Walchem IX Operating Manual

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Page 1

IX-C series (North America)

Safety instructions

Overview Installation Operation Maintenance Specication

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.

Page 2

Order conrmation

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 conrmation

Page 3

Contents

Order conrmation ..........................................................................................................................................2

Safety instructions .................................................................... 6

Warning ..........................................................................................................................................................7

Caution ...........................................................................................................................................................8

Precautions for use ....................................................................................................................................10

Overview ...................................................................................12

Introduction .................................................................................................................................................12

Pump structure & Operating principle ......................................................................................................12

Features ...................................................................................................................................................13

Operational function ...................................................................................................................................13

Manual mode ...........................................................................................................................................13

EXT mode ................................................................................................................................................14

Analogue proportional control .............................................................................................................14

Pulse control .......................................................................................................................................16

Batch control .......................................................................................................................................16

Interval batch control ...........................................................................................................................18

AUX function ............................................................................................................................................18

Priming function .......................................................................................................................................18

STOP functions ........................................................................................................................................19

STOP function .....................................................................................................................................19

Pre-STOP function ..............................................................................................................................19

Analogue output function .........................................................................................................................19

Protective functions ..................................................................................................................................20

Interlock function .................................................................................................................................20

Diaphragm rupture detection ..............................................................................................................20

Pressure overload/Failed rotation control detection ...........................................................................20

Alarm output function ..........................................................................................................................21

Other functions .........................................................................................................................................21

Suction speed setting ..........................................................................................................................21

Maximum ow rate setting ..................................................................................................................21

Diaphragm position adjustment ..........................................................................................................21

Anti chattering programming ...............................................................................................................21

Output logic setting .............................................................................................................................21

Flow unit setting ..................................................................................................................................21

Language setting ................................................................................................................................21

Keypad lock .........................................................................................................................................21

Default setting .....................................................................................................................................21

Part names ...................................................................................................................................................22

Pump ........................................................................................................................................................22

Contents

Page 4

Operational panel .....................................................................................................................................23

Basic displays & Pump states .............................................................................................................24

Identication codes ....................................................................................................................................25

Pump ........................................................................................................................................................25

Installation .............................................................................. 26

Pump mounting ...........................................................................................................................................26

Pipework ......................................................................................................................................................27

Piping layout ........................................................................................................................................27

Drain port (Vent hole) .................................................................................................................................28

Wiring ...........................................................................................................................................................29

End terminals ...........................................................................................................................................29

Power voltage/Earthing ............................................................................................................................30

Signal wire connection .............................................................................................................................31

EXT IN ................................................................................................................................................32

STOP IN ..............................................................................................................................................32

AUX IN/Analog OUT ...........................................................................................................................33

Alarm OUT (DIN connector) ................................................................................................................33

Operation ................................................................................. 34

Before operation .........................................................................................................................................34

Points to be checked ................................................................................................................................34

Retightening of pump head xing bolts ....................................................................................................34

Commissioning .........................................................................................................................................35

Before a long period of stoppage (One month or more) ..........................................................................35

Perform a calibration ..................................................................................................................................36

Calibration process ..................................................................................................................................37

Operation programming .............................................................................................................................39

Programming ow ....................................................................................................................................40

Menu screen ............................................................................................................................................41

EXT mode selection ............................................................................................................................42

Calibration ...........................................................................................................................................44

Signal input setting ..............................................................................................................................45

Analogue output setting ......................................................................................................................46

Alarm output setting (OUT 1) <Mechanical relay> ..............................................................................47

Alarm output setting (OUT 2) <PhotoMOS relay> ..............................................................................49

Data logging ........................................................................................................................................50

Programming of other functions ..........................................................................................................51

Operation .....................................................................................................................................................54

Manual operation .....................................................................................................................................54

EXT operation ..........................................................................................................................................54

AUX function ............................................................................................................................................55

Priming function .......................................................................................................................................55

Keypad lock ..............................................................................................................................................56

Contents

Page 5

Keypad lock activation ........................................................................................................................56

Keypad lock release ............................................................................................................................56

Emergency stop ..................................................................................................................................56

Maintenance .............................................................................57

Troubleshooting ..........................................................................................................................................58

Pump ...................................................................................................................................................58

Error messages ...........................................................................................................................................59

Inspection ....................................................................................................................................................59

Daily inspection ........................................................................................................................................59

Periodic inspection ...................................................................................................................................59

Wear part replacement ...............................................................................................................................60

Wear part list ............................................................................................................................................60

Before replacement ..................................................................................................................................62

Valve set replacement ..............................................................................................................................62

Diaphragm replacement ...........................................................................................................................63

Exploded view .............................................................................................................................................67

Pump head, Drive unit & Control unit .......................................................................................................67

Pump head ...............................................................................................................................................68

IX-C150 TC N ......................................................................................................................................68

IX-C150 TC FA ....................................................................................................................................69

IX-C150 S6 N ......................................................................................................................................70

IX-C150 S6 FA ....................................................................................................................................71

IX-C060 TC N .....................................................................................................................................72

IX-C060 TC FA ....................................................................................................................................73

IX-C060 S6 N ......................................................................................................................................74

IX-C060 S6 FA ....................................................................................................................................75

Specications/Outer dimensions ..............................................................................................................76

Specications ...........................................................................................................................................76

Pump ...................................................................................................................................................76

Power cable ........................................................................................................................................76

Body colour .........................................................................................................................................76

Control unit ..........................................................................................................................................77

Outer dimensions .....................................................................................................................................78

IX-C060/-C150 TC/TE N-TB ...............................................................................................................78

IX-C060/-C150 TC/TE FA-TB .............................................................................................................79

IX-C060/-C150 TC/TE N-RF ...............................................................................................................80

IX-C060/-C150 TC/TE FA-RF .............................................................................................................81

IX-C060/-C150 S6 N-TB .....................................................................................................................82

IX-C060/-C150 S6 FA-TB ...................................................................................................................83

IX-C060/-C150 S6 N-RF .....................................................................................................................84

IX-C060/-C150 S6 FA-RF ...................................................................................................................85

Contents

Page 6

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 injury

WARNING

CAUTION

A symbol accompanies each precaution, suggesting the use of "Caution", "Prohibited actions" and specic "Requirement".

accident.

Indicates mishandling could lead to personal injury or prop-

erty damage.

Caution marks Prohibition mark Requirement mark

Caution

Electrical

shock

Prohibition

Do not remodel

Requirement

Wear

protectors

Earthing

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

Page 7

Electrical

shock

Requirement

Safety instructions

WARNING

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.

Couper l’alimentation électrique de la pompe avant intervention

Intervenir sur la pompe sans avoir au préalablement coupé l’alimentation électrique peut déclencher des décharges électriques. Avant d’entreprendre n’importe quel type d’intervention, veillez à mettre la pompe et tout dispositif connexe hors tension à l’aide de l’interrupteur prévu à cet effet.

Stop operation

If you notice any abnormal or dangerous conditions, suspend operation immediately and inspect/solve problems.

Arrêter le fonctionnement

Si vous détectez une anomalie ou des signes suspects et inhabituels pendant le fonctionnement, interrompez immédiatement les opérations et inspectez, résolvez les problèmes.

Prohibition

Do not remodel

Wear

protectors

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 specied may result in failure or injury. Use this product in specied conditions only.

Se conformer uniquement aux applications prévues

La pompe doit être utilisée conformément à l’usage pour lequel elle a été

prévue et dans le respect de ses caractéristiques techniques. Toute utilisa-

tion non conforme peut entraîner un incident ou endommager le dispositif.

Do not modify the pump

Alterations to the pump carries a high degree of risk. It is not the manufacturer's responsibility for any failure or injury resulting from alterations to the pump.

Ne pas modier la pompe

Ne jamais modier une pompe sous peine de causer un incident grave. Iwaki ne pourra en aucun cas être tenu responsable d’un incident ou de dégâts survenus à la suite d’une modication du dispositif.

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 specic solution will dictate the degree of protec-

tion. Refer to MSDS precautions from the solution supplier.

Porter un équipement de protection

Toujours porter un équipement de protection (lunettes, gants ré-

sistants aux produits chimiques, masque, casque) durant le démontage, l’assemblage et la maintenance. Le travail effectué dictera le degré de protection. Référez-vous au MSDS de la solution proposée par le fournisseur.

Prohibition

Do not damage the power cable

Do not pull, knot, or crush the power cable. Damage to the power cable could lead to a re or electrical shock if cut or broken.

Ne pas endommager le câble électrique

Ne pas tirer ou faire un nœud avec le câble électrique. Endommager un câble électrique pout provoquer une incendie ou une décharge électrique.

Do not operate the pump in a ammable atmosphere

Do not place explosive or ammable material near the pump.

Ne pas utiliser la pompe dans une atmosphère explosive

Pour votre sécurité, du matériel dangereux ou inammable ne doit pas être placé près de la pompe.

WARNING

Page 8

Risk of electric shock

This pump is supplied with a grounding conductor and grounding-type attachment plug. To reduce the risk of electric shock, be certain that it is connected only to a properly grounded, grounding type receptacle.

Electrical

shock

Requirement

Prohibition

Risque de choc électrique

La pompe est fournie avec un conducteur pour mise à la terre et une prise courant. An de réduire le risque de choc électrique, veillez à ce que la terre soit correctement raccordée.

CAUTION

Qualied personnel only

The pump should be handled or operated by qualied personnel with a full understanding of the pump. Any person not familiar with the product should not take part in the operation or maintenance of the pump.

Opérateur qualié uniquement

La pompe doit être manipulée ou utilisée par du personnel qualié con-

naissant parfaitement la pompe. Tout autre personne étrangère ne doit pas prendre part à l’utilisation ou à la maintenance de la pompe.

Use specied power only

Do not apply power other than that specied on the nameplate. Otherwise, failure or re may result. Ensure the pump is properly grounded.

Utilisez une tension appropriée uniquement

Ne pas appliquer une autre tension que celle spéciée sur la plaque sig-

nalétique sinon, il peut en résulter une panne ou une incendie. Assurezvous également de la mise à la terre de la pompe.

Prohibition

Caution

Prohibition

Keep electric parts and wiring dry

Risk of re or electric shock. Install the pump where it can be kept dry.

Ne mouillez pas les parties électriques ou les câbles

Risque d’incendie ou de décharge électrique. Installez la pompe dans un endroit sec.

Ventilation

Fumes or vapors can be hazardous with certain solutions. Ensure proper ventilation at the operation site.

Ventilation

Manipuler un produit toxique ou odorant peut provoquer une intoxication. Prévoyez une ventilation sufsante à l’endroit de la manipulation.

Do not install or store the pump:

• In a ammable atmosphere.

• In a dusty/humid environment.

• Where ambient temperature can exceed 0-50ºC (32-122°F).

• In direct sunlight or wind & rain.

N’installez ou ne stockez pas la pompe dans les endroits suivantes:

• Dans une atmosphère inammable

• Dans un endroit poussiéreux ou humide.

• Dans une place où la température n’est pas comprise entre 0 et 50 °C.

• Directement sous le soleil, le vent ou la pluie.

This pump has been evaluated for use with water only.

Cette pompe a été testée uniquement avec de l'eau.

Caution

CAUTION

Page 9

Spill precautions

Ensure protection and containment of solution in the event of plumbing or pump damage (secondary containment).

Safety instructions

Requirement

Prohibition

Earthing

Electrical

shock

Déversement accidentel

Prenez des mesures protectrices contre tout incident résultant d’un débit trop important de la pompe ou d’une casse de tuyauterie.

Do not use the pump in a wet location

The pump is not waterproof. Use of the pump in wet or extremely humid locations could lead to electric shock or short circuit.

N’utilisez pas la pompe sous l’eau

La pompe n’est pas complètement étanche. Utiliser la pompe dans l’eau ou dans un endroit très humide peut créer une décharge électrique ou un court-circuit.

Grounding

Risk of electrical shock! Always properly ground the pump. Conform to lo-

cal electric codes.

Mise à la terre

Veillez à ne pas faire fonctionner la pompe sans avoir au préalable prévu une mise à la terre. Celle-ci permettra d’éviter d’éventuelles décharges électriques. Vériez que le câble de mise à la terre est bien branché.

Install a GFCI (earth leakage breaker)

An electrical failure of the pump may adversely affect other devices on the same line. Purchase and install a GFCI (earth leakage breaker) separately.

Détecteur de fuites à la terre

Un problème électrique peut affecter défavorablement le dispositif. Achet-

ez et installez un détecteur de fuites à la terre.

Requirement

Prohibition

Requirement

Preventative maintenance

Follow instructions in this manual for replacement of wear parts. Do not disassemble the pump beyond the extent of the instructions.

Remplacement des pièces usées

Suivez les instructions de ce manuel pour remplacer les pièces usées. Ne démontez pas la pompe au-delà des instructions.

Do not use a damaged pump

Use of a damaged pump could lead to an electric shock or death.

N’utilisez pas une pompe endommagée

Utiliser une pompe endommagée peut provoquer une décharge électrique ou la mort.

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.

Elimination des pompes usées

Elle doit se faire en conformité avec les règles locales en vigueur (consult-

ez une entreprise certiée et spécialisée).

Check pump head bolts

Liquid may leak if any of the M8/M5 pump head bolts become loose. Remove the bolt cover and tighten the bolts diagonally and evenly by 12N•m (IX-C150) or 3.5N•m (IX-C060) before initial operation and at regular intervals.

Caution

Serrez la tête de pompe

Il pourrait y avoir une fuite de liquide si les 8 boulons M8/M5 du corps de pompe ne sont pas bien serrés. Enlevez le cache boulon et resserrez les boulons diagonalement et uniformément (12N•m: IX-C150, 3.5N•m: IXC060) avant la première utilisation et à intervalles réguliers.

CAUTION

Page 10

Precautions for use

• Electrical work should be performed by a qualified electrician. Otherwise, personal injury or property damage could result.

Le raccordement électrique de la pompe doit être effectué par du person-

nel qualié sinon, il pourrait y avoir un dommage corporel ou incorporel.

• Do not install the pump:

–In a ammable atmosphere.

–In a dusty/humid place. –In direct sunlight or wind & rain.

–Where ambient temperature can exceed 0-50ºC (32-122°F).

Ne pas installer la pompe dans les endroits suivants: –Dans une atmosphère inammable –Dans une atmosphère poussiéreuse ou humide. –Sous les rayonnements du soleil, dans le vent ou sous la pluie.

–La température ambiante doit être comprise entre 0 et 50°C.

• Select a level location, free from vibration, that won't hold liquid. Anchor

the pump with four M8 bolts so it doesn't vibrate. If the pump is not in-

stalled level, output may be affected. Choisissez un endroit où il n’y a pas de vibrations et où le liquide peut

s’évacuer. Fixez la pompe à l’aide de visses M8 de façon à ne pas avoir de vibrations. Si la pompe est inclinée, le débit peut être réduit.

• When two or more pumps are installed together, vibration may be signifi-

cant, resulting in poor performance or failure. Select a solid foundation (concrete) and fasten anchor bolts securely to prevent vibration during operation.

Caution

Si plusieurs pompes sont installées ensemble, elles interagissent et les vibrations peuvent devenir importantes, ce qui engendre des performances médiocres ou des ratures. Choisissez un endroit solide et xez les boulons correctement pour évitez les vibrations pendant le fonctionnement.

• Allow sufficient space around the pump for easy access and maintenance.

Prévoyez de l’espace autour de la pompe pour faciliter l'accès et la mainte-

nance.

• Install the pump as close to the supply tank as possible. Installez la pompe le plus près possible du tank de produit.

• When handling liquids that generate gas bubbles (sodium hypochlorite or

hydrazine solution), install the pump in a cool and dark place. Flooded suc-

tion installation is strongly recommended. Installez la pompe dans une place froide à l’abri du soleil lorsqu’il s’agit

du dosage de produits dégazant tels que l’hypochlorite de sodium ou l’hydrazine. Mettre la pompe en charge est vivement recommandé.

• The suction line I.D. should be equal to or wider than the I.D. of the pump. La ligne d’aspiration doit être plus large que l’entrée de la pompe.

• Build up a flooded suction system for the viscous liquid delivery of 300mPa•S or more.

Caution

Pour les liquides ayant une viscosité supérieure ou égale à 300 mPa.s il faut mettre la pompe en charge.

Precautions for use

Caution

Page 11

• Use measures to keep the pump connections free from stress. Weight and thermal expansion/contraction of the piping can stress connection points.

Safety instructions

La pompe ne doit pas être soumise à des effets éventuels de dilation ou de contraction du pipe dus à un stress thermique.

• Overload protection will stop pump operation when discharge pressures reach 1.3 to 2 times higher than the pump maximum. If the discharge line cannot conservatively handle the maximum pressure, use a relief valve to safely depressurize the discharge line.

Un dispositif de protection en cas de surcharge doit pouvoir arrêter le dos-

age quand la pression au refoulement s’élève de 1,3 à 2 fois le maximum admis. Installez une vanne de sécurité pour relâcher la pression de la ligne de refoulement si la ligne de refoulement ne peut pas supporter de haute pression.

• 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.

Veillez à ne pas laisser tomber la pompe sur le sol. Un impact important pourrait réduire les performances de la pompe. Ne pas utiliser une pompe endommagée sinon il pourrait y avoir un courant de fuite ou une décharge électrique.

• The pump has a rating of IP65 equivalent, but is not waterproof. Do not op-

erate the pump while wet with solution or water. Failure or injury may result. Immediately dry off the pump if it gets wet.

Caution

La pompe est IP65 équivalent mais n’est pas complètement étanche. Ne

pas laisser la pompe couverte de liquide pompé ou sous la pluie. Il pour-

rait y avoir des ratés ou préjudices. Si la pompe a été mouillée, sechez-la directement.

• Do not close discharge line during operation. Solution may leak or pump and piping may break. Install a relief valve to ensure safety and prevent damaged plumbing.

Ne fermez pas la ligne de refoulement lorsque la pompe est en fonc-

tionnement sinon il pourrait y avoir des fuites de liquide ou la pompe et la tuyauterie pourraient céder. Installez une soupape de sécurité pour des raisons de sécurité et pour éviter tout dommage de la tuyauterie.

• Solution in the discharge line may be under pressure. Release the pres-

sure from the discharge line before disconnecting plumbing or disassembly of the pump to avoid solution spray.

Le liquide au refoulement peut être sous pression. Relâchez la pression du refoulement avant de démonter la pompe ou d’enlevez le tubage pour éviter tout jet de liquide.

• Wear protective clothing when handling or working with pumps. Consult solution MSDS for appropriate precautions. Do not come into contact with residual solution.

Portez un équipement de sécurité lorsque vous manipulez la pompe. Consultez le MSDS pour utilisez les précautions appropriées. Evitez tout con-

tact avec le liquide chimique.

Caution

Requirement

Caution

• Do not clean the pump or nameplate with a solvent such as benzine or thinner. This may discolour the pump or erase printing. Use a dry or damp cloth or a neutral detergent.

Ne nettoyez pas la pompe ou la plaque signalétique à l’aide d’un solvant comme le benzène ou le white spirit. Cela pourrait décolorer la pompe ou effacer l’impression. Utilisez un tissu sec ou mouillé avec de l’eau ou un détergent neutre.

Benzine

Precautions for use

Thinner

Page 12

Overview

Pump characteristics, features and part names are described in this section.

Introduction

Pump structure & Operating principle

The IX series are diaphragm pumps with a brushless DC (BLDC) motor and feature a high turndown ratio & automatic controls.

Principle of operation

In the IX series design, a BLDC motor rotation controls the ow rate.

Motor rotation is transmitted to an eccentric cam through a reduction gear and then converted to reciprocating

motion. Volumetric change occurs in the pump chamber as the diaphragm moves back and forth and liquid is

pumped because of the suction and discharge check valves. Discharge speed changes the ow rate while the

suction speed remains the same at any ow rate.

Control unitPump head Drive unit

Pump head valve

(discharge side)

Pump head

Eccentric cam

Diaphragm

Pump head valve

(suction side)

Brushless motor

OUT

Keypads

Introduction

Page 13

Features

● High turndown ratio

Use of a BLDC control motor enables accurate control with a wide turndown ratio.

● High repeatability

Highly-efcient valve design and accurate discharge-/suction-speed controls assure the high repeatability of

chemical dosing (±1%).

● Energy-saving design

Use of helical gears and an assist spring reduces power consumption by 70% compared to our existing me-

tering pump designs (spring back).

● Automatic control

The IX can automatically run along with analogue-, pulse-, batch- or interval batch-operation programming.

● Multivoltage operation

The IX series can be used in all countries thanks to the universal power voltage (100-240VAC).

● Safety design

A diaphragm rupture detection ensures user safety and a pressure overload detection protects the pump and

pipework from an accidental discharge line pressure rise.

● Ingress protection rating of IP65

Overview

Operational functions

Manual mode

Run/stop the pump by key operation. The ow rate can be changed by the up and the down keys at any time

during operation or stop. The operation LED lights in green colour during operation. See page 54 for detail.

Key operation

(Push key)

Run

Pump operation

Stop

Run

Stop

Operational functions

Page 14

EXT mode

■ Analogue proportional control

ANA. P (analogue preset) programming (see page 42 & 54)

Select a proportional control pattern. 4 - 20mA, 20 - 4mA, 0 - 20mA and 20 - 0mA are available. During opera-

tion, the display shows the current ow rate. To show the current value, push the key. To return to the ow

rate display, push the key.

Max

Flow rate

[L/H]

Min

0 4 20

4-20mA analogue signal

Example of use: pH control in a water treatment system

Supply tank

pH meter

Electrode

The left graph shows the flow rate at each

pattern.

a. 4 - 20mA

b. 20 - 4mA

c. 0 - 20mA

d. 20 - 0mA

* The ow rate falls to 0mL/H if the pump runs

beneath the minimum rate.

* The pump does not run over the maximum ow

rate at any current value.

4-20mA signal

Pump

Operational functions

Page 15

ANA. V (analogue variable) programming (see page 42 & 54)

The pump increases/decreases a stroke/ow rate in proportion to 0-20mA. Determine the operational behav-

iour by programming two set points and choosing one of the LINEAR, BOX and LIMIT patterns.

To show the current value, push the key. To return to the ow rate display, push the key.

A stroke/ow rate changes with a current value by a programmed line.

Condition:

Set Point 1 (SP.1) = Ampere : 6mA, Flow rate : 45L/H

Set Point 2 (SP.2) = Ampere : 17mA, Flow rate : 127L/H

150L/H 127L/H

SP.2

Overview

45L/H

0 6

SP.1

20mA

<BOX>

A stroke/ow rate changes with a current value by a programmed line. The rate does not exceed the Set Point

2 but then falls to 0 before the Set Point 1.

Condition:

Set Point 1 (SP.1) = Ampere : 6mA, Flow rate : 45L/H

Set Point 2 (SP.2) = Ampere : 17mA, Flow rate : 127L/H

150L/H 127L/H

45L/H

SP.1

0 6

SP.2

20mA

A stroke/ow rate changes with a current value by a programmed line. The rate does not falls below the Set

Point 1 or exceed the Set Point 2.

Condition:

Set Point 1 (SP.1) = Ampere : 6mA, Flow rate : 45L/H

Set Point 2 (SP.2) = Ampere : 17mA, Flow rate : 127L/H

150L/H 127L/H

45L/H

SP.1

0 6

SP.2

20mA

Operational functions

Page 16

■ Pulse control (see page 42 & 54)

The ow rate is automatically controlled by the ow volume (ml) per pulse and the pulse signal frequency from a

ow meter.

* It takes about 10 pulses for the IX to catch up with the change of the frequency.

10Hz 5Hz 10Hz

Pulse signal

Flow rate at 10Hz

Fow rate at 5Hz

Example of use: Chemical dosing in a sewage treatment system

Flow meter

Flow

Supply tank

Pulse signal

Pump

■ Batch control (see page 42 & 54)

The IX discharges a programmed ow volume per pulse and stops when it is completed. The programmed or

remaining ow volume is shown on the controller until it has reduced to zero. In this control mode, the pump

runs at the MAN speed (the pump speed in the manual mode). The pump behaviour can change depending on

the setting of the buffer. See below.

When the buffer is OFF:

Any input of the external pulse signal will be cancelled when the pump is activated for the earlier pulse input.

The next dosing becomes ready after the programmed ow volume has been completed.

*Note the control stops immediately when the key is pushed once.

Cancelled

Pulse input

Programmed

flow volume

Pump

Signal out

(batch comp alarm)

Operational functions

Run

Stop

Run

Stop

Page 17

Example of use: Chemical dosing in a production line system

Supply tank

Pump

Pulse

signal

Proximity switch

When the buffer is ON:

Every time the external pulse signal is inputted, the programmed ow volume per pulse is accumulated (max

65535 pulses) even when the pump is activated for the earlier pulse input.

*The control stops immediately and all the pulse accumulation is cleared when the key is pushed once.

Pulse input

Overview

Flow volume for

Programmed

flow volume

Pump

Signal out

(batch comp alarm)

the next signal

Run

Stop Stop

Pulse input by the key:

Instead of the pulse signal input, pushing the key can start or stop the batch control. In this case, the pump

behaves as the control with the buffer OFF even when the buffer is set to ON in the batch control mode.

key

Programmed

flow volume

Pump

Run

Stop Stop

Stop

Operational functions

Run

Page 18

■ Interval batch control (see page 42 & 54)

To make an interval batch control, set a date and time interval and the ow volume. The IX discharges the pro-

grammed ow volume at a set interval. In the diagram below, the interval is set to 1 hour.

* The pump runs at the MAN speed. The control is triggered by either the external pulse signal or the push of the key.

Push the

key to stop the control when it is triggered by the key.

Time

Pulse signal/

Push of

key

Flow

1 hr

2 hr 3 hr

Example of use: Water transfer for a sprinkler system

Pump

Supply tank (water) Pulse signal

AUX function

The pump runs at the AUX speed while receiving the external signal via the AUX terminal. See page 51.

* This function works only when the pump is running in either MAN or EXT mode (see page 40.). The pump returns to the

MAN or EXT mode once the AUX signal stops.

AUX signal

Pump operation

RunStop RunStop

Priming function

The pump runs at the MAN speed (or the maximum stroke rate with default setting) while both the UP and DOWN keys are pressed. Use this function for priming or degassing. Release both the keys to stop the pump. See page 55 for detail.

* This function is available at any time except when the pump is in the MAN/EXT selection or menu selection (see page 40.).

Press & hold

Pump operation

RunStop Stop

Press & hold

Run Stop

Operational functions

Page 19

STOP functions

■ STOP function (see page 45)

The start/stop of operation can be controlled by the signal from a level sensor. The operation LED changes

from green to red colour when the pump is receiving the Pre-STOP signal from a level sensor in operation.

See page 32 "STOP IN" for wiring diagram.

Example of use: Liquid level monitoring

Flow

LED lights

in red

Pump OFF

Liquid is below the minimum level

The pump stops when liquid has fallen below the minimum level.

STOP signal

Level sensor

Overview

■ Pre-STOP function (see page 45)

Liquid level in the supply tank can be monitored by the signal from a level sensor. The operation LED changes

from green to orange colour when the pump is receiving the Pre-STOP signal from a level sensor in operation.

See page 32 "STOP IN" for wiring diagram.

Example of use: Liquid level monitoring

Flow

LED lights

in orange

Pump

Liquid is near the minimum level

The operation LED lights in orange colour to inform a user that liquid comes close to the minimum level in a supply tank.

Pre STOP

Level sensor

signal

Analogue output function

The pump transmits the 0-20mA analogue signal in proportion to the preset ow rates. See page 46.

Operational functions

Page 20

Protective functions

■ Interlock function (see page 32 & 47)

Interlock function works in the same way as the STOP function but uses a preference circuit. Use this function

for emergency stop.

■ Diaphragm rupture detection (see page 45)

The pump stops right after a built-in sensor detects a leak in the compartment at the back of the diaphragm. In

this condition, the operation LED lights in red colour. Replace a broken diaphragm as necessary. See page 63

for diaphragm replacement. To release this error condition, push the start/stop key (or the ESC key if the pump

is under the Probus control.).

NOTE

This capacitance sensor does not work properly if liquid conductivity is 1mS/m or below. Before sending pure water, oil or any other low-conductivity liquid, check the conductivity to see if it meets the minimum detection level. If it is not satised, the leak sensor is no longer usable. In this case a leak from the drain port is the only valid indicator. In either case, replace the diaphragm immediately when a leak is found.

A leak is detected.

Leak detection

OFF

Pump operation

Run Stop

■ Pressure overload/Failed rotation control detection

The pump stops with the red operation LED blinking when a built-in pressure sensor detects 1.3-2.0 times high-

er discharge pressure than the maximum level or when the hole IC which monitors the motor rotation has failed.

If the pump is suspended (by the over-current protection) in either condition, the pump resumes operation 30 seconds later. If the suspended operation has recurred 5 times consecutively, the pump will not resume opera-

tion any more and will keep still. These error conditions can be released when the start/stop key is pushed once.

NOTE

The discharge pressure can rise 1.3-2.0 times higher than the maximum allowable level of the pump depending on operating conditions and piping layouts. Also, if the pressure rises too sharp (with the closed dis-

charge), it may not be even detected or curbed by the over-current protection. Set up a relief valve to protect the related devices on the discharge line from the possible pressure rise if their pressure resistance is low.

Overload detection

1 2 3 4 5times

Pump operation

Operational functions

OFF

Run Stop

30sec 30sec 30sec 30sec

Page 21

■ Alarm output function (see page 47)

Enable or disable the output of the batch completion, STOP, Pre-STOP, interlock, diaphragm rupture detection,

pressure overload detection, and/or drive error detection functions which is preset to the Alarm OUT 1 and 2,

or the output of the volume proportional pulse preset only to the Alarm OUT 2. See page 33 "Alarm OUT (DIN

connector)" for wiring diagram.

Alarm OUT 1 (OUT 1) : Mechanical relay output (no voltage contact 1a×1 250VAC 3A, resistive load)

Alarm OUT 2 (OUT 2) : PhotoMOS relay output (no voltage contact 1a×1 24VAC/DC 0.1A, resistive load)

Other functions

■ Suction speed setting (see page 51)

Suction speed is adjustable by 4 levels depending on liquid property. Reduce suction speed so as to reduce

inertia resistance for the delivery of viscous liquid or to prevent cavitation for gaseous liquid. Select 100% (de-

fault), 75%, 50% or 25%.

■ Maximum ow rate setting (see page 51)

The maximum allowable ow rate of the IX can be reduced if necessary. The default setting of the IX-C150 is

150L/H and the IX-C060 is 60L/H.

Overview

■ Diaphragm position adjustment (see page 51)

A pump shaft expands or contracts for easy diaphragm replacement. Select "MAX OUT Pos." through the

"Other Features" menu in order to extend the pump shaft to the maximum. Select "MAX IN Pos." to contract it

to the minimum and mount the pump head. See page 63 "Diaphragm replacement" for detail.

■ Anti chattering programming (see page 51)

Program a pulse recognition time for the IX not to be adversely affected by chattering or noise. Factory default

setting is 5 msec. This means the pump recognizes the pulse length of 5 msec or more. The other options are

1 and 2 msec and should be selected for the shorter pulse length, however, note the shorter the recognition

time is, the more susceptible to the interference of noise the pump becomes. Note the maximum allowable

input frequency of the IX is 100Hz.

■ Output logic setting (see page 51)

Select "normally open" or "normally closed" for the Alarm OUT 1 (OUT 1) and 2 (OUT 2) outputs.

■ Flow unit setting (see page 51)

Select L/H or GPH for the ow rate indication.

■ Language setting (see page 51)

Select your language through the language selection.

■ Keypad lock (see page 56)

The IX-C is shipped with the access codes at default values (00000). In order to prevent against unauthorized

tampering, you will need to change the access codes to your own values.

■ Default setting

Power on the pump while pressing the ESC key to recall default setting. Note the ow volume per shot ob-

tained through the calibration process (see page 37) remains the same.

Operational functions

Page 22

Part names

Pump

Control unit

Used for the start/stop of the pump

and operation control/program-

ming. See next page for detail. Unhook the cover to open it. Push down until it clicks once to close it.

Outlet

Bolt cover

Take out the cover to remove the pump head.

Inlet

Pump head

Nameplate

Describes the pump specifi-

cations.

Base

Always anchor it with bolts.

Drain port (Vent hole)

Chemical liquid will be released from here. * Do not plumb this drain port to a supply tank

with sodium hypochlorite or any other strong acid. Make sure this port "breathes" in a clean atmosphere.

Part names

Page 23

Operation panel

Start/Stop key

Used for starting/stopping the pump operation or moving back to the MAN/ EXT selection.

Display

An operational status, a selected mode and programmed values are shown here.

Overview

ESC key

Used for cancelling pro-

gramming and moving back to a previous menu.

Operation LED

Lights in green in operation and in red during stoppage, programming, error conditions. Lights in orange as Pre-STOP signal is entered. See page 24.

ALARM LED

Lights to notice the damaged diaphragm, the inter-

lock activation or so.

MENU key

Used in the MAN/EXT selection screen for calling up the menu screen.

Left/Right key

Used for moving through items. Press and hold both

keys for 3 seconds to dis-

able keypads.

Enter key

Used for making a deci-

sion in the menu screen or MAN/EXT selection.

UP/DOWN key

Used for changing numeric

values or selecting a programming mode.

The pump enter the priming mode while both the keys are pressed.

Part names

Page 24

■ Basic displays & Pump states

Display

Operation LED

lights in red

Operation LED

lights in green

Operation LED

lights in orange

ALARM LED

lights in red

Operation

―

― AUX operation ― ―

―

― ―

A wait state in manual mode

Operation in manual mode

Operation in EXT mode (Analogue control)

Operation in prim-

ing mode

― ― ―

― ―

Pre-STOP func-

tion is active.

Pre-STOP func-

tion is active.*

A wait state in

EXT mode (ana-

logue control)

MAN/EXT selec-

tion

Menu screen ― ― ―

Pressure overload

Stop

protection is ac-

tive.

Diaphragm is bro-

ken.

Failed rotation control is detected.

Operation stop in manual mode

― ― ―

Pressure overload

― ―

protection is ac-

tive.*

Diaphragm is bro-

ken (Alarm OUT 1 default setting).*

Failed rotation

control is detect-

ed.*

Operation stop in manual mode*

― ― ―

* The Alarm LED becomes active when a function is allocated to the Alarm OUT 1 or 2.

Part names

Interlock function ac-

tivation (Alarm OUT 2 default setting)*

Page 25

Identication codes

Each code represents the following information.

Pump

IX - C 150 TC N - TB - U

a b c d e f g h i

a. Series name

b. Drive unit

c. Pump unit (Max ow)

150 : 150 [L/H]

060 : 60 [L/H]

d. Wet end materials

Code Pump head Ball valve Valve seat O ring Valve gasket Diaphragm

TC TE EPDM EPDM S6 SUS316 SUS316 SUS316

*EPDM is not a wet end.

PVDF CE

FKM FKM

―

PTFE

Overview

PTFE+EPDM*

Material code

PVDF : Polyvinylidene diuoride PTFE : Polytetrauoroethylene

EPDM : Ethylene-propylene rubber FKM : Fluorine-contained rubber

CE : Ceramics SUS316 : Austenite stainless

e. Connection

N : NPT thread

FA : ANSI ange

f. Controller housing

TF : Top Front TB : Top Back TR : Top Right TL : Top Left RF : Right Face LF : Left Face

g. Control code

1 : IX-C060

2 : IX-C150

h. Power plug

Code U U2

Plug shape

115V (1950mm length) 230V (1950mm length)

i. Special version

No code : Standard models

: Customized models will be coded.

Identication codes

Page 26

Installation

This section describes the installation of the pump, piping and wiring. Read through this section before work.

Points to be observed

Observe the following points when installing the pump.

• Risk of electrical shock. Be sure to turn off power to stop the pump and related devices before service is performed.

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.

• Use of a damaged pump could lead to an electric shock or death.

Pump mounting

Select an installation location and mount the pump.

Necessary tools

• Four M8 bolts (pump mounting) • Adjustable wrench or spanner

Select a suitable place.

Always select a at oor free of vibrations. See page 10 for detail.

Anchor the pump by four M8 bolts.

Be sure to x the pump at four points.

NOTE

Select a level location, or the ow may reduce.

Pump mounting

Page 27

Pipework

■ Piping layout

Flooded suction application Suction lift application

Accumulator/Chamber

Pressure gauge

Relief valve

Back pressure valve

Air vent/drain valve

Calibration

cylinder

Pump

Tank

Relief valve

Air vent/

drain valve

Pump

Pressure gauge

Back pressure valve

Installation

Calibration

cylinder

Tank

NOTE

• The suction line I.D. should be equal to or wider than the I.D. of the pump.

• When handling liquids that generate gas bubbles (sodium hypochlorite or hydrazine solution), install the pump

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

Pipework

Page 28

Drain port (Vent hole)

Leaked liquid drains through the drain port at the time of accidental diaphragm rupture. Use an appropriate chemically-resistant tube to the port to safely collect the liquid.

NOTE

• Do not plug the drain port. The port functions as a vent hole to keep the pressure behind the diaphragm back

atmospheric.

• Do not immerse the end of a drain tube in drained liquid, or the liquid may be pumped up into the compart-

ment behind the diaphragm back.

• Liquid in the drain tank is the sign of the damaged diaphragm. Immediate inspection or repair is necessary.

Do not leave this condition as it is. Fumes or vapors from certain solutions may move up into the pump via the

drain tube and attack its inside.

(20)

Do not locate the drain tube end below the liquid level.

Drain port (vent hole) *Applicable tube size

Empty drain tank

Inner diameter: 6mm Outer diameter: 12mm or below

Noncorrosive chemicals in a supply tank. The drain tube end must stay above the liquid level.

(

7.5)

(

Do not take in fumes from corrosive chemicals such as sodium hypochlorite.

Drain port (Vent hole)

Page 29

Wiring

Wiring for power voltage, earthing and external signals.

Points to be observed

Observe the following points during wiring work.

Electrical work should be performed by a qualified electrician. Always observe applica-

• ble codes or regulations.

Do not apply power other than that specified on the nameplate. Otherwise, failure or fire

• may result.

Do not perform wiring work while electric power is on. Otherwise, an electrical shock or

• a short circuit may result. Be sure to turn off the power before wiring work.

Be careful for electric power not to be turned on during work.

•

Replacement of a power cable should be conducted by a manufacturer, his agency or a

• skilled person. Otherwise, an accident may result.

End terminals

Installation

See the following diagram for detail.

Alarm OUT

EXT IN STOP IN

AUX IN/Analog OUT

Fieldbus

Power cable (1950mm)

Wiring

Page 30

Power voltage/Earthing

Points to be checked

• Check that power voltage is turned off.

Insert the plug all the way seated in a socket.

NOTE

• Do not share a power source with a high power device which may generate a surge voltage. Otherwise an

electronic circuit may fail. The conductive noise caused by an inverter also affects the circuit.

• Energize the pump with a power voltage via a mechanical relay or switch. Do not uctuate the voltage, or

CPU may malfunction. See page 31 for the precautions for ON-OFF control by a mechanical relay.

Apply power sharply Do not apply gradually

POWER

ON OFF

POWER

TIME

ON OFF

TIME

Surge voltage

The electronic circuit in the control unit may fail due to a surge voltage. Do not place the pump close to a high power device of 200V or more which may generate a large surge voltage. Otherwise, take any of the following measures.

• Install a surge absorption element (such as a varistor with capacity of 2000A or more) via power cable or,

Surge absorption element

Recommended varisters: Panasonic ER ZV14D431

KOA NVD14UCD430

See manufacturer's catalogues for detail.

A noise cut transformer via the power cable.

•

Noise cut transformer

Wiring

Page 31

Precautions for ON-OFF control by a mechanical relay

The control unit is equipped with a CPU. To ensure the CPU to work properly, always start/stop the pump by the STOP signal for ON-OFF control. Try not to turn on and off the main power. Otherwise, observe the following points:

• Ensure the minimum OFF time of 10 minutes.

• The contact capacity of a mechanical relay should be 5A or more. Or a contact point

may break.

• If the contact capacity of a mechanical relay is 5A, the maximum allowable number of

times the power is turned ON/OFF is 150,000. The contact capacity should be 10A or more when the actual number of times is over 150,000 or when sharing a power source

with a large capacity equipment which may cause a surge voltage and damage a con-

tact point.

• Use a solid state relay (SSR) as necessary (such as the OMRON G3F). See manufac-

turer's catalogues for detail.

Signal wire connection

Installation

Points to be checked

• Check that power voltage is turned off.

Use our optional connector cables below or purchase DIN 4- and 5-pin female connector cables when using signal input and output.

Optional 5m DIN connector cables for: The EXT input signal The STOP input signal The AUX input/Analog output signals The Alarm output signal

NOTE

• Do not lay on these signal cables in parallel with a power cable. Otherwise the electromagnetic induction

noise is generated and malfunction or failure may result.

• The following products are the recommended SSRs (Solid State Relays) for signal input. Any other SSRs

might cause malfunction. See manufacturer's information for details on these SSRs.

–OMRON G3FD-102S or G3FD-102SN

–OMRON G3TA-IDZR02S or G3TA-IDZR02SM

• When using a mechanical relay for signal input, its minimum application load should be 5mA or below.

• Insert the DIN 4- or 5-pin female connector as far as it will go and then tighten the skirt to make a secure con-

nection.

*Use either a no-voltage contact or an open collector for the EXT signal.

Wiring

Page 32

■ EXT IN

To make pulse-, batch-, interval batch- and analogue-control operation or to activate interlock function, connect

signal wires to the EXT terminals via the DIN 5-pin connection.

When using an open collector:

Pay attention to polarity. Pulse (1) and Interlock (2) are plus (+), and COM (4) is minus (-).

When using analogue control:

Pay attention to polarity. Analogue (3) is plus (+) and COM (4) is minus (-). Internal resistance is 200Ω.

When using a no-voltage contact:

Use a mechanical relay designed for an electronic circuit. Its minimum application load should be 5mA or less.

1 : Pulse (Brown)

2 : Interlock (White)

3 : Analogue (Blue)

4 : COM (Black)

5 : 12VDC30mA or below (Green)

* Each wire is coloured as above for

our optional cable. The terminal 5 is an output and is not used. Do

Wiring for

Pulse-, Batch-, Interval

batch-control

Wiring for

Analogue control

Wiring for

Interlock function

not short-circuit this terminal to COM (4).

■ STOP IN

To activate STOP function, connect signal wires to the STOP terminal via the DIN 4-pin connection.

When using an open collector:

Pay attention to polarity. STOP (1) and Pre-STOP (2) are plus (+), and COMs (3 and 4) are minus (-).

When using a no-voltage contact:

Use a mechanical relay designed for an electronic circuit. Its minimum application load should be 5mA or less.

1 : STOP (Brown)

2 : Pre-STOP (White)

3 : COM (Blue)

4 : COM (Black)

Wiring for

STOP function

Wiring for

Pre-STOP function

* Each wire is coloured as above for our optional cable.

NOTE

Our optional cable has 5 wires. Cut off a green wire to use it with the DIN 4-pin connector.

Wiring

Page 33

■ AUX IN/Analog OUT

To activate the AUX function or to use the analogue output, connect signal wires to the AUX terminal or the

4-20mA output terminal via the DIN 5-pin connection.

When using an open collector (for AUX IN):

Pay attention to polarity. AUX (3) is plus (+), and COM (4) is minus (-).

When using a no-voltage contact (for AUX IN):

Use a mechanical relay designed for an electronic circuit. Its minimum application load should be 5mA or less.

When using analogue output:

Pay attention to polarity. The 0-20mA (1) is minus (-) and 0-20mA (5) is plus (+). The max load resistance is 300Ω.

Wiring for

AUX function

Max.300Ω

Wiring for

4-20mA output

1 : 0-20mA (Brown)

2 : N.C. (White)

3 : AUX (Blue)

4 : COM (Black)

5 : 4-20mA (Green)

* Each wire is coloured as above for our optional cable.

■ Alarm OUT (DIN connector)

To transmit the signal to an external device, connect signal wires to the OUT terminal via the DIN 4-pin connection.

Alarm OUT 1 (OUT 1) <Mechanical relay>: Enable or disable the alarm outputs of batch completion, STOP, Pre-STOP, interlock, motor overload (/drive error) and leak detection individually.

*Leak detection only is enabled at factory default setting.

Alarm OUT 2 (OUT 2) <PhotoMOS relay>: Enable or disable the alarm outputs of the volume proportional pulse, batch completion, STOP, Pre-STOP, interlock, motor overload (/drive error) and leak detection individually.

*Interlock only is enabled at factory default setting.

Installation

1 : Alarm OUT 1 (White)

2 : Alarm OUT 1 (Brown)

3 : Alarm OUT 2 (Black)

4 : Alarm OUT 2 (Blue)

* Each wire is coloured as above for our optional cable.

Mounting direction of the output signal cable

Mount the DIN square connector cable in the following direction and secure it with a M3 screw.

Alarm OUT terminal

Gasket

Output signal cable

M3 screw

Wiring

Page 34

Operation

This section describes pump operation and programming. Run the pump after pipework and wiring are completed.

Before operation

First check piping and wiring are correct. And then make commissioning before starting operation.

Points to be checked

Before operation, check if:

• Liquid level in a supply tank is enough.

• Piping is securely connected and is free from leakage and clogging.

• Discharge/suction valves are opened.

• Power voltage range is correct.

• Electrical wiring is correct and is free from the risk of short circuit and electrical leakage.

Retightening of pump head xing bolts

Important

The pump head xing bolts may loosen when plastic parts creep due to temperature change in storage or in

transit, and this can lead to leakage. Be sure to retighten the bolts evenly to the specied tightening torque

below in diagonal order before starting operation.

Tightening torque

Model code Tor q u e Bolts Number of bolts

IX-C150 12 N•m M8 hexagon head bolt 8 IX-C060 3.5 N•m M5 hexagon head bolt 6

*Tighten xing bolts once every three months.

Before operation

Page 35

Commissioning

Always make commissioning when rst mounting the pump in your system or resuming operation after a long

period of stoppage.

Open an air vent and a suction line.

Do not open a calibration line if any.

Air vent valve

Open

Supply the rated power voltage to the pump.

Start the pump at a low ow rate and gradually increase it to a target rate.

Continue operation for 10 minutes and check the pump and pipework for any abnormality.

Close an air vent line to introduce liquid to a main line.

Before a long period of stoppage (One month or more)

Clean wet ends and the inside of piping.

• Run the pump with clean water for about 30 minutes to rinse chemicals off.

Before unplugging the pump

• Always stop the pump by key operation and wait for three seconds before unplugging the pump. Otherwise,

the last key operation may not be put in memory. In this case the pump unintentionally starts to run as pow-

ered on, discharging liquid.

Operation

When the pump does not transfer liquid at resuming operation.

• Clean the valve sets and remove foreign matters.

• If air is in the pump head, expel air through the above commissioning procedure.

Before operation

Page 36

Perform a calibration

Periodically make calibration to monitor an accurate ow through control display.

The pump is calibrated by pumping clean water at the maximum operating pressure before shipping (in the absence of a designation by a user), however, make calibration again in an actual operating condition as necessary. Follow the calibration process on the next page.

NOTE

The ow rate shown on the screen is a calculated value based on calibration and is not an actual ow rate.

Calibration is made to determine liquid volume per shot. Arrange your piping system according to the guide

below to ensure the calibration is made correctly.

Suggested piping layout

Use a calibration cylinder connected to a suction line.

Accumulator/Chamber

Pressure gauge

Relief valve

Back pressure valve

Air vent valve

Calibration

cylinder

Pump

Tank

Bad example

Do not immerse a calibration tube in liquid level in a calibration cylinder. Otherwise, tube volume is added to

the liquid volume to be measured, and calibration will be upset.

Tank

Calibration

cylinder

Pump

Perform a calibration

Before calibration

Tube in liquid

After calibration

Calibration cylinder

Page 37

Calibration process

Obtain accurate ow volume per shot (e.g. about 16ml/shot for the C150 type, about 6ml/shot for the C060

type) by dividing the delivered liquid volume by the number of strokes.

Fill a calibration cylinder with liquid.

Open a calibration line to lead liquid from a supply tank to a calibration cylinder. And then close the suc-

tion line and measure liquid volume in the cylinder.

Air vent valve

Open

Close after the cylinder is filled with liquid.

Supply the rated power voltage to the pump and programme a ow rate in the manual

mode.

See page 13 for detail.

NOTE

The calibration accuracy won't change at any ow rate. The higher the ow rate is, the shorter time it

takes, and vice versa.

Select the calibration mode through the menu screen.

See page 44 for detail.

Calibration operation programming

Set a waiting time and the number of strokes. The number of strokes should be determined depending

on how much liquid remains in the calibration cylinder.

Waiting time to start calibration operation : 10(default)-999s

Number of strokes : 60(default)-120ST

Operation

Use UP and DOWN keys to set a waiting time.

Use UP and DOWN keys to set the number of strokes.

Perform a calibration

Page 38

Start calibration operation.

Push the Enter key after setting the number of

strokes. The pump starts the countdown.

Pump starts

Pump stops

Measure liquid volume in the calibration cylinder again.

Enter how much liquid has reduced.

Use the UP and DOWN keys to set the volume reduction.

The pump starts to run for the set number of

strokes as it comes to zero.

Push the Enter key once. The screen shows ow volume

per shot.

The screen shows "ERROR! Volume Out Of Range!!" if

the reduction is too little or too large. Enter correct liquid

volume or recalibrate it.

NOTE

Calibration with high viscosity liquid at a full suction

speed will often give rise to this error. Reduce a suction

speed along with viscosity.

Push the ESC key to return to the wait mode.

Perform a calibration

Page 39

Operation programming

The setting is made with the controller. The pump behaviour differs with each control mode.

Menu Control mode/Function Parameter Default

Mode se-

lection

Analog preset control 0 - 20mA/ 4 - 20mA/ 20 - 0mA/ 20 - 4mA 4-20mA

Analog variable con-

trol

External control

Signal input

Alarm

Analogue output

Others

* For these control modes, the calibrated ow volume per shot is applied to the minimum settable ow volume.

Pulse control*

Batch control*

Interval batch control*

Probus control Address : 1 - 126 50

STOP Closed = Pump OFF/ Closed = Pump ON Closed = Pump OFF PreSTOP Closed = Pump OFF/ Closed = Pump ON Closed = Pump OFF

Interlock Closed = Pump OFF/ Closed = Pump ON Closed = Pump OFF

Leak detection Enable/ Disable Enable

OUT 1

OUT 2

Suction speed 100%/ 75%/ 50%/ 25% 100%

Maximum ow rate

AUX speed

Diaphragm position MAX OUT Pos./ MAX IN Pos. MAX OUT Pos.

Buffer Enable/ Disable Disable

Anti-Chattering 1msec/ 2msec/ 5msec 5msec

Output logic (OUT 1) Normally Open/ Normally Close Normally Open

Output logic (OUT 2) Normally Open/ Normally Close Normally Open

Unit Litter/ US gallon Litter

Keypad lock 00000 - 99999 00000

Language English/Dutch/French/Danish/Spanish/German English

- MAN/EXT MAN

SP1 current 0.0 - 20.0mA 4.0mA

SP1 ow rate

SP2 current 0.0 - 20.0mA 20.0mA

SP2 ow rate

0.00625mL/PLS - 120mL/PLS (C060) 0.00625mL/PLS

0.0156mL/PLS - 300mL/PLS (C150) 0.01562mL/PLS

6.25mL/PLS - 120L/PLS (C060) 6.25mL/PLS

15.6mL/PLS - 300L/PLS (C150) 15.62mL / PLS

0 - 9day, 0 - 23Hr, 1 - 59min 0D : 0H : 1M

6.25mL - 120L/PLS (C060) 6.25mL/PLS

15.6mL - 300L/PLS (C150) 15.62mL / PLS

Batch Complete/ STOP/ Pre-STOP/ Interlock/ Leak Detection/ Motor Overload/ Drive Error

Volume Prop. PLS/ Batch Complete/ STOP/ Pre-STOP/ Interlock/ Leak Detection/ Motor Overload/ Drive Error

SP1 current 0.0 - 20.0mA 4.0mA

SP1 ow rate

SP2 current 0.0 - 20.0mA 20.0mA

SP2 ow rate

80mL/H - 60L/H (C060) 60L/H

200mL/H - 150L/H (C150) 150L/H

80mL/H - 60L/H (C060) 60L/H

200mL/H - 150L/H (C150) 150L/H

0mL/H - 60L/H (C060) 0mL/H

0mL/H - 150L/H (C150) 0mL/H

0mL/H - 60L/H (C060) 60L/H

0mL/H - 150L/H (C150) 150L/H

Leak Detection: Enable Other alarms: Disable

Interlock: Enable Other alarms: Disable

0mL/H - 60L/H (C060) 0mL/H

0mL/H - 150L/H (C150) 0mL/H

0mL/H - 60L/H (C060) 60L/H

0mL/H - 150L/H (C150) 150L/H

Operation

Operation programming

Page 40

Programming ow

Power ON

MAN/EXT selection

Wait state

Operation

Menu screen

MAN modeEXT mode

Use keys to scroll.

* See page 41 for setting at each menu.

* To revert back to the default setting with the pump calibrated, turn on power while pressing the ESC key.

Operation programming

Page 41

Menu screen

Push the MENU key in the MAN/EXT selection mode and call up the menu screen. Use the right and left keys to scroll through each menu item and then push the Enter key to make a selection. Pushing the MENU key again or ESC key in the menu screen, the previous mode will be recalled.

EXT mode selection

The pump can run in four different operating modes of Analogue,

Pulse, Batch and Interval Batch for the external signal. See page

14-18 and 42 for detail.

Calibration

Calibrate the pump to obtain a correct ow rate on the screen.

See page 37 and 44.

Signal input setting

Program STOP, Pre-STOP, Interlock functions and diaphragm

rupture detection. See page 19, 20, 45 and 46.

Analog output setting

Set the output current at SP1 and 2 ow rates to congure the

analog signal output behaviour. See page19 and 46.

Alarm output setting (OUT 1)

Enable or disable the output of the batch completion, STOP,

Pre-STOP, interlock, diaphragm rupture detection, overload/failed

speed detection, and/or drive error detection functions. See page

21 and 47.

Alarm output setting (OUT 2)

Enable or disable the output of the batch completion, STOP,

Pre-STOP, interlock, diaphragm rupture detection, overload/failed

speed detection, drive error detection, and/or volume proportional

pulse functions. See page 21 and 49.

Data logging

The pump can display operating time, total ow volume, power-on

time, the number of ON/OFF and software version. See page 50.

Operation

Programming of other functions

Program a suction speed, a max ow rate, an AUX speed, a dia-

phragm position, an anti-chattering time, butter ON/OFF, output

logics, a ow rate unit and your language or so. See page 21, 51,

52 and 53.

Operation programming

Page 42

■ EXT mode selection

key to confirm

key to return to menu screen

key to scroll

key to change values

Mode selection screen

Analogue preset

Analogue variable

Pulse control

Batch control

Interval batch control

Profibus control

Analogue preset control

Mode setting screen

Operation programming

Page 43

Analogue vairable control SP1 current setting

SP1 flow rate setting

SP2 current setting

to change the value

SP2 flow rate setting

Behavioural pattern selection

Pulse control

to change the value

Operation

to select the pattern

Set flow volume per pulse.

Batch control

Set flow volume per pulse.

Operation programming

Page 44

Interval batch control

Profibus control

Set “Day”.

Set “Hour”.

Set “Minute”.

Set a flow rate.

■ Calibration

key to confirm

key to return to menu screen

Set an address.

*See page 37 "Calibration process" for detail.

key to select

key to change values

Operation programming

Page 45

■ Signal input setting

key to confirm

Function selection screen

STOP function

Pre-STOP function

key to return to menu screen

key to scroll

key to change values

Interlock function

Diaphragm rupture detection

Function setting screen

STOP function

Closed=Pump OFF : Pump stops running

at contact input.

Closed=Pump ON : Pump starts to run at

contact input.

Operation

Pre-STOP function

Interlock function

Closed=Pump OFF : Operation LED lights in

orange at contact input.

Closed=Pump ON : Operation LED does not

lights at contact input.

Closed=Pump OFF : Pump stops running

at contact input.

Closed=Pump ON : Pump starts to run at

contact input.

Operation programming

Page 46

Diaphragm rupture detection

Disable : Rupture detection is not

used.

Enable : Rupture detection is used.

■ Analogue output setting

key to confirm

key to return to menu screen

key to scroll

key to change values

Function selection screen

SP1 current setting

to change the value

SP1 flow rate setting

to change the value

SP2 current setting

to change the value

Operation programming

SP2 flow rate setting

to change the value

Page 47

■ Alarm output setting (OUT 1) <Mechanical relay>

Output selection screen

Batch completion

STOP function

key to confirm

key to return to menu screen

key to scroll

key to change values

Drive error

Pre-STOP function

Overload detection

Interlock function

Diaphragm rupture detection

Operation

Batch completion

STOP function

Output setting screen

Disable : OUT1 is inactive. Enable : OUT1 is activated at input

of the completion signal.

Disable : OUT1 is inactive. Enable : OUT1 is activated at input

of STOP signal.

Operation programming

Page 48

Pre-STOP function

Interlock function

Diaphragm rupture detection

Disable : OUT1 is inactive. Enable : OUT1 is activated at input

of Pre-STOP signal.

Disable : OUT1 is inactive. Enable : OUT1 is activated at input

of interlock signal.

Disable : OUT1 is inactive. Enable : OUT1 is activated at input

of the detection signal.

Overload/Failed speed detection

Drive error detection

Disable : OUT1 is inactive. Enable : OUT1 is activated at input

of the detection signal.

Disable : OUT1 is inactive. Enable : OUT1 is activated at input

of the detection signal.

Operation programming

Page 49

■ Alarm output setting (OUT 2) <PhotoMOS relay>

Output selection screen

Volume proportional pulse

Batch completion

key to confirm

key to return to menu screen

key to scroll

key to change values

Drive error

STOP function

Overload detection

Pre-STOP function

Interlock function

Operation

Diaphragm rupture detection

Output setting screen

Volume proportional pulse

Disable : OUT2 is inactive. Enable : OUT2 is activated to make the pulse signal.

For the functions of the batch completion, STOP, Pre-STOP, interlock, diaphragm rupture detection, overload/failed speed detection and drive error detection, enabling or disabling of these functions can be set to the OUT 2 in the same way as the OUT 1.

Operation programming

Page 50

■ Data logging

key to confirm

Data logging screen

Operating time

Total flow volume

key to return to menu

key to scroll

Press 3 sec to delete data

Software version

Powered-on time

Number of ON/OFF

3 sec Return to a previous screen.

*A selected data will be cleared except the version information.

Operation programming

Page 51

■ Programming of other functions

Suction speed

Max flow rate

key to confirm

key to return to menu screen

AUX speed

key to scroll

key to change values

Diaphragm position

Other selection screen

Language selection

Pin number entry

Flow rate unit

Output 2 logic

Buffer

Anti chattering

Suction speed

Output 1 logic

Operation

Other setting screen

Operation programming

Page 52

Max flow rate

Set a flow rate.

AUX speed

Set a flow rate.

Diaphragm position

MAX OUT Pos. : The diaphragm comes to the top dead point. MAX IN Pos. : The diaphragm comes to the bottom dead point.

* Either one of the above indication keeps ashing as long as the diaphragm

is at either end. See page 63 for diaphragm replacement.

Buffer

Anti chattering

Disable : Buffer OFF Enable

Buffer ON

Operation programming

Page 53

Output 1 logic

Flow rate unit

Set the output 2 logic as necessary.

Pin number entry

Language selection

key to change values key to move through each digit

key to confirm

Operation

Operation programming

Page 54

Operation

Read this section before operation.

Manual operation

Run or stop the pump by keypad operation.

Supply the rated power voltage to the pump.

The operation LED lights in red colour, and a previous mode at the last shutoff returns.

* The pump enters the MAN/EXT selection mode when turning on power with a default setting.

Push the ESC key to enter the MAN/EXT selection mode.

Push the start/stop key to stop operation if the IX is running in the previous mode.

Push the left key to select "MAN" and the Enter key to enter that choice.

The pump enters a waiting state. Use the UP and DOWN keys to set the ow rate.

Push the start/stop key to start operation.

The operation LED lights in green colour during operation.

EXT operation

The pump operation is controlled by the external signal.

Supply the rated power voltage to the pump.

The operation LED lights in red colour, and a previous mode at the last shutoff returns.

* The pump enters the MAN/EXT selection mode when turning on power with a default setting.

Push the ESC key to enter MAN/EXT selection mode.

Push the start/stop key to stop operation if the IX is running in the previous mode.

Operation

Page 55

Push the right key to select "EXT" and the Enter key to enter that choice.

Waiting state display

*The pump enters the analogue preset, analogue variable, pulse, batch or interval batch mode.

Push the start/stop key to start operation. The pump runs along with operation program-

ming and the external signal. Pushing the same key again stops operation.

In the analogue variable control mode, the current value will show up when the key is pushed. Push

the key to return.

The operation LED turns green during operation.

AUX function

Operation at an AUX speed starts while receiving the external signal via the AUX terminal when the IX is running in manual mode or EXT mode. Set an AUX speed before operation. See page 51 for detail.

Priming function

This key operation runs the pump at the maximum stroke rate in operation.

Operation

Press and hold both the UP and DOWN keys.

The pump runs at the maximum stroke rate while both the keys are pressed.

* This function is available at any time except when the MAN/EXT selection or the menu screen is

opened.

Operation

Page 56

Keypad lock

Keypad lock can be active for the prevention of erroneous key operation.

NOTE

• Any key operation is not acceptable when the keypad lock is active. In an emergency, however, pressing

the start/stop key for two seconds, the pump enters a wait state and stops running. Enter the PIN number to

release this state before resuming operation.

• This function is available at any time except when the menu screen is opened.

■ Keypad lock activation

Press and hold both the right and left keys for 3 seconds.

3 sec

"KEY LOCKED!" appears on the screen for one second.

* This indication comes up every time any key is pushed.

■ Keypad lock release

Push the ESC key.

Enter the PIN number.

key to change value

key to move through each digit

■ Emergency stop

Press and hold the start/stop key for 2 seconds to stop the pump.

Release the keypad lock mode to resume operation.

Operation

Page 57

Maintenance

This section describes troubleshooting, maintenance, wear part replace-

ment, exploded views and specications.

Points to be observed

Observe the following points during maintenance work:

• Observe instructions in this manual for maintenance, inspection, dismantlement and as-

sembly. Do not dismantle the pump beyond the extent of the instructions.

• Always wear protective clothing such as an eye protection, chemical resistant gloves, a

mask and a face shield during disassembly, assembly or maintenance work. The spe-

cific solution will dictate the degree of protection. Refer to MSDS precautions from the solution supplier.

• Risk of electrical shock. Be sure to turn off power to stop the pump and related devices

before service is performed.

Before unplugging the pump:

Always stop the pump by key operation and wait for three seconds, especially when disconnecting the pump from a piping system. Otherwise, the stop command may not be saved, and the pump may unintentionally start to run and deliver uid into an imperfect piping system as it is powered on once again.

NOTE

• It's not the manufacture's responsibility for any failure due to corrosion or erosion occurred in your operating

condition.

• Contact your distributor or a manufacturer of the host machine in which our product is built for repair.

• Be sure to drain chemicals and flush the inside of the pump before return so that a harmful chemical does not

spill out in transit.

Maintenance

Page 58

Troubleshooting

First check the following points. If the following measures do not help remove problems, contact your nearest distributor.

■ Pump

States Possible causes Solutions

The pump does not run ( the operation LED

does not light or the

screen is blank.).

Liquid can not be

pumped up.

A ow rate uctuates. Air trapped in the pump head. • Expel air. See page 35.

Power voltage is too low. • Observe the allowable voltage range of

90-264VAC.

The pump is not powered. • Check the pump is switched on.

• Correct wiring.

• Replace a breaking wire to new one.

Air lock in the pump • Expel air. See page 35.

Air ingress through a suction line • Check for the ingression point and x/re-

route the suction line as necessary.

An O ring is not tted to a valve set. • Fit O ring to the valve set.

Foreign matters are stuck in the pump

head valves.

A ball valve is stuck on a valve seat. • Dismantle, inspect and clean the valve.

A vale seat has been pressed in the

valve guide.

Overfeeding occurs. • Mount a back pressure valve to keep the

• Dismantle, inspect and clean the valves.

Replace as necessary.

• Do not push the valve seat into the valve

guide. See page 62.

discharge line pressure constant.

Foreign matters are stuck in the pump

head valves.

Diaphragm is broken. • Replace the diaphragm. See page 63.

Pressure uctuates at an injection

point.

Liquid leaks. A tting is loose. • Tighten the nut to x the tting.

Loose t of the pump head • Retighten the pump head. See page 34. An O ring is not tted to a valve set. • Fit O ring to the valve set. See page 62.

Diaphragm is broken.

A leak from the drain port (vent hole)

• Dismantle, inspect and clean the valves.

Replace as necessary.

• Maintain the pressure constant by opti-

mizing piping or by relocating the injection

point.

• Replace the diaphragm. See page 63.

Troubleshooting

Page 59

Error messages

Take measures below when any of the error messages appears during operation. Contact us or your nearest distributor as necessary.

Error messages Possible causes Measures

• Check a discharge line for clogging and re-

Pressure overload protection is active.

move it as necessary. If this error happens dur-

ing the transfer of high viscosity liquid, make a discharge line I.D. wider and its length shorter.

Diaphragm is broken.

Failed rotation control is de-

tected.

• Replace the broken diaphragm with new one.

See page 63 for detail.

• If this error state is removed by pushing the start/stop key, a possible cause is an instantaneous surge of discharge line pressure. In-

spect/solve the problem and then restart.

• If not, failure of a motor rotation detector is pos-

sible. Contact us or your nearest distributor.

Inspection

Perform daily and periodic inspection to keep the best pump performance and safety.

Daily inspection

Check the following points. If you notice any abnormal or dangerous conditions, suspend operation immediately and inspect/solve problems. See the "Troubleshooting" section as necessary. When wear parts come to the life limit, replace them with new ones. Contact your distributor for detail.

No. States Points to be checked How to check

Flow meter, pressure gauge or visual inspection

Visual or audio inspection

1 Pumping

2 Noise and vibration

Air ingress from the

pump head joints and the suction line

• If liquid is pumped.

• If discharge pressure is normal. Pressure gauge

• If liquid is deteriorated, crystallized or settled. Visual or audio inspection

• If abnormal noise or vibration occurs. They are

signs of abnormal operation.

• If leakage occurs.

• If pumped liquid includes air bubbles, check lines

for leakage and retighten as necessary.

Periodic inspection

Retighten the pump head mounting bolts evenly to the following torque in diagonal order.

* Mounting bolts may loosen in operation. How fast the bolts start to loosen is depending on operating conditions.

Tightening torque

Model code Tor q u e Bolts Number of bolts

IX-C150 12 N•m M8 hexagon head bolt 8 IX-C060 3.5 N•m M5 hexagon head bolt 6

Maintenance

Inspection

Page 60

Wear part replacement

To run the pump for a long period, wear parts need to be replaced periodically. It is recommended that the following parts are always stocked for immediate replacement. Contact your nearest distributor for detail.

Precautions

• Solution in the discharge line may be under pressure. Release the pressure from the discharge line before disconnecting plumbing or disassembly of the pump to avoid solu-

tion spray.

• Rinse wet ends thoroughly with tap water.

• Every time the pump head is dismantled, replace the diaphragm and the valve sets with

new ones.

Wear part list

Pump head Parts # of parts Estimated life

(IX0007)

C150

Valve set

(TC type)

Outlet

(IX0022)

Inlet

(IX0021)

Valve set

(TE type)

Outlet

(IX0034)

Inlet

(IX0033)

Valve set (S6 type)

IX0032

(IX0003)

(IX0002)

(IX0004)

(IX0008)

Outlet Inlet

(IX0005)

(IX0007)

(IX0038)

(IX0003)

(IX0002)

(IX0037)

(IX0039)

Outlet Inlet

(IX0005)

(IX0038)

(IX0027)

(IX0025)

(IX0024)

(IX0027)

(IX0026)

(IX0027)

(IX0006)

2 sets 8000 hours

Wear part replacement

Diaphragm

(IX0014)

1 4000 hours

Page 61

Pump head Parts # of parts Estimated life

C150 Retainer 1 8000 hours

Valve set

(TC type)

IX0069

Valve set

(TE type)

IX0070

(IX0015)

(IX0051)

(IX0048)

(IX0047)

(IX0049)

(IX0051)

(IX0053)

(IX0051)

(IX0052)

(IX0048)

(IX0047)

(IX0050)

(IX0052)

(IX0053)

(IX0052)

2 sets 8000 hours

C060

(IX0075)

Valve set (S6 type)

IX0082

Diaphragm 1 4000 hours

Retainer 1 8000 hours

(IX0073)

(IX0072)

(IX0075)

(IX0074)

(IX0075)

(IX0061)

(IX0062)

2 sets 8000 hours

Maintenance

* Wear part duration varies with the pressure, temperature and characteristics of liquid. * The estimated life is calculated based on pumping clean water at ambient temperature. * Parenthetic codes are selection codes.

Wear part replacement

Page 62

Before replacement

Stop the pump operation.

Close the suction line.

Open the drain valve to release liquid out of the discharge line.

NOTE

Open the valve gradually. Chemicals may be purged if the

discharge line pressure maintains the higher pressure than the

atmospheric pressure.

Drain valve

Open

Valve set replacement

Remove pipes from the pump.

NOTE

• Be careful not to get wet with residual chemicals in piping.

• Rinse chemicals or crystals off the parts as necessary.

• Use care handling the valve set. Do not drop it especially when the suction pipe is removed from the

pump inlet.

• Remove the IX-C060 TC/TE nuts while holding the adapter with a spanner.

IX-C150 TC/TE IX-C060 TC/TE IX-C150 S6 IX-C060 S6

Nut

Adapter

Nut

Remove the bolt

Remove the valve cap

Wear part replacement

Page 63

Take out valve sets from the pump head and take them

apart to replace worn parts as necessary.

Clean the pump head as necessary.

Valve set

Reassemble and remount the valve sets in the pump head.

Observe the mounting order and direction of valve set components. See the exploded view at each

model.

NOTE

• Observe the mounting direction of the valve set.

• The valve seat must be held in the valve guide by

the seat holder when assembling an IX-C060 TC/

TE valve set. Do not push the valve seat down

into the valve guide. Otherwise, a leak may result.

O ring

Valve guide

Seat holder

Valve seat

Valve

Do not push the valve seat

Connect pipes and the pump.

Diaphragm replacement

Necessary tools

• 3mm hexagon wrench • Spanner (C150:13mm / C060:8mm) • Torque wrench

Remove pipes from the pump.

NOTE

• Use care handling the valve set. Do not drop it especially when

the suction pipe is removed from the pump inlet.

• Be careful not to get wet with residual chemicals in the pump

head or the discharge pipe.

Maintenance

Wear part replacement

Page 64

Remove the bolt cover by a 3mm hexagon

wrench (TC/TE types).

Use a 13mm spanner to remove the six M8 bolts and de-

tach the pump head with a reinforcing plate.

Hexagon wrench

Bolt cover

Pump head

Reinforcing plate (TC/TE types)

Extend the pump shaft by keypad operation.

* With the diaphragm rupture detection ON and the error message of "LEAK DETECTED!", the diaphragm has

been fully extended. In this instance, skip to the next step.

Select "Diaphragm Pos." through the menu screen and

push the Enter key. See page 51 for detail.

Select "MAX OUT Pos." by the right and left keys and push

the Enter key.

The diaphragm extends to the maximum and "MAX OUT

Pos." blinks on the screen.

Rotate and remove the diaphragm and the retainer.

Pump shaft

Wear part replacement

Diaphragm

Retainer

Pump head holder

Page 65

Clean the retainer or replace it with a new one. Apply the grease (Dow Corning Toray MOLYKOTE® HP-500) on its surface and the screw burning protective agent to the shaft of a new diaphragm.

Fit a new diaphragm and the retainer into the pump shaft.

Slide the retainer, dome end rst, onto the diaphragm shaft. And then screw the shaft into the pump

shaft and tighten it until bottoms out and will not turn further.

NOTE

If it is tted loose, failure may result.

Retract the pump shaft by keypad operation.

Push the Enter key.

Mount the pump head.

Tighten the bolts evenly to 12N•m for the C150 or 3.5N•m

for the C060 in diagonal order.

NOTE

Check the pump shaft has contracted to the full before mounting the pump head, or a leak or damage may result.

Select "Diaphragm Pos." and push the Enter key.

Select "MAX IN Pos." by the right and left keys.

Push the Enter key.

The diaphragm contracts and "MAX IN Pos." ashes.

Maintenance

Wear part replacement

Page 66

Fix the bolt cover by the hexagon wrench (TC/TE types).

Connect pipes to the ttings and then tighten the nuts.

NOTE

Check if the valve set mounting direction is correct. Both the

valve sets must be oriented to the same direction.

Valve set

Go back to the waiting state.

Push the Enter key once to shift to the left display.

Push the start/stop key to return to the MAN/EXT selec-

tion.

Wear part replacement

Page 67

Exploded view

Pump head, Drive unit & Control unit

Do not dismantle the pump beyond the extent shown in the diagram below.

Nut

Valve set

Pump head

Pump

Bolt cover

Reinforcing

Pump head

plate

Diaphragm

Valve set

Nut

Retainer

Drive unit

Maintenance

*Pump head material and size differ with models.

Exploded view

Page 68

Pump head

■ IX-C150 TC N

No. Part names # of parts

1 Pump head 1 2 Valve 2 3 Valve guide 2 4 Valve seat 2 5 Out seat holder 1 6 In seat holder 1 7 O ring 4

8 O ring 2 19 Hex socket head bolt 2 20 Hexagon head bolt 8 21 Spring washer 8 28 Bolt cover 1 29 Reinforcing plate 1 30 Diaphragm 1 31 Retainer plate 1 50 Nut 2 73 Fitting 2

4 8

4 8 6 7

Exploded view

Page 69

■ IX-C150 TC FA

No. Part names # of parts

1 Pump head 1

2 Valve 2

3 Valve guide 2

4 Valve seat 2

5 Out seat holder 1

6 In seat holder 1

7 O ring 4

8 O ring 2 19 Hex socket head bolt 2 20 Hexagon head bolt 8 21 Spring washer 8 28 Bolt cover 1 29 Reinforcing plate 1 30 Diaphragm 1 31 Retainer plate 1 45 Flange unit 2

4 8

4 8 6 7

Maintenance

Exploded view

Page 70

■ IX-C150 S6 N

No. Part names # of parts

1 Pump head 1

2 Valve 2

3 Valve guide 2

4 Valve seat 2 10 Valve gasket 6 20 Hexagon head bolt 8 21 Spring washer 8 30 Diaphragm 1 31 Retainer plate 1 55 Setting ange 2 73 Fitting 2 83 Hexagon head bolt 8

3 2

Exploded view

Page 71

■ IX-C150 S6 FA

No. Part names # of parts

1 Pump head 1

2 Valve 2

3 Valve guide 2

4 Valve seat 2 10 Valve gasket 6 20 Hexagon head bolt 8 21 Spring washer 8 30 Diaphragm 1 31 Retainer plate 1 45 Flange unit 2 83 Hexagon head bolt 8

3 2

Maintenance

Exploded view

Page 72

■ IX-C060 TC N

No. Part names # of parts

1 Pump head 1

2 Valve 2

3 Valve guide 2

4 Valve seat 2

7 O ring 8

9 Seat holder 2 16 Adapter 2 19 Hex socket head bolt 2 20 Hexagon head bolt 6 21 Spring washer 6 22 Plain washer 6 28 Bolt cover 1 29 Reinforcing plate 1 30 Diaphragm 1 31 Retainer plate 1 50 Nut 2 73 Fitting 2

3 2

4 7

9 7

7 3

2 4

7 9 7

Exploded view

Page 73

■ IX-C060 TC FA

No. Part names # of parts

1 Pump head 1

2 Valve 2

3 Valve guide 2

4 Valve seat 2

7 O ring 8

9 Seat holder 2 16 Adapter 2 19 Hex socket head bolt 2 20 Hexagon head bolt 6 21 Spring washer 6 22 Plain washer 6 28 Bolt cover 1 29 Reinforcing plate 1 30 Diaphragm 1 31 Retainer plate 1 45 Flange unit 2

3 2 4

7 9

7 3

2 4

7 9 7

Maintenance

Exploded view

Page 74

■ IX-C060 S6 N

No. Part names # of parts

1 Pump head 1

2 Valve 2

3 Valve guide 2

4 Valve seat 2 10 Valve gasket 6

13 Valve cap 2 20 Hexagon head bolt 6 21 Spring washer 6 22 Plain washer 6 30 Diaphragm 1 31 Retainer plate 1 73 Fitting 2

73 10

3 2

Exploded view

Page 75

■ IX-C060 S6 FA

No. Part names # of parts

1 Pump head 1 2 Valve 2 3 Valve guide 2 4 Valve seat 2

10 Valve gasket 6

13 Valve cap 2 20 Hexagon head bolt 6 21 Spring washer 6 22 Plain washer 6 30 Diaphragm 1 31 Retainer plate 1 45 Flange unit 2

3 2

Maintenance

Exploded view

Page 76

Specications/Outer dimensions

Specications

Information in this section is subject to change without notice.

■ Pump

Flow rate

Model code

IX-C060 TC/TE

IX-C060 S6

IX-C150 TC/TE

IX-C150 S6

*The above information is based on pumping clean water at rated voltage and ambient temperature.

* Pressure overload protection will stop operation when a discharge pressure has risen 1.3 to 2 times higher than the maxi-

mum level. *Allowable room temperature: 0-50°C (32-122°F) *Allowable liquid temperature: 0-50°C (32-122°F) for the TC/TE type, 0-80°C (32-176°F) for the S6 type *Allowable power voltage deviation: Within ±10% of the rated range *Ambient humidity: 30-90%RH (non condensing) * When running the IX-C150 S6 at or below 1.0L/H or the IX-C060 S6 at or below 0.4L/H, an actual ow rate may not meet

a target rate. * Noise level: 70dB(A) for the TC and TE types and 80dB(A) for the S6 type.

FA ANSI 150Lb 1/2" 9

N 1/2"NPT 11

FA ANSI 150Lb 1/2" 12

FA ANSI 150Lb 3/4" 9

N 3/4"NPT 11

FA ANSI 150Lb 3/4" 13

L/H

(GPH)

0.08-60

(0.02-15.9)

0.2-150

(0.05 -39.6)

Max.

discharge

pressure

MPa (psi)

1.0

(145)

0.4

(58)

Avg. power

consump-

tion

62 0.8

Current

value

Connection

1/2"NPT 9

3/4"NPT 9

Weight

■ Power cable

Conduction section area 18AWG Triplex cable (L/N/PE)

Length 1950 [mm]

Standard

Terminal treatment Plug

■ Body colour

Blue Munsell colour system 7.5PB 3/8

U type : SJT W-A

U2 type : SJT W

Specications/Outer dimensions

Page 77

■ Control unit

MAN (Manual) A ow rate is set with (Up) and (Down) keys.

Analogue preset 4-20/0-20/20-4/20-0mA (proportional control of a ow by current patterns)

Analogue variable 0-20mADC (proportional control of a ow by user-settable two points )

0.00625mL/PLS - 120mL/PLS (C060)

Pulse control*

Operation modes

EXT

Batch control*

Interval batch control*

Probus control

LCD 16×2 backlit LCD

Monitors

OPERATE

LED

ALARM Lights in red colour when Alarm OUT 1 or 2 is activated.

Operation

Key-

pads

(Start/Stop), MENU, ESC, (Enter), (Up), (Down), (Left) and (Right) keys

STOP Pump OFF at contact input* PRIME Max spm operation while the UP and DOWN keys are pressed.

Keypad lock PIN number entry disables the function.

Control functions

Interlock Pump OFF at contact input*

AUX Pump ON at AUX speed at contact input

Maximum ow rate setting The max ow rate can be set at each control mode.

Buffer Accumulates the entered external pulse signal with buffer ON.

Current value indication An input current is displayed during operation in the ANA.V mode.

Stop/ Pre-STOP No-voltage contact or open collector*

AUX No-voltage contact or open collector*

Input

Interlock No-voltage contact or open collector*

Analogue 0-20mADC (internal resistance is 200Ω.)

Pulse No-voltage contact/open collector (max 100Hz, min ON time: 5msec)

Alarm (OUT 1)

Output

Alarm (OUT 2)

Power supply 12VDC 30mA or below

Analogue User-settable between 0-20mADC (allowable load resistance: 300Ω)

Power voltage*

For these control modes, the calibrated ow volume per shot is applied to the minimum settable ow volume per shot.

The setting can be changed to "pump ON at contact input".

The maximum applied voltage from the IX to an external contact is 12V at 5mA. When using a mechanical relay, its

minimum application load should be 5mA or below.

Once the Batch Complete output is set to enabled, other output functions turn disabled.

Once the Volume Prop. PLS output is set to enabled, other output functions turn disabled.

Observe the specied power voltage range. Otherwise failure may result. The allowable power voltage range is 90-

264VAC.

0.01560mL/PLS - 300mL/PLS (C150)

6.25mL/PLS - 120L/PLS (C060)

15.6mL/PLS - 300L/PLS (C150)

0-9day, 0-23hr, 1-59min

6.25mL - 120L/PLS (C060)

15.6mL - 300L/PLS (C150)

Probus-DP Compliant to EN50170 (IEC61158)

Lights in green colour during pump operation.

Lights in orange colour when a Pre-STOP signal is input.

Lights in red colour when the pump has stopped or ashes when pres-

sure overload is detected.

No voltage contact (mechanical relay) 250VAC 3A (resistive load) Enable or disable the Batch Complete*4, STOP, Pre-STOP, Interlock, Leak Detection (default: ON) and Motor Overload (/Drive Error).

No voltage contact (PhotoMOS relay) 24VAC/DC 0.1A (resistive load) Enable or disable the Volume Prop. PLS*5, Batch Complete*4, STOP, Pre-STOP, Interlock (default: ON), Leak Detection and Motor Overload (/ Drive Error).

100-240VAC 50/60Hz

Specication

Specications/Outer dimensions

Page 78

Outer dimensions

■ IX-C060/-C150 TC/TE N-TB

(E)

(C)

142 156

(5)

(B)

Center of inlet/outlet

13.5

(421)

199

(D)

126

135

A B C D E F

IX-C150 TC/TE N 294 45 47 339 386 102 IX-C060 TC/TE N 325 30 35 339.5 375 102.5

Specications/Outer dimensions

Page 79

■ IX-C060/-C150 TC/TE FA-TB

142 156

(5)

(B)

Center of inlet/outlet

13.5

(421)

199

(D)

126

135

A B C D E F

IX-C150 TC/TE FA 317 34 ─ 339 ─ 102

IX-C060 TC/TE FA 335 25 ─ 339.5 ─ 102.5

Specications/Outer dimensions

Specication

Page 80

■ IX-C060/-C150 TC/TE N-RF

(115)

(E)

(C)

(B)

142 156

13.5

Center of inlet/outlet

199

(D)

135

A B C D E F

IX-C150 TC/TE N 294 45 47 339 386 102 IX-C060 TC/TE N 325 30 35 339.5 375 102.5

126

Specications/Outer dimensions

Page 81

■ IX-C060/-C150 TC/TE FA-RF

(115)

(B)

142 156

13.5

Center of inlet/outlet

199

(D)

135

A B C D E F

IX-C150 TC/TE FA 317 34 ─ 339 ─ 102

IX-C060 TC/TE FA 335 25 ─ 339.5 ─ 102.5

126

Specications/Outer dimensions

Specication

Page 82

■ IX-C060/-C150 S6 N-TB

(E)

(C)

142 156

(5)

(B)

Center of inlet/outlet

13.5

(421)

199

(D)

126

135

A B C D E F

IX-C150 S6 N 287 48 30 333.5 363 96.5

IX-C060 S6 N 240 72 25 339 364 102

Specications/Outer dimensions

Page 83

■ IX-C060/-C150 S6 FA-TB

142 156

(5)

(B)

Center of inlet/outlet

13.5

(421)

199

(D)

126

135

A B C D E F IX-C150 S6 FA 335 24 ─ 333.5 ─ 96.5 IX-C060 S6 FA 270 57 ─ 339 ─ 102

Specications/Outer dimensions

Specication

Page 84

■ IX-C060/-C150 S6 N-RF

(115)

(E)

(C)

(B)

142 156

13.5

Center of inlet/outlet

199

(D)

135

A B C D E F

IX-C150 S6 N 287 48 30 333.5 363 96.5

IX-C060 S6 N 240 72 25 339 364 102

126

Specications/Outer dimensions

Page 85

■ IX-C060/-C150 S6 FA-RF

(115)

142 156

(B)

13.5

199

(D)

Center of inlet/outlet

135

A B C D E F IX-C150 S6 FA 335 24 ─ 333.5 ─ 96.5 IX-C060 S6 FA 270 57 ─ 339 ─ 102

126

Specications/Outer dimensions

Specication

Page 86

Page 87

Page 88

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TEL: +49 2154 9254 0 FAX: +49 2154 9254 48

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TEL: +49 2154 9254 50 FAX: +49 2154 9254 55

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TEL: +46 8 511 72900 FAX: +46 8 511 72922

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TEL: +44 1743 231363 FAX: +44 1743 366507

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TEL: +1 508 429 1440 FAX: +1 508 429 1386

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http://www.iwakipumps.jp

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TEL: +86 21 6272 7502 FAX: +86 21 6272 6929

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TEL: +82 2 2630 4800 FAX: +82 2 2630 4801

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TEL: +84 613 933456 FAX: +84 613 933399

/ IWAKI Pumps Co., Ltd.

T938-1 ‘16/05