IWAKI PUMPS AMP Series User manual

Read this manual before use of product
IWAKI Magnetic Drive Pump
AMP Series (Asia Edition: English)
Instruction Manual

Thank you for selecting an Iwaki AMP Series Magnetic Drive Pump. This instruction manual
deals with "Safety instructions", "Outline", "Installation", "Operation", and "Maintenance"
sections. Please read through this manual carefully to ensure the optimum performance, safety
and service of your pump.
Contents
Important instructions ···································································· 1
Safety instructions ·········································································· 2
Outline 1. Unpacking & Inspection ..................................................5
2. Model code.......................................................................6
3. Operating conditions........................................................7
4. Part names........................................................................8
Installation 1. Before installation ..........................................................10
2.Piping
.............................................................................11
3.Wiring
............................................................................14
4. Protection equipment .....................................................14
Operation 1. Before operation.............................................................16
2. Operation........................................................................17
3. Shutdown........................................................................17
Maintenance 1. Troubleshooting..............................................................19
2. Maintenance & Inspection.............................................21
3. Disassembly & Assembly...............................................23
4. Spare & Wear parts........................................................29
This instruction manual should be kept on hand by the end user for
quick reference.
Contact us or your nearest dealer if you have any questions.

- 1 -
Important instructions
For exportation
Technology related to the use of goods in this instruction manual falls in the category of
technology contained in the Foreign Exchange Order Attachment, which includes com-
plementary export control of technology. Please be reminded that export license, which
is issued by the Ministry of Economy, Trade, and Industry could be required, when this is
exported or provided to someone even in Japan.
Nonobservance or misapplication of “Caution” sec-
tions could lead to a personal injury or property
damage.
For the Safe and
Correct Handling of the Pump
●"Safety Instruction" section deals with important details about handling of the product. Before
use, read this section carefully for the prevention of personnel injury or property damage.
●Observe the instructions accompanied with "WARNING" or "CAUTION" in this manual. These
instructions are very important for protecting users from dangerous situations.
●The symbols on this instruction manual have the following meanings:
WARNING
Nonobservance or misapplication of “Warning” sec-
tions could lead to a serious accident which may
result in death.
CAUTION
Types of Symbols
Indicates that “Warning” or “Caution” must be exercised. Inside this triangle, a con-
crete and practical image provided as a warning or caution message is depicted.
Indicates a prohibited action or procedure. Inside or near this circle, a concrete and
practical image of the activity to be avoided is depicted.
Indicates an important action or procedure which must be performed or carried out
without fail. Failure to follow the instructions herein can lead to malfunction or
damage to the pump.

- 2 -
Safety instructions
●Pay attention to the magnet field
The magnet drive pump has a pair of strong magnets. The strong magnet
field could adversely affect the persons who are assisted by electronic
devices such as the pacemaker.
●Power OFF
Be sure to turn off the power before starting a maintenance/repair work.
Make sure no one turns on the power while working on the pump, other-
wise it may result in a serious accident. If your work field is noisy or dark,
let other people know about the situation by displaying a notice such as
"POWER OFF (Maintenance)" near the power switch.
●Wear protective clothing
Always wear protective clothing such as eye protection and protective
gloves during pipework or dismantlement of the pump.
●When lifting the pump
Chain the pump via eye bolts to lift it up.
●Do not remodel the pump
Do not remodel the pump. We are not responsible for a personal injury or
pump damage due to any modification.
●When handling dangerous liquid
For the transfer of the harmful liquid as mentioned below, be sure to con-
duct daily inspection and maintenance for the prevention of liquid/gas leak-
age or other failure.
1. Explosive or flammable liquid
2. Corrosive or stimulus toxic liquid
3. Health hazardous liquid
●Ventilation
Poisoning may result when handling a toxic or odorous liquid. Keep good
ventilation in your operating site.
WARNING
Turning of f power
Prohibited
Wear protective
gear
No Remodeling

- 3 -
Safety instructions
●Attention to magnetic force
A pair of strong magnets is mounted in the pump and may cause personal
injury. Follow "Disassembly & Assembly" section when dismantling and/or
assembling the pump.
●Do not run pump dry
Do not run pump dry (Operation without liquid). Friction heart in the dry run-
ning causes the pump damage. If the pump is operated with a suction side
valve closed, the pump runs dry.
Note that the CF type of high density carbon bearing can run dry within one hour.
●Restriction on pump operator
The pump must be handled or operated by a qualified person with a full
understanding of the pump.
●For a specified application only
Use of the pump in any application other than those clearly specified may
result in pump failure or damage.
●Static electricity
Take countermeasures to remove the static electricity when low electric
conductivity liquids such as ultra-pure water and fluor inactive liquid (e.g.
FluorinertTM) are handled. Otherwise, the static electricity may generate in
the pump and may cause static discharge.
●Static electricity
Always run the pump for air elimination before full operation. Note that
hydrogen peroxide and sodium hypochlorite easily generate gas. If the
pump runs without full air elimination, the pump is damaged by friction heat.
●Countermeasure against efflux
Take a protective measurement against accidental chemical efflux and
splash at pump or piping breakage. Also, take an appropriate measure-
ment to prevent accidental outflow from directly soaking into the ground.
Otherwise, It leads to personal injury or environmental damage.
●Pump disposal
Any used or damaged pump must be disposed of in accordance with local
laws and regulations as an incombustible (Consult a licensed industrial
waste products disposing company.). Neutralize and flush out chemicals
before disposal. Do not incinerate fluororesin parts. Fluororesin emits harm-
ful gas when it is burnt and affects human health and environment.
CAUTION
Prohibited
Prohibited

- 4 -
Outline
1. Unpacking & Inspection........................5
2. Model code...........................................6
3. Operating conditions.............................7
4. Part names...........................................8

- 5 -
1. Unpacking & Inspection On unpacking the product, check the following
points. If you find any problems, contact your
nearest dealer.
1. Check the information on nameplate and con-
firm the product is delivered as per order.
2. Check for transit damage, deformation, and
loose bolts.
Tighten the rear casing support mounting bolts
to the specified tightening torque. See "13.
Disassembling & Assembling" section for the
specified tightening torque.
3. Check if accessories are included.
Bolt for back pull-out:
M12×100mm (2pcs)
Optional accessories (if ordered):
Spare parts and the dry run protector, etc.
Pump unit (Liquid feeding section)
Not capable of self-priming:
Before operating the pump, feed liquid
through the suction or discharge port.
Drain port
Drain a liquid into a suitable container.
Follow an applicable local regulation
at disposal of liquid. Never allow the
discharged liquid to flow directly onto
the ground.
Motor nameplate
Use only the power
voltage specified on the
nameplate. Follow an
applicable local power
regulation.
Suction port
Base plate
Discharge port
Foot support
Nameplate
Eye bolt
CAUTION
When cleaning the pump, do not wipe the nameplates, labels or the pump body with
any solvent.
Outline

- 6 -
2. Model code
AMP40 - 150 1 KK F 075 J - D 2
Pump discharge bore:
Suction Discharge
40: 50 × 40
50: 65 × 50
Nominal impeller diameter: 110 - 165 (mm)
Impeller code: 1
Bearing/Spindle material: KK: SiC/SiC CF: High density carbon/High purity ceramic
Motor type: F: Flanged motor
Motor output: 037: 3.7 kW, 055: 5.5 kW, 075: 7.5 kW
Flange/Motor standards J: JIS pump flange + JIS motor A: ANSI pump flange + JIS motor
Drain/Custom product
Number of motor poles: 2: Two pole motor
NOTE: In this manual, model code is simplified by using pump discharge bore code and
impeller range code .
Base plate Standard or Custom product
A
With base plate
Standard
S
D
X Custom product
B
Without base plate
Standard
Y
E
Z
Drain
Without drain Custom product
With drain Standard
Without drain Custom product
With drain Standard
Custom product
Outline

- 7 -
3. Operating conditions
1. Permissible pressure
Pump permissible pressure is 1.0MPa. Do not allow the pump discharge pressure to exceed the limit.
2. Slurry liquid
Slurry liquid can not be used except for the KK type of SiC bearing. The KK type can handle slurry in the fol-
lowing conditions:
• Slurry concentration up to 5 wt%
• Slurry hardness up to 80 Hs
• Slurry size up to 50 μm
Contact us for detail before slurry transfer.
NOTE: Not only friction parts but also plastic parts are worn when handling slurry liquid.
Note that periodic pump change is needed.
3. Performance change along with specific gravity and viscosity
Shaft power, discharge capacity and discharge head vary with specific gravity and viscosity. The pump has
been made in accordance with the specified operating condition at order phase. If the operating condition
has been changed since then, contact us before use of the pump.
4. Influence by liquid temperature
Viscosity, vapour pressure and corrosiveness vary with the temperature change. Pay attention to the change
of liquid characteristics.
• Liquid temperature range: 0-80˚C
• Ambient temperature range: 0-40˚C
• Ambient humidity range: 35-85% RH
Outline

- 8 -
NO. Parts name Q'ty NO. Parts name Q'ty
100.1 Front casing 1 554.2 Spring washer 2
100.2 Cover 1 554.4 Spring washer 8
122.1 Drain plate 1 554.5 Spring washer 4
158 Rear casing 1 554.6 Spring washer 4
159 Rear casing cover 1 554.7 Spring washer 2
161 Rear casing support 1 801 Motor 1
210 Spindle 1 858 Drive magnet unit 1
230 Impeller 1 859 Magnet capsule unit 1
310 Bearing 1 890 Base plate 1
314.1 Liner ling 1 900 Eye bolt 1
314.2 Mouth ring 1 901.1 Hex. head bolt 2
314.3 Rear thrust ring 1 901.2 Hex. head bolt 2
314.4 Rear ring 1 901.4 Hex. head bolt 8
330 Bracket 1 901.5 Hex. head bolt 4
400.1 Gasket 1 901.6 Hex. head bolt 4
400.2 Drain gasket 1 901.7 Hex. head bolt 2
500.1 Plain washer 2 903.1 Hex. head bolt 5
500.2 Plain washer 2 908.1 Hex. socket set screw 2
554.1 Spring washer 2 942 Pin 2
See the construction drawing for details.
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4. Part names
Outline

- 9 -
Installation
1. Before installation ...............................10
2. Piping.................................................. 11
3. Wiring.................................................14
4. Protection equipment..........................14

- 10 -
1. Before installation
Example of recommended piping
Discharge pipe
Discharge valve
Check valve
Pressure gauge
Motor
Pump
Flexible joint
Vacuum gauge
Suction pipe
Suction valve
Gate valve
Air vent piping
Pipe support
1
2
3
11
10
13
10
12
11
65
97
4
87
12
Within
1m
Concrete foundation
Foundation bolt
Baseplate Liner
Liner
Installation
1. Installation location
• The pump should be installed on a flat foundation where is free from vibration or torsional force.
• Spacing for the motor removal (for back pull out) and maintenance (assembly and dismantlement) are
needed.
• Installation surface should be larger than the pump base.
2. Positioning
• Install the pump as close to the suction tank in flooded suction system.
• If the flooded suction system can not be realized, install the auxiliary piping for priming and a foot valve at
the suction pipe end.
3. Pump mounting
• See the diagram below for mounting the pump in the foundation.
• For the pump without the base plate, note that the pump can not be dismantled with the foot supports of
the cover and bracket fixed in the foundation.

2. Piping
■Tightening torque between discharge/ suction ports and pipes
Connections between the pipes and the pump ports should be tightened according to the table below.
Tightening torque (RV)
■Piping load and momentum
The permissible piping weight and moment to the pump are as below.
- 11 -
Bolt size
M16
Tightening torque
78.4 N•m
Z
X
Y
X
Z
Y
Load direction Suction flange
Fx
Fy (Contraction/Tension) 0.58
Fz 0.71
Load kN
Discharge flange
AMP 40 & 50
0.71 0.89
0.58
AMP 40 & 50
0.89/0.44
Load direction Suction flange
Mx
My 0.35
Mz 0.23
Moment kN · m
Discharge flange
AMP 40 & 50
0.35 0.46
0.23
AMP 40 & 50
0.46
Installation
Permissible moment to the pump flange
Permissible stress to the pump flange

- 12 -
■Suction piping
1. Flooded suction system
Always realize the flooded suction system.
2. Suction piping bore
A suction piping bore should be equal to or larger than pump inlet.
3. Shortest piping length
Have piping shortest with the minimum number of bends.
4. Straight pipe length
The piping end right before the pump inlet should be straight.
When the pump inlet bore is 50A or smaller, the straight pipe length should be of 500 mm or longer
When the pump inlet bore is 65A or larger, the straight pipe length should be eight times longer than inlet
bore. For the easy pump removal and maintenance, install a removable pipe of 300mm in straight piping.
5. Air pocket
Do not make any projection or arched line where air may be trapped.
The suction pipe should be laid on a rising gradient of 1/100 toward the pump.
6. Use of the eccentric reducer pipe
If the pump inlet bore is different from that of suction pipe, use the eccentric reducer pipe. Upper side
should always be level. The air may be trapped if it is mounted upside down.
7. Gate valve installation
In flooded suction, install a gate valve on the suction piping for easier overhaul & inspection.
8. Flushing piping
Install the flushing piping for cleaning the pump when handling a harmful liquid.
9. Suction piping end
The suction piping end should always be at least 500 mm lower than a liquid level for the prevention of the
air ingress.
10. In a piping system other than the flooded suction
• The distance between the end of suction piping and the bottom of a suction tank should be 1 to 1.5
times wider than the suction pipe bore.
• Be sure to install a foot valve or a check valve on the suction piping.
11. Piping support
Support piping by pipe supports so that the pump is not subject to piping weight or thermal stress.
12. Connections
Each connection must be completely sealed so that air can not be sucked in. Imperfect sealing can cause
the air ingress and it results in the insufficient suction and the seizure of bearing.
Installation

- 13 -
Installation
■Discharge piping
1. Discharge piping bore
When the discharge piping is long but the piping bore is equal to the pump outlet bore, the specified
performance may not be obtained because pipe resistance becomes high. Calculate pipe resistance in
advance to decide a discharge piping bore.
2. Discharge valve installation
Install a discharge valve on the piping about 1m away from the pump. The air bleed piping should be pro-
vided near the discharge valve in order to prevent the air from remaining.
3. Gate valve installation
Install a gate valve on the discharge piping to adjust flow rate and to protect the motor from overload. If a
check valve is installed, the optimum installation order is : Pump →Check valve →Gate valve.
4. Pressure gauge
A pressure gauge is required on the discharge piping to check operating conditions such as discharge
capacity and head.
5. Check valve
A check valve is required in the following cases.
• Discharge piping length is between 15 and 20 meters.
• Actual head is higher than 15 meters.
• The distance between the liquid level in the tank and the top end of discharge piping is 9 meters or more.
• Two pumps run in parallel.
6. Air vent
Install an air vent on the discharge piping when the horizontal piping length is between 15 and 20 meters.
7. Drain
Install a drain valve when draining of liquid is required (to protect the pump from freezing, etc.).
8. Piping support
Support the piping by pipe supports so that the piping weight does not totally weigh the pump.
9. Priming piping
A priming line is required on the discharge piping when piping is not flooded suction.

- 14 -
3. Wiring
Electrical works or wiring must be carried out by a qualified person according to local laws or regulations.
• Use the electromagnetic switch which conforms to the motor specifications of voltage and capacity etc.
• When installing the pump out of doors, take a measure to prevent rain water from getting into the switch
when wiring.
• Install the electromagnetic or the push-button switch apart from the pump.
• The star-delta starter, inverter, or soft starter is recommended to start the motor of 5.5kW or more.
* See the instruction manual of the motor manufacturer for the motor detail.
4. Protection equipment
It is recommended to install the following monitoring devices in order to protect the pump.
1. Current sensor/ Power sensor The sensors monitor the motor load and stop the pump on the detection
of load change, giving an alarm.
2. Pressure sensor The sensor monitors the starting pressure and stops the pump on the
detection of pressure change, giving an alarm.
3. Flow sensor The sensor monitors the discharge flow and stops the pump on the
detection of flow change, giving an alarm.
4. Level sensor The sensor monitors the liquid level and stops the pump when it falls
below the specified level, giving an alarm.
It is recommended to install two or more monitoring devices. The more monitoring devices, the more possi-
bility of protecting the pump.
The DR series dry running protector (electric current sensing type) is also available as an option. Contact us
for detail.
Installation

- 15 -
Operation
1. Before operation .................................16
2. Operation............................................17
3. Shutdown............................................17

- 16 -- 16 -
CAUTION
●Never run pump dry or shut off a suction valve during operation. Otherwise the pump
fails in a short period.
●Check the rotational direction of the pump. Clockwise seen from the motor end is a
correct direction. Operation in the reverse direction may cause pump damage. Always
carry out rotation check with the pump full of liquid.
●Stop the pump within one minute if cavitation occurs.
●Do not run the pump when air enters the suction line.
●Stop the pump immediately when the magnet coupling is disconnected. The magnet
force reduces if the pump keeps on running for more than one minute in this condition.
●The maximum number of ON/OFF operation should be within six times an hour.
Frequent ON-OFF operation can reduce the pump life.
●Keep liquid temperature change within 80˚C through operation and stopping.
●Start the pump with a discharge valve full close in order to avoid water hammer.
●Closed-discharge operation should be within one minute. If the pump runs with a dis-
charge valve closed for a long time, the liquid temperature inside the pump rises and
it damages the pump.
●If power is interrupted when the pump is running, switch off and close a discharge
valve.
●Take extra care so that the discharge pressure does not exceed the pump limit.
●When high temperature liquid is transferred, the pump surface becomes very hot.
Take a protective measure against burn. See below.
Liquid temperatuer Surface temperature
80°C 75°C
●Noise level is 90dB (A scale - one meter)
In case the pump noise affects human health or the communication to secure a safety,
provide a noise reduction cover. Be careful not to reduce cooling effect by a motor fan.
1. Before operation
Operation

- 17 -- 17 -
Operation
2. Operation
1. Fully close a discharge valve and fully open a suction valve.
2. Prime the pump.
• If the pump is in flooded suction system, fully open both discharge and suction valves.
• If the pump is other than flooded suction system, prime the suction piping as well as the pump.
3. Check rotating direction of the motor.
• Close a discharge valve. Power the motor for a quick moment (within a second) in order to check the
rotation direction. A correct direction is shown with an "arrow" mark on the pump (Clockwise seen from
motor fan side).
• Check if the motor fan smoothly stops when it is powered off.
NOTE: If the motor does not stop smoothly, check rotating parts.
4. Air elimination
• Before full operation, eliminate the air in the pump.
• Fully open the valve on the air bleed piping. Run the pump for one second and repeat it 3 to 5 times for
air elimination.
• After the air elimination, fully close the discharge valve.
NOTE: In case air bleed piping is not equipped, repeat the momentary run several times
with a discharge valve open.
5. Starting operation
• Start the pump with a discharge valve fully closed. Stop the closed-discharge operation within one minute.
• Confirm that discharge pressure rises to the shut off pressure.
• Gradually open discharge valve to obtain the specified pressure (capacity).
NOTE: Pay attention to the over-load caused by an excessively opened valve.
Precautions on operation
1. Check for loose bolts on the pump. Retighten the rear casing support mounting bolts by the specified
torque of 85N•m.
2. When the pump keeps running in negative rotation, the pump breaks.
3. Closed-discharge operation should be within one minutes.
4. Make sure that a flow rate is always equal to or more than the minimum one. The operation below the mini-
mum flow can reduce the lubricant and cooling functions on the sliding parts. This could lead to failure.
Minimum discharge capacity is 50 /min.
3. Shutdown
1. Slowly close a discharge valve.
Quick closing by a solenoid valve may cause water hammer and damages the pump. Be sure to slowly
close any discharge valve.
2. Switch off and stop the pump.
Check that the pump stops smoothly. If the pump stops roughly, inspect it.
NOTE: When leave the pump stopped for a long period, take a countermeasure against
freezing for the prevention of freeze in the pump and piping. In case a blackout inter-
rupts the pump operation, switch off the pump and close discharge valves.

- 18 -
Maintenance
1. Troubleshooting ..................................19
2. Maintenance & Inspection...................21
3. Disassembly & Assembly....................23
4. Spare & Wear parts............................29