Realax RP Series Operating Instructions Manual
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Realax RP Series Operating Instructions Manual

Peristaltic pump
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Operating instructions
RP Series
Peristaltic pump
ALL THE HOSE PUMP YOU'LL EVER NEED
1

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  • Page 1 Operating instructions RP 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 RP 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 RP 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 of the 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)

  • Page 6: Safety

    Operating instructions Peristaltic Pump RP 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 RP 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 RP 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 RP 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 RP Series Key performance data and noice levels DESCRIPTION UNIT RP 25 RP 32 RP 40 RP 60 RP 70 RP 80 RP 100 1.08 1.86 4.79 10.83 18.09 28.08 36.00 Max. Capacity Continuous Duty 4.76 8.19...

  • 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 RP 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 shoes (see also section 9.4.1 for instructions): • Remove the front cover • Remove the shoe 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 RP Series Models RP 60, RP 70, RP 80 and RP 100: Use lifting equipment to elevate the pump. WEIGHTS RP 60 RP 70 RP 80 RP 100 Total pump 346 kg 642 kg 1,150 kg...
  • Page 17 Commissioning 8.2.1 Testing prior to commissioning the pump The following tests are to be carried out: - Check that the shoes are correctly fitted and fastened. - Check that the drive and the Pump Housing are properly lubricated. The specially formulated lubricant can be obtained from the authorized distributor.
  • Page 18 Operating instructions Peristaltic Pump RP Series 8.3.1 Suction side - Install a manometer in the pressure line if the back-pressure value is unknown. Maximum pressure on suction/inlet side is 3 bar (45 psi approx.). - The pump is to be positioned as near as possible to the liquid container, so that the suction side is kept as short and straight as possible.
  • Page 19 Maximum permissible loads on the pump flange FORCE UNIT RP 25 RP 32 RP 40 RP 60 RP 70 RP 80 RP 100 1,200 1,300 1,500 1,700 lb-f lb-f lb-f 8.3.3 Discharge side - The discharge line is to be kept as straight and short as possible, in order to avoid performance reduction.
  • Page 20 Operating instructions Peristaltic Pump RP Series Adjusting the shoe pressure - The peristaltic pump is equipped with shims, in order to adjust the precise distance from the axis of rotation to the shoe 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. 8.4.1 Model RP 25 Hose materials – NR, NBR, EPDM, CSM and NBR-A: Number of shims of 0.5 mm thickness (part number AX100.01.13) in each location (i.e.
  • Page 22 Operating instructions Peristaltic Pump RP Series 8.4.3 Model RP 40 Hose materials – NR, NBR, EPDM, CSM and NBR-A: Number of shims of 0.5 mm thickness (part number AX109.00.04) in each location (i.e. multiply by 2 for total quantity). NOTE: for fluid temperatures >...
  • Page 23 > 60 ºC: reduce shim quantities by 1. Revolutions/minute 0-19 20-39 40-59** – – 5.0* – – – 12.5 – – – – *Factory default setting if working pressure is not specified. **In case of a need for higher speed, please consult your realax distributor.

  • Page 24: Maintenance

    – 12.5 – – – – *Factory default setting if working pressure is not specified. **In case of a need for higher speed, please consult your realax distributor. MAINTENANCE Components weights RP 25 RP 32 RP 40 RP 60 RP 70...
  • Page 25 Torque values DESCRIPTION UNITS RP 25 RP 32 RP 40 RP 60 RP 70 RP 80 RP 100 Shoe M16 10.9 M16 10.9 M18 10.9 M18 10.9 support 13 mm 19 mm 19 mm 24 mm 24 mm 27 mm 27 mm bolts spanner...
  • Page 26 Operating instructions Peristaltic Pump RP Series Lubricant quantity table UNIT RP 25 RP 32 RP 40 RP 60 RP 70 RP 80 RP 100 Lubricant realax realax realax realax realax realax realax Liters Required quantity Gallons 11.9 18.5 Check that the level of lubricant in the casing of the pump is correct - The correct level is shown on the inspection window cover installed on the front cover.
  • Page 27 Dismantle the pipes from both discharge and suction sides. Empty all lubricating liquid from the pump housing by removing the lower drain plug. There are 3 drain plugs located at the rear of the pump housing. Remove the lower drain plug, located behind the lower connection.
  • Page 28 Operating instructions Peristaltic Pump RP Series Remove the press flange and hydraulic connections from pump housing: a. RP 25, RP 32 have flanges and Inserts. b. RP 40, RP 60, RP 70, RP 80, RP 100 have flanges. a) flange connection with Insert b) flange connection Mount back the front cover.
  • Page 29 9.4.2 Installation of the new hose Rotate the rotor 180° so that the shoe that is still assembled no longer presses the hose. Clean the interior surfaces of the pump housing with a clean dry cloth. Lubricate with our original lubricant the hose and the internal surfaces of the pump housing at the contact surfaces to the pump hose and the external part of the new hose.
  • Page 30 Operating instructions Peristaltic Pump RP Series realax Approximate distance model outside press ring RP 25 3–7 mm RP 32 3–7 mm Figure 1 realax Approximate distance model inside press flange RP 40 5 mm RP 60 6 mm RP 70...
  • Page 31 Fasten the press flange and the connections to the pump casing and tighten progressively the bolts in a star pattern (1, 3, 2, 4 & 1, 3, 2, 4, etc.), until the flange is fully tightened. Mount the front cover. Turn the rotor with the help of the mo- tor so that the remaining shoe presses against the pump hose.
  • Page 32 Operating instructions Peristaltic Pump RP Series 13. Attach the front cover to the pump housing. 14. Fill the body of the pump with lubricant up to the marked level via the upper filling or inspection cover. 15. Mount the pipes from both discharge and suction sides.
  • Page 33 Addition of high-level sensor The standard breather supplied with the RP pump should be removed from the pump housing. Dismantle and replace elbow with the T-fitting. Screw electro-optical detector to cap, then attach cap to T-fitting. Reassemble the breather and detector assembly to the pump housing. Standard breather HIgh level sensor with T-fitting and breather...

  • Page 34: Troubleshooting

    Operating instructions Peristaltic Pump RP 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 35 Abnormal elevation of temperature Check number of shims the hoses 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 36: Spare Parts

    Operating instructions Peristaltic Pump RP Series SPARE PARTS 11.1 Spare parts exploded view RP 25 Model...
  • Page 37 Peristaltic Hose EPDM RP 25 AX100.01.10 Peristaltic Hose CSM RP 25 AX100.01.37 Front cover RP 25 AX100.01.50 Inspection window kit RP 25 AX100.99.30 Contact realax Base plate distributor Contact realax Base plate S.S. distributor Drive Seal Kit RP 25 AX100.99.10 Seal Screw AX104.01.23...
  • Page 38 Operating instructions Peristaltic Pump RP Series 11.2 Spare parts exploded view RP 32 Model...
  • Page 39 Peristaltic Hose EPDM RP 32 AX104.01.10 Peristaltic Hose CSM RP 32 AX104.01.21 Front cover RP 32 AX104.00.50 Inspection Window Kit RP 32 AX104.99.30 Contact realax Base plate distributor Contact realax Base plate S.S. distributor Drive Seal Kit RP 32 AX104.99.20 Seal Screw AX104.01.23...
  • Page 40 Operating instructions Peristaltic Pump RP Series 11.3 Spare parts exploded view RP 40 Model...
  • Page 41 AX108.00.22 Peristaltic Hose EPDM RP 40 AX108.00.24 Peristaltic Hose CSM RP 40 AX108.00.25 Front cover RP 40 AX109.00.50 Inspection Window Kit RP 40 AX109.99.30 Contact realax Base plate distributor Contact realax Base plate S.S. distributor Drive Seal screw AX104.01.23 Seal Kit RP 40 AX109.99.20...
  • Page 42 Operating instructions Peristaltic Pump RP Series 11.4 Spare parts exploded view RP 40 NbR-A Version...
  • Page 43 Connection S.S. Tri-clamp 2” RP 40 NBR-A AX108.00.53 Peristaltic Hose NBR-A RP 40 AX108.01.23 Front cover RP 40 AX109.00.50 Inspection Window Kit RP 40 AX109.99.30 Contact realax Base plate distributor Contact realax Base plate S.S. distributor Drive Seal screw AX104.01.23 Seal Kit RP 40 AX109.99.20...
  • Page 44 Operating instructions Peristaltic Pump RP Series 11.5 Spare parts exploded view RP 60...
  • Page 45 Peristaltic Hose NBR RP 60 AX111.00.20 Peristaltic Hose NBR-A RP 60 AX111.00.21 Peristaltic Hose EPDM RP 60 AX111.00.22 Peristaltic Hose CSM RP 60 AX111.00.57 Contact realax Base plate distributor Contact realax Base plate S.S. distributor Drive Seal Kit RP 60 AX111.99.20...
  • Page 46 Operating instructions Peristaltic Pump RP Series 11.6 Spare parts exploded view RP 70...
  • Page 47 AX112.00.20 Peristaltic Hose EPDM RP 70 AX112.00.22 Peristaltic Hose CSM RP 70 AX112.00.23 Front cover RP 70 AX114.01.53 Inspection Window Kit RP 70 AX114.99.30 Contact realax Base plate distributor Contact realax Base plate S.S. distributor Drive Seal Screw AX111.00.08 Seal Kit RP 70 AX114.99.20...
  • Page 48 Operating instructions Peristaltic Pump RP Series 11.7 Spare parts exploded view RP 70 NbR-A Version...
  • Page 49 Connection S.S. TRI CLAMP 3" RP 70 AX112.00.59 NBR-A Peristaltic Hose NBR-A RP 70 AX112.00.21 Front cover RP 70 AX114.01.53 Inspection Window Kit RP 70 AX114.99.30 Contact realax Base plate distributor Contact realax Base plate S.S. distributor Drive Seal Screw AX111.00.08 AX114.99.20...
  • Page 50 Operating instructions Peristaltic Pump RP Series 11.8 Spare parts exploded view RP 80...
  • Page 51 AX118.00.16 Peristaltic Hose EPDM RP 80 AX118.00.14 Peristaltic Hose CSM RP 80 AX118.00.17 Front cover RP 80 AX120.00.60 Inspection Window Kit RP 80 AX118.99.30 Contact realax Base plate distributor Contact realax Base plate S.S. distributor Drive Seal Screw AX119.00.45 Seal Kit RP 80 AX120.99.20...
  • Page 52 Operating instructions Peristaltic Pump RP Series 11.9 Spare parts exploded view RP 100...
  • Page 53 AX119.00.23 Peristaltic Hose EPDM RP 100 AX119.00.21 Peristaltic Hose CSM RP 100 AX119.00.24 Front cover RP 100 AX119.00.52 Inspection Window Kit RP 100 AX119.99.30 Contact realax Base plate distributor Contact realax Base plate S.S. distributor Drive Seal Screw AX119.00.45 Seal Kit RP 100 AX119.99.20...
  • Page 54 Operating instructions Peristaltic Pump RP Series 11.10 breathers realax Breather Elbow Breather pump Components model RAC500H12H12PP RP 25 & RAC200M12M12PP AX100.01.39 AX100.01.38 RP 32 RP 40 RAC500M12H12 RP 60 RAC500H34H34PP RP 70 AX114.00.25 AX114.00.24 & RAC200M34M34PP RAC500H112H112PP RP 80 &...

  • Page 55: End Of Life

    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: - Pump housing - Rotor and shoes - Baseplate...

  • Page 56: Declaration Of Conformity

    Operating instructions Peristaltic Pump RP Series DECLARATION Of CONfORMITY...

  • Page 57: 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 58: Where To Buy

    Operating instructions Peristaltic Pump RP Series Für weitere Informationen über Für weitere Informationen und realax Schlauchpumpen und für umfassenden Service wenden Sie Service und Support kontaktieren sich bitte an: Sie bitte: Beratung, Verkauf und Service AxFlow GesmbH AxFlow GmbH Seering 2/2. OG Theodorstrasse 105 8141 Premstätten, Österreich...
  • Page 59 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. 04-664 Warszawa 1239 Budapest Telefon centrala: +48 613 00 12 Tel.: +36 1 454-3080...
  • Page 60 Operating instructions Peristaltic Pump RP Series 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 61 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 62 ALL THE HOSE PUMP YOU’LL EVER NEED www.realaxpumps.com...

This manual is also suitable for:

Rp 25Rp 32Rp 40Rp 60Rp 70Rp 80 ... Show all

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