Realax ISI Series Operating Instructions Manual
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Realax ISI Series Operating Instructions Manual

Peristaltic pump
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Operating instructions
ISI Series
Peristaltic pump
ALL THE HOSE PUMP YOU'LL EVER NEED

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  • Page 1 Operating instructions ISI Series Peristaltic pump ALL THE HOSE PUMP YOU’LL EVER NEED...
  • Page 2 – after all, best is what you want, second best should never be an option. We hope you’ll find using your realax pump simple, trouble- free and that it makes a positive contribution to the success of your process.

  • Page 3: Table Of Contents

    Operating instructions Peristaltic Pump ISI Series TAbLE Of CONTENTS Introduction ..........

  • Page 4: Introduction

    This instruction manual must accompany the pump at all times for as long as it is in use. The ISI series peristaltic pump is a machine for fluid handling intended to be used in industrial areas, as such the instruction manual is part of the legislative provisions for the safe and correct use of the pump.
  • Page 5 Service and support For information with respect to specific adjustments, installation, maintenance or repair jobs which fall beyond the scope of this manual, contact your AxFlow representative. Make sure you have the serial number hose pump at hand. Environment and disposal of waste Enquire within your local government about the possibilities for reuse or environment friendly processing of packaging materials, (contaminated) lubricant.

  • Page 6: Safety

    Operating instructions Peristaltic Pump ISI Series SAfETY Explanation of the safety information In this manual the following symbols are used: This symbol identifies the instructions of this manual, which must be observed to avoid failure to meet safety standards. This symbol identifies the instructions of this manual, which must be observed to avoid compromising electrical safety.
  • Page 7 the front cover. Depending on the specific working conditions or accesso- ries used, additional safety instructions can be required. User qualifications Pumps are machines that can present dangers due to moving parts and the presence of a pressurised fluid within the hose. THE fOLLOWING CAN CAUSE SERIOUS DAMAGE AND INJURY •...
  • Page 8 Operating instructions Peristaltic Pump ISI Series General safety information Live parts Possible consequence: fatal or very serious injuries. - Risk mitigation: the device must be disconnected from the power supply before it is opened. - Isolate damaged, faulty or manipulated devices from the mains in order to de-energise.
  • Page 9 - This pump is NOT supplied for use in areas of risk from explosion. ATEX versions of Realax pumps are available and they are supplied with a special ATEX version of the instruction manual.
  • Page 10 Operating instructions Peristaltic Pump ISI Series - (although most unlikely) incorporation of particles from the hose into the product being pumped. This can be achieved by means of filtration, a hose rupture alarm or other means suitable for the respective process.

  • Page 11: Functional Description

    DESCRIPTION The ISI Series is a positive displacement pump. The feed liquid is conveyed by the rotor squeezing the hose in the direction of flow. No valves are needed for this. This ensures gentle handling of the metered media.

  • Page 12: Description

    Operating instructions Peristaltic Pump ISI Series Key performance data and noice levels DESCRIPTION UNIT ISI 10 ISI 13 ISI 16 ISI 19 ISI 22 0.10 0.16 0.38 0.52 Max. Capacity Continuous Duty 0.42 0.70 1.67 2.29 4.40 0.13 0.19 0.44 0.78...

  • Page 13: Construction

    Identification of the gearbox (b) The gearbox has an identity plate with the model, serial number and manufacturer’s details as well as information relevant to its’ function such as reduction ratio. Identification of the electric motor (C) The motor has an identity plate with the model, serial number and manufacturer’s details as well as information relevant to its’...

  • Page 14: Pump Hose

    Operating instructions Peristaltic Pump ISI Series PUMP HOSE General description A: Inner layer B: Nylon reinforcement layers C: Outer layer The pump hose liner material should be chemically resistant with the product to be pumped. Depending on the specific requirements of your application a corresponding pump hose must be selected.
  • Page 15 Storage for more than 1 month - Avoid areas open to harsh weather or excessive humidity and temperatures lower than 0 °C or higher than 30 °C. IMPORTANT! Disassemble one of the rollers (see also section 9.4.1 for instructions): • Remove the front cover • Remove the roller that is not touching the pump hose • Mount back the front cover • Turn the rotor with the help of the motor so that the...

  • Page 16: Assembly, Commissioning & Installation

    Operating instructions Peristaltic Pump ISI Series ASSEMbLY, COMISSIONING AND INSTALLATION Ambient conditions Assembly is to be carried out in the following order. If the pump has to be installed outdoors, then it is to be equipped with protection against sunlight and weather influences.
  • Page 17 - Confirm that pump has been properly earthed - Connect the electric motor according to local applicable rules and regulations. The electrical installation work must be carried out by qualified personnel. - Check that the optional electrical components are connected and are working properly.
  • Page 18 Operating instructions Peristaltic Pump ISI Series - The pump is reversible and the suction side can be connected to either hydraulic connection of the Pump. Normally the option is selected which is best suited to the physical conditions of the rest of the installation.
  • Page 19 8.3.3 Discharge side - The discharge line is to be kept as straight and short as possible, in order to avoid performance reduction. - The diameter must correspond to the rated diameter of the pump hose. larger diameter is recommended in the event of viscous liquids.
  • Page 20 Operating instructions Peristaltic Pump ISI Series Adjusting the roller pressure - The peristaltic pump is equipped with shims, in order to adjust the precise distance from the axis of rotation to the roller for correct hose compression (also dependent on speed and operating pressure).
  • Page 21 The shims are fitted in the factory. The number of shims can be adapted to the actual operating conditions according to the following tables. Slight variations in colour of polyurethane rollers is normal. 8.4.1 Model ISI 10 Hose materials – NR, NBR, EPDM, CSM, NR-A and NBR-A: Number of shims of 0.5 mm thickness (part number AX102.01.49).
  • Page 22 Operating instructions Peristaltic Pump ISI Series 8.4.2 Model ISI 13 Hose materials – NR, NBR, EPDM, CSM, NR-A and NBR-A: Number of shims of 0.5 mm thickness (part number AX102.01.49). NOTE: for fluid temperatures > 60 ºC: reduce shim quantities by 1.
  • Page 23 8.4.3 Model ISI 16 Hose materials – NR, NBR, EPDM, CSM, NR-A and NBR-A: Number of shims of 0.5 mm thickness (part number AX101.02.35). NOTE: for fluid temperatures > 60 ºC: reduce shim quantities by 1. Revolutions/minute 0-19 20-39 40-59 60-79 80-99 4.0*...
  • Page 24 Operating instructions Peristaltic Pump ISI Series 8.4.5 Model ISI 22 Hose materials – NR, NBR, EPDM, CSM, NR-A and NBR-A: Number of shims of 0.5 mm thickness (part number AX101.02.35). NOTE: for fluid temperatures > 60 ºC: reduce shim quantities by 1.

  • Page 25: Maintenance

    MAINTENANCE Components weights DESCRIPTION ISI 10 / 13 ISI 16 ISI 19 ISI 22 14 kg 23 kg 49 kg Total weight 30 lbs 50 lbs 108 lbs 0.11 kg 3.26 kg 3.58 kg Pump cover 0.24 lbs 7.19 lbs 7.89 lbs Roller 0.30 kg...
  • Page 26 Operating instructions Peristaltic Pump ISI Series DESCRIPTION UNITS ISI 10 / 13 ISI 16 ISI 19 ISI 22 Roller support bolts 8 mm 13 mm 13 mm Spanner Spanner Spanner Manual, Manual, Manual, Cover bolts no bolts no bolts no bolts...
  • Page 27 Dismantle the pipes from both discharge and suction sides. Remove the front cover. Front covers of ISI Series can be removed manually (< 3 kg). Remove the roller incl. roller support (the roller that is not touching the hose). Check the roller. Ensure that the roller surfaces are not...
  • Page 28 Operating instructions Peristaltic Pump ISI Series Rotate the rotor 180° to liberate the hose. Remove the press and connection and hydraulic connections from pump housing. Flange connection Remove the pump hose to be exchanged. Dismount the connections of the hose.
  • Page 29 9.4.2 Installation of the new hose Clean the interior surfaces of the pump housing with a clean dry cloth. Lubricate with our original lubricant the internal surfaces of the pump housing. Before lubricating, insert the connections into the replaced tube. Lubricate with our original lubricant the hose and at the contact surfaces between the pump hose and the external part of...
  • Page 30 Operating instructions Peristaltic Pump ISI Series Assemble the flanges. Mount the front cover. Turn the rotor with the help of the mo- tor so that the remaining roller presses against the pump hose. Dismount the front cover. 10. Re-attach the second roller with shims back onto the rotor.
  • Page 31 12. Mount back the front cover. 13. Mount the pipes from both discharge and suction sides. 14. Open all of the valves. Replacement of electric motor For repair or replacement of the electric mo- tor and the gear reducer they could be disas- sembled from the pump housing.

  • Page 32: Troubleshooting

    Operating instructions Peristaltic Pump ISI Series TROUbLESHOOTING PROBLEM POSSIBLE CAUSE SOLUTION Pump hose has no lubricant Lubricate pump hose Increased product temperature Reduce product temperature Increased pump Insufficient or poor suction Check suction line condition temperature conditions Pump speed too high...
  • Page 33 Check the suction conditions the hoses Abnormal elevation of Check number of shims temperature Unsuitable lubricant Use realax lubricant Insufficient quantity of grease Reapply lubricant High inlet pressure (> 3 bar) Reduce inlet pressure Pump hose Pump hose filled with deposits...

  • Page 34: Spare Parts

    Operating instructions Peristaltic Pump ISI Series SPARE PARTS 11.1 Spare parts exploded ISI 10 Model...
  • Page 35 POS. DESCRIPTION QUANTITY REFERENCE Pump Housing AX102.01.01 Roller Kit ISI 10 / 13 AX102.99.01 Press flange standard AX102.00.11 Connection S.S. BSP 3/8” ISI 10 AX102.00.10 Connection P.P. BSP 3/8” ISI 10 AX102.00.15 Connection PVDF BSP 3/8” ISI 10 AX102.00.16 Connection S.S. NPT 3/8”ISI 10 AX102.00.17 Connection PVC NPT 3/8”...
  • Page 36 Operating instructions Peristaltic Pump ISI Series 11.2 Spare parts exploded ISI 10 Model - NORPRENE / SILICONE...
  • Page 37 POS. DESCRIPTION QUANTITY REFERENCE Pump Housing AX102.01.01 Roller Kit ISI 10 / 13 AX102.99.01 Press flange (Thermoplastic Hose) AX102.00.23 Connection S.S. BSP 3/8” ISI 10 AX102.00.10 Connection P.P. BSP 3/8” ISI 10 AX102.00.15 Connection PVDF BSP 3/8” ISI 10 AX102.00.16 Connection S.S.
  • Page 38 Operating instructions Peristaltic Pump ISI Series 11.3 Spare parts exploded ISI 13 Model...
  • Page 39 POS. DESCRIPTION QUANTITy REFERENCE Pump Housing AX102.01.01 Roller Kit ISI 10 / 13 AX102.99.01 Press flange standard AX103.00.11 Connection S.S. BSP 3/8” ISI 13 AX103.00.10 Connection P.P. BSP 3/8” ISI 13 AX103.00.15 Connection PVDF BSP 3/8” ISI 13 AX103.00.16 Connection S.S. NPT 3/8” ISI 13 AX103.00.17 Connection PVC NPT 3/8”...
  • Page 40 Operating instructions Peristaltic Pump ISI Series 11.4 Spare parts exploded ISI 13 Model - NORPRENE / SILICONE...
  • Page 41 POS. DESCRIPTION QUANTITy REFERENCE Pump Housing AX102.01.01 Roller Kit ISI 10 / 13 AX102.99.01 Press flange standard AX102.00.11 Connection S.S. BSP 3/8” ISI 13 AX103.00.10 Connection P.P. BSP 3/8” ISI 13 AX103.00.15 Connection PVDF BSP 3/8” ISI 13 AX103.00.16 Connection S.S. NPT 3/8” ISI 13 AX103.00.17 Connection PVC NPT 3/8”...
  • Page 42 Operating instructions Peristaltic Pump ISI Series 11.5 Spare parts exploded ISI 16 Model...
  • Page 43 POS. DESCRIPTION QUANTITY REFERENCE Pump Housing AX101.03.01 Roller Kit ISI 16 / 19 AX101.99.01 Press flange standard AX101.03.22 Connection S.S. BSP ¾” ISI 16 AX101.00.13 Connection P.P. BSP ¾” ISI 16 AX101.00.14 Connection PVDF BSP ¾” ISI 16 AX101.00.15 Connection S.S. NPT ¾” ISI 16 AX101.00.16 Connection PVC NPT ¾”...
  • Page 44 Operating instructions Peristaltic Pump ISI Series 11.6 Spare parts exploded ISI 16 Model - NORPRENE / SILICONE...
  • Page 45 POS. DESCRIPTION QUANTITY REFERENCE Pump Housing AX101.03.01 Roller Kit ISI 16 / 19 AX101.99.01 Press flange Thermoplastic Hose AX101.03.23 Connection S.S. BSP ¾” ISI 16 AX101.00.13 Connection P.P. BSP ¾” ISI 16 AX101.00.14 Connection PVDF BSP ¾” ISI 16 AX101.00.15 Connection S.S.
  • Page 46 Operating instructions Peristaltic Pump ISI Series 11.7 Spare parts exploded ISI 19 Model NORPRENE / TYGON...
  • Page 47 POS. DESCRIPTION QUANTITY REFERENCE Pump Housing AX101.03.01 Roller Kit ISI 16 / 19 AX101.99.01 Press flange ISI 19 AX101.03.22 Connection S.S. BSP 1” ISI 19 AX105.00.13 Connection P.P. BSP 1” ISI 19 AX105.00.14 Connection PVDF BSP 1” ISI 19 AX105.00.15 Connection S.S.
  • Page 48 Operating instructions Peristaltic Pump ISI Series 11.8 Spare parts exploded ISI 22 Model...
  • Page 49 POS. DESCRIPTION QUANTITY REFERENCE Pump Housing AX113.00.01 Roller Kit ISI 22 AX113.99.01 Press flange AX113.00.19 Connection S.S. BSP 1” ISI 22 AX113.00.10 Connection P.P. BSP 1” ISI 22 AX113.00.11 Connection PVDF BSP 1” ISI 22 AX113.00.12 Connection S.S. NPT 1” ISI 22 AX113.00.13 Connection PVC NPT 1”...
  • Page 50 Operating instructions Peristaltic Pump ISI Series 11.9 Spare parts exploded ISI 22 Model - NORPRENE / SILICONE...
  • Page 51 POS. DESCRIPTION QUANTITY REFERENCE Pump Housing AX113.00.01 Roller Kit ISI 22 AX113.99.01 Press flange (Thermoplastic) AX113.00.20 Connection S.S. BSP 1” ISI 22 AX113.00.10 Connection P.P. BSP 1” ISI 22 AX113.00.11 Connection PVDF BSP 1” ISI 22 AX113.00.12 Connection S.S. NPT 1” ISI 22 AX113.00.13 Connection PVC NPT 1”...

  • Page 52: End Of Life

    Operating instructions Peristaltic Pump ISI Series END-Of-LIfE WARNING! Danger from hazardous substances! Possible consequence: Fatal or very serious injuries. Customer must decontaminate the pump with suitable agents (refer to the material safety data sheet for the fluid). 12.1 Recycling Once cleaned the following components can be scrapped/recycled:...

  • Page 53: Declaration Of Conformity

    DECLARATION Of CONfORMITY...

  • Page 54: Warranty

    WARRANTY We guarantee against all manufacturing defects and guarantee the mate- rials that compose the realax pump for two years from the date of deliv- ery. This guarantee does not cover the hose or the lubricant as these are elements that have a normal function wear, irrespective of their duration.

  • Page 55: Where To Buy

    E-mail: info@axflow.de E-mail: office@axflow.at Service-Stützpunkt und Werkstatt www.axflow.at AxFlow Service Süd Kiryat-Shmona-Straße 11 87700 Memmingen, Deutschland For more information about realax Tel. +49 8331 3309 hose pumps please contact: service.sued@axflow.de AxFlow Ltd. 27 Prof. Kiril Popov Street, ground floor Sofia city Tel.: +359 (0) 879 380 202...
  • Page 56 Operating instructions Peristaltic Pump ISI Series A realax tömlőszivattyúkkal Aby uzyskać więcej informacji na kapcsolatos további temat pomp realax węża prosimy o információkért forduljon: kontakt: AxFlow Kft. AxFlow Sp. z o. o. Bilk Centre, B1 ép. ul. Floriana 3/5 Európa utca 6.
  • Page 57 För mer information om realax For service and support to your slangpumpar vänligen kontakta: realax hose pumps please contact: AxFlow AB AxFlow Services Ostmästargränd 12 Phone: +44 1484 543649 120 40 Årsta Fax: +44 1484 512608 (Box 90162, 120 22 Stockholm) E-mail: service@axflow.co.uk...
  • Page 58 CUSTOMER: PHONE: CONTACT: FAX: INTENTION: Repair Warranty Return MATERIAL DELIVERED: Pump only Complete unit Spare part UNITS: PUMP TyPE: PUMP REFERENCE: SERIAL NUMBER: OPERATION TIME (years): OPERATING HOURS (h/day): APPLICATION DATA (* Indicate units): PRODUCT VISCOSITy * DENSITy * FLOW * DANGEROUS Corrosive Flammable...
  • Page 60 ALL THE HOSE PUMP YOU’LL EVER NEED www.realaxpumps.com...

This manual is also suitable for:

Isi 10Isi 13Isi 16Isi 19Isi 22

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