

X

Permissible stress to the pump flange

Load direction Suction flange

Fx

Fy (Contraction/Tension) 0.58

Fz 0.71

Permissible moment to the pump flange

Load direction

Mx
My 0.35
Mz 0.23

Load kN

Discharge flange

AMP 40 & 50

0.71 0.89

0.89/0.44

0.58

Moment kN · m

Discharge flange

AMP 40 & 50

0.35 0.46

0.46

0.23

AMP 40 & 50

Suction flange

AMP 40 & 50

- 11 -

Installation

■

Suction piping

1. Flooded suction system

Always realize the flooded suction system.

2. Suction piping bore

A suction piping bore should be equal to or larger than pump inlet.

3. Shortest piping length

Have piping shortest with the minimum number of bends.

4. Straight pipe length

The piping end right before the pump inlet should be straight.

When the pump inlet bore is 50A or smaller, the straight pipe length should be of 500 mm or longer

When the pump inlet bore is 65A or larger, the straight pipe length should be eight times longer than inlet

bore. For the easy pump removal and maintenance, install a removable pipe of 300mm in straight piping.

5. Air pocket

Do not make any projection or arched line where air may be trapped.

The suction pipe should be laid on a rising gradient of 1/100 toward the pump.

6. Use of the eccentric reducer pipe

If the pump inlet bore is different from that of suction pipe, use the eccentric reducer pipe. Upper side

should always be level. The air may be trapped if it is mounted upside down.

7. Gate valve installation

In flooded suction, install a gate valve on the suction piping for easier overhaul & inspection.

8. Flushing piping

Install the flushing piping for cleaning the pump when handling a harmful liquid.

9. Suction piping end

The suction piping end should always be at least 500 mm lower than a liquid level for the prevention of the

air ingress.

10. In a piping system other than the flooded suction

• The distance between the end of suction piping and the bottom of a suction tank should be 1 to 1.5

times wider than the suction pipe bore.

• Be sure to install a foot valve or a check valve on the suction piping.

11. Piping support

Support piping by pipe supports so that the pump is not subject to piping weight or thermal stress.

12. Connections

Each connection must be completely sealed so that air can not be sucked in. Imperfect sealing can cause

the air ingress and it results in the insufficient suction and the seizure of bearing.

-

-

12

Installation

■

Discharge piping

1. Discharge piping bore

When the discharge piping is long but the piping bore is equal to the pump outlet bore, the specified

performance may not be obtained because pipe resistance becomes high. Calculate pipe resistance in

advance to decide a discharge piping bore.

2. Discharge valve installation

Install a discharge valve on the piping about 1m away from the pump. The air bleed piping should be pro-

vided near the discharge valve in order to prevent the air from remaining.

3. Gate valve installation

Install a gate valve on the discharge piping to adjust flow rate and to protect the motor from overload. If a

check valve is installed, the optimum installation order is : Pump → Check valve → Gate valve.

4. Pressure gauge

A pressure gauge is required on the discharge piping to check operating conditions such as discharge

capacity and head.

5. Check valve

A check valve is required in the following cases.

• Discharge piping length is between 15 and 20 meters.

• Actual head is higher than 15 meters.

• The distance between the liquid level in the tank and the top end of discharge piping is 9 meters or more.

• Two pumps run in parallel.

6. Air vent

Install an air vent on the discharge piping when the horizontal piping length is between 15 and 20 meters.

7. Drain

Install a drain valve when draining of liquid is required (to protect the pump from freezing, etc.).

8. Piping support

Support the piping by pipe supports so that the piping weight does not totally weigh the pump.

9. Priming piping

A priming line is required on the discharge piping when piping is not flooded suction.

-

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13

Installation

3. Wiring

Electrical works or wiring must be carried out by a qualified person according to local laws or regulations.

• Use the electromagnetic switch which conforms to the motor specifications of voltage and capacity etc.

• When installing the pump out of doors, take a measure to prevent rain water from getting into the switch

when wiring.

• Install the electromagnetic or the push-button switch apart from the pump.

• The star-delta starter, inverter, or soft starter is recommended to start the motor of 5.5kW or more.

* See the instruction manual of the motor manufacturer for the motor detail.

4. Protection equipment

It is recommended to install the following monitoring devices in ord er to protect the pump.

1. Current sensor/ Power sensor The sensors monitor the motor load and stop the pump on the detection

of load change, giving an alarm.

2. Pressure sensor The sensor monitors the starting pressure and stops the pump on the

detection of pressure change, giving an alarm.

3. Flow sensor The sensor monitors the discharge flow and stops the pump on the

detection of flow change, giving an alarm.

4. Level sensor The sensor monitors the liquid level and stops the pump when it falls

below the specified level, giving an alarm.

It is recommended to install two or more monitoring devices. The more monitoring devices, the more possi-

bility of protecting the pump.

The DR series dry running protector (electric current sensing type) is also available as an option. Contact us

for detail.

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14

Operation

1. Before operation

2. Operation

3. Shutdown

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15

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16
17
17

Operation

1. Before operation

CAUTION

● Never run pump dry or shut off a suction valve during operation. Otherwise the pump

fails in a short period.

● Check the rotational direction of the pump. Clockwise seen from the motor end is a

correct direction. Operation in the reverse direction may cause pump damage. Always

carry out rotation check with the pump full of liquid.

● Stop the pump within one minute if cavitation occurs.

● Do not run the pump when air enters the suction line.

● Stop the pump immediately when the magnet coupling is disconnected. The magnet

force reduces if the pump keeps on running for more than one minute in this condition.

● The maximum number of ON/OFF operation should be within six times an hour.

Frequent ON-OFF operation can reduce the pump life.

● Keep liquid temperature change within 80˚C through operation and stopping.

● Start the pump with a discharge valve full close in order to avoid water hammer.

● Closed-discharge operation should be within one minute. If the pump runs with a dis-

charge valve closed for a long time, the liquid temperature inside the pump rises and

it damages the pump.

● If power is interrupted when the pump is running, switch off and close a discharge

valve.

● Take extra care so that the discharge pressure does not exceed the pump limit.

● When high temperature liquid is transferred, the pump surface becomes very hot.

Take a protective measure against burn. See below.

Liquid temperatuer Surface temperature

80°C 75°C

● Noise level is 90dB (A scale - one meter)

In case the pump noise affects human health or the communication to secure a safety,

provide a noise reduction cover. Be careful not to reduce cooling effect by a motor fan.

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--

-

16

16

Operation

2. Operation

1. Fully close a discharge valve and fully open a suction valve.

2. Prime the pump.

• If the pump is in flooded suction system, fully open both discharge and suction valves.

• If the pump is other than flooded suction system, prime the suction piping as well as the pump.

3. Check rotating direction of the motor.

• Close a discharge valve. Power the motor for a quick moment (within a second) in order to check the

rotation direction. A correct direction is shown with an "arrow" mark on the pump (Clockwise seen from

motor fan side).

• Check if the motor fan smoothly stops when it is powered off.

NOTE: If the motor does not stop smoothly, check rotating parts.

4. Air elimination

• Before full operation, eliminate the air in the pump.

• Fully open the valve on the air bleed piping. Run the pump for one second and repeat it 3 to 5 times for

air elimination.

• After the air elimination, fully close the discharge valve.

NOTE: In case air bleed piping is not equipped, repeat the momentary run several times

with a discharge valve open.

5. Starting operation

• Start the pump with a discharge valve fully closed. Stop the closed-discharge operation within one minute.

• Confirm that discharge pressure rises to the shut off pressure.

• Gradually open discharge valve to obtain the specified pressure (capacity).

NOTE: Pay attention to the over-load caused by an excessively opened valve.

Precautions on operation

1. Check for loose bolts on the pump. Retighten the rear casing support mounting bolts by the specified

torque of 85N•m.

2. When the pump keeps running in negative rotation, the pump breaks.

3. Closed-discharge operation should be within one minutes.

4.

Make sure that a flow rate is always equal to or more than the minimum one. The operation below the mini-

mum flow can reduce the lubricant and cooling functions on the sliding parts. This could lead to failure.

Minimum discharge capacity is 50 /min.

3. Shutdown

1. Slowly close a discharge valve.

Quick closing by a solenoid valve may cause water hammer and damages the pump. Be sure to slowly

close any discharge valve.

2. Switch off and stop the pump.

Check that the pump stops smoothly. If the pump stops roughly, inspect it.

NOTE: When leave the pump stopped for a long period, take a countermeasure against

freezing for the prevention of freeze in the pump and piping.

In case a blackout inter-

rupts the pump operation, switch off the pump and close discharge valves.

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-

17

17

Maintenance

1. Troubleshooting

2. Maintenance & Inspection

3. Disassembly & Assembly

4. Spare & Wear parts

-

-

18

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19
21
23
29

1. Troubleshooting

Maintenanc e

Troubles

Liquid can not
be discharged.

Symptom

When a discharge

valve is closed.

The pump can not be
primed.

After starting, the
pressure drops as
a discharge valve is
opened.

When a discharge

valve is opened.

The readings of pressure/
vacuum gauges fluctuate
and drops to zero.

The readings of
pressure/ vacuum
gauges fluctuate and
drops to zero.

Cause

• Priming liquid level
is too low.

• Dry running

• The foot valve
malfunction due to
foreign matter clog­ging.

• Air ingress through
the suction pipe end
or seal face.

• A disconnection of
the magnet coupling

Check

&

Countermeasures

• Stop and prime the
pump and resume oper­ation.

• Clean the foot valve.

• Check if suction pip con­nections are completely
sealed.

• Check if liquid level in
supply tank is not too
low.

• Check if the motor is not
overloaded by checking
amperage.

• Check if foreign matters
do not lock the impeller
or magnet capsule.

• Check if voltage is nor­mal.

Discharge
capacity is
too low.

Pressure gauge
keeps showing low
pressure.

Pressure & vacuum
are normal.

Vacuum is high.

Vacuum is very high.

The readings of pres­sure gauge & vacu­um gauge fluctuate.

Vacuum gauge indi­cates high but pres­sure is normal.

• Low pump speed

• The pump rotates in
reverse.

• The strainer is
clogged with for­eign matters.

• Air pocket in suc­tion piping

• Foreign matters are
clogged at impeller
inlet.

• Air ingress from
suction pipe or seal
face.

• Discharge piping
clogs with foreign
matters.

• Resistance such as
air pocket in suction
line.

• Check wiring or motor.

• Correct wiring.

• Remove foreign matters.

• Check and correct suc­tion piping.

• Remove foreign matters.

• Check pipe connections
and retighten as neces­sary.

• Remove foreign matters
or scale from pump/pip­ing.

• Check if there is no
arched pipework.

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--

-

19

19

Maintenanc e

Troubles

Discharge
capacity is
too low.

Motor is
overheated.

Discharge
capacity is
rapidly re­duced.

Pump
vibrates.

Symptom

When discharge

valve is closed.

Pressure & vacuum
are normal.

Pressure is low and
vacuum is very low.

When discharge
valve is opened.

Pressure is high but
vacuum is normal.

Pressure and vacu­um are low.

Vacuum gauge indi­cates high figure.

Points to be checked

Cause

Countermeasures

• Actual head is too
high or pipe resist­ance is too large.

• Motor rotates in
reverse.

• Power voltage is
low.

• Overload • Check specific gravity

• Ambient tempera­ture is too high.

• Suction piping
clogs with foreign
matters.

• Poor foundation • Reinstall the pump.

• Loose mounting
bolts.

• Cavitation occurs. • Remove the cause of

• The bearing is worn
or melted.

• Magnet capsule or
spindle is broken.

• Dynamic balance
of drive magnet is
upset.

• Motor bearing is
worn.

• Check actual head and
pipe resistance.

• Interchange motor wir­ing.

• Check voltage or fre­quency.

and viscosity of liquid.

• Keep a good ventilation.

• Remove foreign matters.

• Retighten the bolts.

cavitation.

• Replace as necessary.

• Replace as necessary.

• Remove the cause.
Replace as necessary.

• Replace bearing or
motor.

&

-

20

20

--

-

Maintenanc e

2. Maintenance & Inspection

WARNING

● Do not have the medical electronics close to magnet.

Any person who is equipped with the medical electronic such as a pacemaker should
not be close to the magnet of pump.

● Pay attention to magnet force

The magnet force is powerful. Take care not to catch the finger in metal parts.

■

Periodic inspection (Every six months)

Part names Inspection items Measures

Drive magnet unit

Rear casing

Magnet capsule

Impeller

Front casing

Spindle

Rear casing support

● If there is a friction trace.

● If the drive magnet housing is cor-

rectly mounted or if the hex. socket set
screws are not loosened.

● Decentering of the magnet and motor
shaft (Max.1/10mm).

● If there is a friction trace in inner surface.

● If there is a crack on wet-end material.

● If the rear thrust ring is worn.

● If the inside is dirty.

● If there is a friction trace on surface.

● If there is a crack on surface.

● Measure the bearing inner bore.

● If the impeller is secured to the magnet capsule.

● Measure the mouth ring thickness.

● If there is a crack.

● If there is a cavitation trace.

(Abnormality related to the mouth ring
such as wear and seizure.)

● If the impeller is not clogged.

● If the impeller is deformed.

● Wet-ends are dirty.

● If there is a crack.

● If there is an abnormal wear, crack and

friction trace on liner ring.

● If drain is clogged.

● If gasket is swelled or O ring is cracked.

● If there is a friction trace.

● If there is a crack.

● If the bearing is worn beyond the limit.

● If the rear casing support mounting

bolts are not loose.

○ If abnormality is found, contact us.
○ Remount the drive magnet to motor

shaft or retighten the set screws.

○ Retighten the hex. socket set screws

or replace the drive magnet (Contact
us for replacement.).

○ If abnormality is found, consult us.
○ Replace as necessary.
○ If it is worn, contact us.
○ Clean the inside.
○ If abnormality is found, contact us.
○ If abnormality is found, contact us.
○

Replace it if it is worn beyond the wear limit.

○ If it is loose, replace or contact us.
○ Replace as necessary.
○ Replace as necessary.
○ Remove the cause of cavitation.

○ Remove clogs.
○ Replace as necessary.
○ Clean them.
○ Replace as necessary.
○ Contact us if abnormality is found.

○ Clean the drain.
○ Replace as necessary.
○ Contact us.
○ Replace as necessary.
○ Replace as necessary.

○ Retighten the bolt by the specified torque.
○ When a frequent ON-OFF operation is

made or liquid temperature fluctuates,
retighten the bolt periodically.

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21

21

Maintenanc e

■

Wear limits of bearing and spindle

Model

AMP40-1, AMP50-1 26 27 26 25

1. The values on the table shows wear limit at each part.

2. If the clearance between the inner diameter of the bearing and the outer diameter of the spindle exceeds

1 mm, either the bearing or spindle, whichever has greater wear, should be replaced regardless of the

wear limit.

Carbon bearing (CF) type: Normally the carbon bearing will be replaced first.

SiC bearing (KK) type : Replace the bearing and spindle at the same time.

3. Sliding parts may suffer initial wear in an initial operation phase but this is not abnormal.

■

Wear limit of mouth ring

The step between the surfaces of the mouth ring and the impeller is 2 mm before use. When the step

becomes 0 mm, replace the mouth ring.

Model

Thickness of mouth ring

Before use

Bearing inner diameter Spindle outer diameter

Before use Wear limit Before use Wear limit

Before use

2mm

Wear limit

Impeller

AMP40-1

AMP50-1

8 mm 6 mm

9 mm 7 mm

Mouth ring

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22

22

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Maintenanc e

3. Disassembly & Assembly

WARNING

● Pay attention to magnet field

The magnet drive pump has a pair of strong magnets. The strong magnet field
could adversely affect the persons who are assisted by electronic devices
such as the pacemaker.

● Do not catch the finger

The magnet force of the pump is powerful. Take care not to catch the finger in
the bracket.

● Wear protective clothing

Coming in contact with a harmful chemical liquid may cause eye or skin trou­ble. Wear protective clothing such as a protective mask, goggles, gloves dur­ing the work.

● Turn off power during the maintenance work

Risk of electrical shock. Make sure the power source is turned off, and the
pump and devices are stopped prior to the work.

Prohibited

Caution

Wear protective

gear

Tur ning of f pow er

CAUTION

●

Pay attention to magnet force

The magnet force is powerful. Take care so that iron pieces and iron powder do not
stick to the magnet of pump.

●

The powerful magnet force can break the data of the magnetic card, disc or so. Do not

have the magnetic product close to the magnet of pump.

Tool list
Following tools are necessary to disassemble and assemble the pump.

Tool AMP40-1, AMP50-1

Spanner 13 mm, 19 mm, 24 mm 1 pc/each
Hex. wrench 4 mm, 5 mm 1 pc/each

Plastic round bar 34 mm dia. × 100 L To remove & mount bearing

Plastic welder or
industrial dryer

Hand press 1 unit
Plastic hammer 1 pc

1 unit

Remarks

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23

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Maintenanc e

■

Pump casing disassembly

1. Remove the hex. bolts (901.1) and drain plate (122.1) to

drain liquid out of the pump unit.

For the pump model without drain, neutralize the liquid

or flush the pump unit out. And then remove liquid by

dismantling the pump or pipework.

WARNING

If the hex. bolts are loosened at once, liquid may
fly off, resulting in personal injury.

2. Remove two mounting hex. bolts (901.7) on the foot

support.

3. Remove four pump unit mounting hex. bolts (901.5) on

the bracket (330).

4. Pull the motor backward by alternatively screwing in

the two bolts (M12×100: for back pull out). Screw in

the bolts by approximately 80 mm.

5. Pull out the motor with bracket, lifting it by the crane.

Draw the motor out straight so that the drive magnet

(858) does not come in contact with the rear casing

(158).

Keep the motor balanced when it is lifted up.

6. Unscrew the hex. bolts (901.4) which is fixing the rear

casing support to the cover (100.2) and then remove

the rear casing support.

NOTE: The rear casing and the rear casing

cover may be removed together with the
rear casing support.
Be careful not to drop the impeller (230)/
magnet capsule (859) unit from the rear
casing.

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24

-

Maintenanc e

7. Remove the rear casing cover (159) from the rear cas-

ing (158). Be careful not to drop the impeller (230)/

magnet capsule (859) unit from the rear casing.

When the rear casing can not be removed from the

rear casing support, hit the bottom of the rear casing to

detach it.

■

Removal of the impeller and bearing

1. Heat the lugs on the rear ring (314.4) by a plastic

welder or industrial dryer and open the lugs up.

2. Warm the impeller assembly in the hot water of 80˚C.

If it is not warmed up enough, the bearing or the rear

ring may break.

Wear protective clothing for the prevention of

scald.

3. Apply the plastic round bar (34 mm dia. 100L) to the

impeller-side bearing end and then push out the bear-

ing (310) and rear ring (314.4) by the hand press.

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25

-

Maintenanc e

4. Push off the pin (942) by the screw driver.

5. Remove the impeller (230) from the magnet capsule

(859). If the impeller can not be removed, hit the

impeller back lightly with the plastic hammer.

■

Mouth ring replacement

1. Heat the lugs on the mouth ring by a plastic welder or

industrial dryer and open the lugs up.

2. Warm the impeller in the hot water of 80˚C and then

replace the mouth ring (314.2) with new one.

Wear protective clothing for the prevention of

scald.

3. Heat the lugs on the mouth ring by a plastic welder or

industrial dryer and then close the lugs down.

- 26 -

Maintenanc e

■

Spindle replacement

1. The spindle (210) is slightly pressed into the rear cas-

ing (158). Pull the spindle out by the hand.

Warm the rear casing in hot water if the spindle can

not be pulled out. Then pull the spindle out by lightly

moving it from side to side and up and down. The

rear thrust ring (314.3) comes off as the spindle is

removed.

Wear protective clothing for the prevention of

scald.

2. Clean the insertion part of the spindle. Fit the rear

thrust ring in the rear casing with no interference to the

spindle insertion. Press the spindle into place by the

hand or the hand press.

■

Impeller/ Bearing mounting

1. Fit the impeller into the magnet capsule, mating the

insert ports of the pin.

Note that the mated connection of the impeller and the

magnet capsule need to be machined. We have all the

impeller machined in advance.

2. Insert the pin. Use pliers for easy insertion.

3. Turn the magnet capsule upside down with the

impeller fitted. Warm the magnet capsule in the hot

water of 80˚C. after it is warmed, press the bearing into

the magnet capsule by the hand press.

Check that the pin is fully inserted and there

is no interference during press fitting.

Wear protective clothing for the prevention of

scald.

4. Insert the rear ring. Heat the lugs on the mouth ring by

a plastic welder or industrial dryer and then close the

lugs down.

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27

Maintenanc e

■

Assembly

Assembly can be made in reverse procedures to disman-

tlement. Pay attention to the following points.

Gasket replacement

Always replace the gasket with new one every time

the pump unit is assembled. Do not twist or catch the

gasket in the parts. Clean the sealing surfaces before

mounting.

Tightening of bolts

Tighten the bolts diagonally and evenly.

Cleaning magnet capsule

Waste metal such as Iron pieces can be attracted to

the magnet capsule. Remove such foreign matters

before assembly.

1. Place the gasket in the front casing (100.1).

2. Put the impeller assembly in the rear casing. Fit the

rear casing together with the impeller assembly, rotat-

ing the rear casing right and left.

3. Mount the rear casing cover and the rear casing sup-

port. And then tighten the rear casing support mount-

ing hex. bolts by 85N•m diagonally and evenly.

NOTE: Loose the bolts (901.7) on the foot sup-

port before retightening the rear casing
support mounting bolt.

4. Remove foreign matters from the drive magnet on the

motor shaft.

5. Screw the two bolts (M12×100: for back pull out) in the

bracket half way. Direct the motor bracket to the pump

unit parallel.

6. Slowly close the motor to the pump unit by alterna-

tively unscrewing the two bolts (M12×100: for back pull

out).

Fit the motor straight to the pump unit so that the drive

magnet (858) does not come in contact with the rear

casing.

Fix the bracket and the rear casing support by mount-

ing hex. bolts.

After assembly, retighten the rear casing

support mounting bolts.

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-

28

4. Spare & Wear parts

159

Maintenanc e

901.6

554.6

801

158

314.3

210

400.1

314.4

310

859

230

942

908.1

100.1

314.1

858

900

330.1

330

901.5

554.5

314.2

901.4

901.7

554.4

554.7

901.2

161

890

554.2

500.2

554.8

901.8

100.2

903.1

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29

400.2

500.1

554.1

122.1

901.1

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Maintenanc e

Always stock spare parts, especially wear parts, for a long period of continuous operation.
Contact us with the following items when placing an order for spare parts.

1. Part name and part number (See the exploded view.)

2. Model code and MFG.No (See the nameplate)

3. Drawing number (If you have an approved drawing.)

No. Part names ID Material

210 Spindle CF Alumina ceramic 99.5% AMP0012 AMP0012

KK SiC AMP0013 AMP0013

310 Bearing CF High density carbon AMP0014 AMP0014

KK SiC AMP0015 AMP0015

314.2 Mouth ring CF Filled PTFE AMP0016 AMP0055
KK SiC AMP0017 AMP0056

314.3 Rear thrust ring PTFE AMP0018 AMP0018

400.1 Gasket, Casing PTFE AMP0024 AMP0024

400.2 Gasket, Drain PTFE AMP0025 AMP0025

Assembly parts are also available. Contact us for detail.

AMP40J/40A AMP50J/50A

Reference code

-

30

30

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Aust ra li a IWAKI Pumps Aust ralia P ty. Ltd.
Austria IWAKI (Austria) GmbH
Belgium IWAKI Belgium n.v.
China IWAKI Pumps (Shanghai) Co., Ltd.
Ch ina IWAKI Pumps (Guandong) Co., Ltd.
China
China

GFTZ I WAKI Engine ering & Trading (Gu angzhou)

GFTZ I WAKI Enginee ring & Trading (Be ijing)
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Indonesia

IWAKI Singapore (Indonesia Branch)

( )Country codes

IWAKI CO.,LTD. 6-6 Kanda-Sudacho 2-chome Chiyoda-ku Tokyo 101-8558 Japan

TEL : [phone] FA X : 2 9899 2421
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Tai wan

IWAKI Pu mps Taiwan (Hsin- chu) Co., Ltd . TEL : [phone] FA X : (886)3 573 5798

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T667-4 '09/02