IWAKI PUMPS TD Series, TD-01, TD-05, TD-M01, TD-M05 Instruction Manual
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IWAKI Metering Pump
TD series
Safety instructions Overview Installation Operation Maintenance Specication
Instruction manual
Thank you for choosing our product.
Please read through this instruction manual before use.
This instruction manual describes important precautions and instructions for the product. Always keep it on hand for quick reference.
©2011 IWAKI CO., LTD.
Order conrmation
Open the package and check that the product conforms to your order. If any problem or
inconsistency 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 ordered.
b. Check if the delivery is damaged or deformed.
Check for transit damage and loose bolts.
Order conrmation
2
Contents
Order conrmation ..........................................................................................................................................2
Safety instructions .................................................................... 5
Warnings ........................................................................................................................................................6
Cautions .........................................................................................................................................................8
Precautions for use ....................................................................................................................................10
Overview ...................................................................................11
Introduction ................................................................................................................................................. 11
Pump structure & Operating principle ...................................................................................................... 11
Pump mechanism ....................................................................................................................................12
Flow pulsation reduction mechanism ..................................................................................................12
Part names ...................................................................................................................................................13
Pump ........................................................................................................................................................13
TD .......................................................................................................................................................13
Identication codes ....................................................................................................................................14
Installation ...............................................................................15
Pump mounting ...........................................................................................................................................15
Before installation .....................................................................................................................................15
Pipework ......................................................................................................................................................16
Piping layout .............................................................................................................................................16
Necessary devices ...................................................................................................................................17
Relief valve ..........................................................................................................................................17
Back pressure valve ............................................................................................................................17
Strainer ................................................................................................................................................17
Pressure gauge ...................................................................................................................................17
Pump inlet/outlet connections ..................................................................................................................18
Tube connection ..................................................................................................................................18
Union connection ................................................................................................................................18
Piping precautions ....................................................................................................................................19
Prohibited piping .................................................................................................................................19
Slurry delivery ..........................................................................................................................................20
Wiring ...........................................................................................................................................................21
Inverter-Motor ...........................................................................................................................................21
Inverter-Grid power ..................................................................................................................................21
IPM motor terminal box ............................................................................................................................22
Contents
3
Operation ................................................................................. 23
Before operation .........................................................................................................................................23
Operation .....................................................................................................................................................24
Starting procedure ...................................................................................................................................24
Inverter operation .....................................................................................................................................25
Start/Stop of operation ........................................................................................................................25
Flow rate adjustment ...........................................................................................................................25
Before stoppage .......................................................................................................................................26
Resumption after a long period of stoppage ............................................................................................26
Maintenance ............................................................................ 27
Troubleshooting ..........................................................................................................................................27
Inspection ....................................................................................................................................................29
Daily inspection ........................................................................................................................................29
Periodic inspection ...................................................................................................................................29
Maintenance of IPM motor .......................................................................................................................29
Oil replacement (drive unit) ......................................................................................................................30
Replacement procedure ......................................................................................................................31
Wear part replacement ...............................................................................................................................32
Before assembly/disassembly ..................................................................................................................33
Exploded view .............................................................................................................................................34
Pump head ...............................................................................................................................................34
TD-01/-03 VC/V6 ................................................................................................................................34
TD-05/-1 VC/V6/VS ............................................................................................................................36
TD-01/-03 VS ......................................................................................................................................38
TD-2/-4/-6/-8 VC/V6/VS .....................................................................................................................40
TD-01/-03 S6 ......................................................................................................................................42
TD-05/-1 S6 ........................................................................................................................................44
TD-2/-4/-6/-8 S6 .................................................................................................................................46
Specications/Outer dimensions ..............................................................................................................48
Specications ...........................................................................................................................................48
Pump ...................................................................................................................................................48
Inverter ................................................................................................................................................49
Outer dimensions .....................................................................................................................................50
FF type ................................................................................................................................................50
HH type ...............................................................................................................................................51
UU type ...............................................................................................................................................51
Performance curves .................................................................................................................................52
TD-VC/-V6 ...........................................................................................................................................52
TD-S6 ..................................................................................................................................................54
TD-VS .................................................................................................................................................56
Contents
4
Safety instructions
Read through this section before use. This section describes important
information for you to prevent personal injury or property damage.
■ Symbols
In this instruction manual, the degree of risk caused by incorrect use is noted with the follow-
ing symbols. Please pay attention to the information associated with the symbols.
Indicates mishandling could lead to a fatal or serious
WARNING
CAUTION
accident.
Indicates mishandling could lead to personal injury or prop-
erty damage.
Safety instructions
A symbol accompanies each precaution, suggesting the use of "Caution", "Prohibited actions"
or specic "Requirements".
Caution marks Prohibition mark Requirement mark
Caution
Electrical
shock
Prohibited
Do not rework
or alter
Fire ban
Requirement
Wear
protection
Grounding
Export Restrictions
Technical information contained in this instruction manual might be treated as controlled tech-
nology in your countries, due to agreements in international regime for export control.
Please be reminded that export license/permission could be required when this manual is
provided, due to export control regulations of your country.
Safety instructions
5
Requirement
WARNINGS
Turn off power before service
Risk of electrical shock. Be sure to turn off power to stop the pump and
related devices before service is performed.
Stop operation
If you notice any abnormal or dangerous conditions, suspend operation
Requirement
Prohibited
Do not remodel
Wear
protectors
immediately and inspect/solve problems.
Do not use the pump in any condition other than its intended purpose
The use of the pump in any conditions other than those clearly specied
may result in failure or injury. Use this product in specied conditions only.
Do not modify the pump
Alterations to the pump carries a high degree of risk. It is not the manufac-
turer's responsibility for any failure or injury resulting from alterations to the
pump.
Wear protective clothing
Always wear protective clothing such as an eye protection, chemical re-
sistant gloves, a mask and a face shield during disassembly, assembly or
maintenance work. The specic solution will dictate the degree of protec-
Prohibited
tion. Refer to MSDS precautions from the solution supplier.
Stay out from under suspended loads
Risk of personal injury. Keep away from the pump while it is lifted up.
WARNINGS
6
WARNINGS
Do not stand on the pump
Do not use the pump as a platform. Injury or damage may result when the
Safety instructions
Prohibited
Caution
Requirement
Prohibited
pump turns over.
Do not get access to the inside of the driven unit during operation
Risk of personal injury. A reciprocating diaphragm/shaft may catch the fin-
ger or hand.
Qualied personnel only
The pump should be handled or operated by qualified personnel with a
full understanding of the pump. Any person not familiar with the product
should not take part in the operation or management of the pump.
Closed-discharge operation is not allowed
Do not close a discharge line during operation. Otherwise, overpressure
will cause liquid leakage or break the pump and piping. Note for the TD
series, a discharge valve is not used for controlling a ow rate.
Requirement
Do not use grid power directory to the pump
Always use an applicable inverter for powering the pump, or fire may
result.
WARNINGS
7
Fire ban
CAUTIONS
Use specied power only
Do not apply power other than that specied on the nameplate. Otherwise,
Requirement
Prohibited
Requirement
Caution
failure or re may result. Ensure the pump is properly grounded.
Do not install/store the pump:
• In a ammable/explosive/corrosive atmosphere.
• In a dusty/humid environment.
• Where ambient temperature can exceed 0-40ºC.
• Under mechanical vibrations.
Spill precautions
Ensure protection and containment of solution in the event of plumbing or
pump damage (secondary containment).
Do not touch the pump or pipe with bare hands
Risk of burning. The surface temperature of the pump or pipe rises high
along with liquid temperature in or right after operation.
Electrical
shock
Requirement
Do not bring the pump close to a ammable substance
Keep the pump away from a ammable substance for the prevention of
re. Do not allow a leak of lubricating oil. Observe local rules and regula-
tions for handling of oils.
Install a GFCI (earth leakage breaker)
An electrical failure of the pump may adversely affect other devices on the
same line. Purchase and install an earth leakage breaker separately.
Foreign matter
When foreign matters enter the pump, turn off power immediately to re-
move them. Using the pump with foreign matters may result in failure.
CAUTIONS
8
CAUTIONS
Preventative maintenance
Follow instructions in this manual for replacement of wear parts. Do not
Safety instructions
Requirement
Prohibited
Requirement
Prohibited
disassemble the pump beyond the extent of the instructions.
Do not use a damaged pump
Use of a damaged pump could lead to an electric shock or death.
Disposal of a used pump
Dispose of any used or damaged pump in accordance with local rules
and regulations. If necessary, consult a licensed industrial waste disposal
company.
Do not cover the pump with cloth
The motor temperature may build up and a re or an electric/mechanical
failure may result.
Non freezing
Frozen liquid may damage the pump and piping. Drain liquid before leav-
Requirement
Requirement
ing it for a long time or use measures to prevent liquid from freezing in
winter.
Pressure removal
Solution in the discharge line may be under pressure. Release the pres-
sure from the discharge line before disconnecting plumbing or disassem-
bly of the pump to avoid solution spray.
CAUTIONS
9
Precautions for use
• Electrical work should be performed by a qualied electrician. Otherwise,
personal injury or property damage may result.
• Shipping inspection with tap water is conducted on every pump. Be sure to
dry off the pump head before operation, or residual water may cause unde-
sirable reaction when having contact with some chemicals.
• Use care handling the pump. Do not drop. An impact may affect pump
performance. Do not use a pump that has been damaged to avoid the risk
of electrical damage or shock.
• The pump is not waterproof. Do not operate the pump while wet with solu-
tion or water, or failure or injury may result. Immediately dry off the pump if
it gets wet.
Caution
Requirement
Caution
Caution
• Do not clean the pump or nameplate with a solvent such as benzine and
thinner. This may discolour the pump or erase printing. Use a dry or a
damp cloth or a neutral detergent.
• Drain liquid before leaving the pump for a long time.
Caution
Requirement
Precautions for use
10
Overview
Pump characteristics, features and part names are described in this section.
Introduction
The TD series is the mechanically-driven diaphragm pump. Its pulse-reduction design en-
sures low ow pulsation without the need of an air chamber. A wide selection range of wet
ends allows for delivery of acid, alkaline, viscous liquid, slurry and solvent in various plants or
built-in applications.
Pump structure & Operating principle
Motor rotation is transmitted to an eccentric cam via a reduction gear and then converted to reciprocating
motion. Volumetric change occurs in the pump chamber as the diaphragm moves back and forth, so liquid is
delivered through the outlet with the assistance of the suction and discharge check valves.
Suction process
When the diaphragm moves back, negative pressure in the pump head opens the suction check valve to take
in liquid while closing the discharge check valve.
Overview
Discharge process
When the diaphragm moves forward, positive pressure in the pump head opens the discharge check valve to
deliver liquid while closing the suction check valve.
Motor
Outlet
Check valve
Pump head
Inlet
Diaphragm
Gear unit
Pump shaft
: Liquid flow
: Motor rotation
: Diaphragm reciprocation
: Valve movement
Introduction
11
Pump mechanism
0
■ Flow pulsation reduction mechanism
The reduction mechanism consists of the two factors. One is the use of a highly-precise constant-velocity cam,
which makes a trapezoidal waveform of each discharge. The other is the phase shift of two different discharge,
The rear head moves out of phase with the front by 180 degrees to make a constant synthesized waveform.
The ow rate of the TD can change with a motor rotation speed (inverter frequency).
* Note suction pulsation is not reduced.
Constant-velocity cam and Phase shift
Inlet
Discharge/Suction waveform
Discharge process
Pump shaft
One cycle
Front head
SpringOutlet Diaphragm
Constant-velocity cam
Constant synthesized waveform
Rear head
Outlet
Inlet
Suction process
Discharge/Suction volume of the front head
Discharge/Suction volume of the rear head
Total discharge volume consists of both heads
NOTE
The mechanically-driven diaphragm pump including the TD by its nature involves flow pulsation during op-
eration. The reduction mechanism can reduce but can't eliminate the pulsation completely, and the pulsation
becomes greater as a discharge pressure gets higher. This is because the diaphragm transiently depressed
under a high pressure as with every other mechanically-driven diaphragm pumps.
12
Introduction
Part names
Pump
■ TD
Rear pump head
Motor
Overview
Outlet
Gear unit
Nameplate
Driven unit
Baseplate
Pipe unit
Front pump head
Inlet
Oil gauge
Terminal box
Oil-filler cap
Oil-drain port
Part names
13
Identication codes
Each code represents the following information.
TD - 2 VC FF 1 S - 02 S
a b c d e f g h i
a. Series name
TD
b. Drive unit
M : High-efciency IPM fan motor
No code : High-efciency IPM fanless motor
c. Diaphragm size
01, 03, 05, 1, 2, 4, 6, 8
d. Wet end materials
Code Pump head Valve Valve seat O ring Valve gasket Diaphragm
VC PVC CE
V6 PVC SUS316
VS PVC SUS316 SUS304 EPDM PTFE PTFE+EPDM
S6 SUS316/SCS14 SUS316 SUS316 - PTFE PTFE+EPDM
*DS stands for diaphragm size
FKM: 01-1 (*DS)
PVC: 2-8 (*DS)
EPDM: 01-1 (*DS)
PVC: 2-8 (*DS)
FKM PTFE PTFE+EPDM
EPDM PTFE PTFE+EPDM
Material code
PVC : Polyvinyl chloride SUS316 : Austenitic stainless steel
SUS304 : Austenitic stainless steel SCS14 : Stainless cast steel (SUS316)
CE : Alumina ceramics FKM : Fluorine-contained rubber
EPDM : Ethylene-propylene rubber PTFE : Polytetrauoroethylene
e. Connection type
FF : JIS ange
UU : Union
HH : Tube
* These three connection codes are standard options. Other codes such as FU or UH can be selectable as necessary. In
this case the rst code represents the inlet and the second code the outlet, e.g. FU means JIS ange inlet + union outlet.
*Any union connection is not available for the pumps with 2, 4, 6 and 8 diaphragm sizes and of the S6 type.
*Any tube connection is not available for the pumps with 2, 4, 6 and 8 diaphragm sizes and of the S6 type.
f. Connection direction
1 : Horizontal inlet and outlet
2 : Vertical inlet and outlet
3 : Horizontal inlet and Vertical outlet
4 : Vertical inlet and Horizontal outlet
*The 3rd option is available only for pumps with UU or HH connection type.
g. Special version (pump head)
No code : Standard S : Custom design (e.g. special check valves or pipe I.D.)
h. Motor
0.2 : 0.2kW
i. Special version (drive unit)
No code : Standard S : Custom design (e.g. special motors or baseplates)
14
Identication codes
Installation
This section describes the installation of the pump, piping and wiring.
Read through this section before installation is performed.
Points to be observed
Observe the following points when installing the pump:
• Be sure to turn off power to stop the pump and related devices before installation is per-
formed.
• If you notice any abnormal or dangerous conditions, suspend operation immediately and
inspect/solve problems.
• Do not place explosive or ammable material near the pump.
• Do not use a pump that has been damaged to avoid the risk of electrical damage or
shock.
• Use care handling the pump. Do not drop. An impact may affect pump performance.
• Keep the pump as level and as low as possible when it must be lifted up.
• Fumes or vapours can be hazardous with certain solutions. Ensure proper ventilation at
the operation site.
• Observe information on the appropriate drawing and specification sheet.
Pump mounting
Before installation
Check if installation doesn't adversely affect facility, surrounding equipment and the pump. Install the pump according to the following instructions to ensure the optimum performance, safety and service.
• Allow sufcient space around the pump for easy access and maintenance.
• Select a level location, free from vibration, that won't hold liquid. Always use a level gauge.
• Install the pump as close to a supply tank in a ooded suction system.
• Avoid installing the pump:
- In direct sunlight or wind & rain.
- In a dusty/humid place.
- In a corrosive atmosphere.
- In a place where proper ventilation is not maintained.
Installation
Pump mounting
15
Pipework
Pipework must be done according to the following instructions to ensure the optimum performance, safety and service.
Piping layout
Arrange pump and pipework based on the following piping layout for a long period of operation.
Back pressure valve
Discharge line
Relief valve
(overfeeding prevention)
Injection point
: Pipe support
Flooded suction
Supply tank
Discharge pressure
monitoring gauge
Air vent valve
Y shaped strainer
Suction line
Suction valve
(shut off valve)
P
Maintenance valve
Drain valve
NOTE
• Design an optimal layout to meet NPSHr, especially when planning to deliver slurry.
• If pipework directory weighs on the pump, the pump may be damaged. Be sure to install pipe supports.
16
Pipework
Necessary devices
The following devices are needed to the metering pump. Be sure to install, or personal injury or property damage may result.
■ Relief valve
The metering pump by nature keeps working, exceeding the limit pressure of discharge line if it is blocked. This
may damage the pump/piping system and burn out the motor. Install a relief valve close to the pump and x its
set pressure below the maximum allowable pressure of the pump/discharge line.
■ Back pressure valve
Discharge line pressure must be 0.03MPa or higher than suction line pressure. Otherwise, check valve may
not check ow and overfeeding may result. Install a back pressure valve on the discharge line to keep the mini-
mum pressure difference as necessary.
■ Strainer
Provide a 40-mesh strainer at the end of a suction line and clean it periodically. Otherwise, clogging may
result.
Installation
■ Pressure gauge
Install a pressure gauge to monitor the discharge line pressure.
Glossary
Overfeeding is the condition that check valves in the pump head stay open and liquid continues flowing
into discharge line. Always keep the discharge line pressure 0.03MPa or higher than a suction line pres-
sure.
Pipework
17
Pump inlet/outlet connections
Arrange the pump inlet and outlet according to a piping system in which the pump is incorporated.
■ Tube connection
Cut the tube ends at.
1
NOTE
Otherwise a leak may result.
Pass a tube into the tting nut and stopper and
2
then slide it down to the tube adapter as far as
it will go.
NOTE
The tube end must come within at least 2mm from the
bottom of the adapter.
Fitting nut
Stopper
Tube
Tube adapter
Tube end (Side view)
Within 2mm
from the bottom
Place an O ring into the inlet/outlet unit (part # 70/71).
3
Secure the tube end (with the tube adapter) on the inlet/outlet unit by hand-tightening the
4
tting nut.
NOTE
The plastic tting nut may be broken if tightened too much.
■ Union connection
Connect the union socket (72) to a plastic ange or joint of your piping system. Use an adhesive to secure the
connection.
NOTE
Do not allow an extra amount of adhesive to enter the pump.
18
Pipework
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