Realax APY Series User manual

Operating instructions
APY Series
Peristaltic pump
ALL THE HOSE PUMP YOU’LL EVER NEED

Congratulations!
And welcome to the world of realax
hose pumps.
Drawing on extensive interaction with real users of peristaltic
pumping technology and examining applications as diverse as
food, water and wastewater, chemicals and pharmaceuticals,
construction and mining, we have tried to tailor our range of
pumps more precisely to your needs.
Our range of hoses and accessories reect what hose pump
customers really need and use – after all, best is what you want,
second best should never be an option.
We hope you’ll nd using your realax pump simple, trouble-
free and that it makes a positive contribution to the success of
your process. If you have any questions you can’t nd answers to
in these pages, check our website or call your local represent-
ative on the number on the contact page of this guide.
Of course this manual is available in your language.
Please download it from the attached USB ash drive.

Operating instructions Peristaltic Pump APY Series
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TABLE OF CONTENTS
1 Introduction ................................................4
2 Safety .......................................................6
3 Functional description ....................................11
4 Description.................................................12
5 Construction ...............................................13
6 Transport and storage.....................................14
7 Assembly, commissioning & installation ................ 15
8 Torque values ............................................. 17
9 Troubleshooting ...........................................26
10 Spare parts .................................................28
11 End of life ..................................................32
12 Declaration of conformity.................................33
13 Warranty ...................................................34
14 Where to buy ..............................................35

Operating instructions Peristaltic Pump APY Series
4
1 INTRODUCTION
This instruction manual must accompany the pump at
all times for as long as it is in use.
The APY series peristaltic pump is a machine for uid
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.
This instruction manual does not substitute any
installation standard or any additional future standard.
1.1 How to use this manual
This manual is intended as a reference book by means of which qualied
users are able to install, commission and maintain the hose pumps
mentioned on the front cover.
1.2 Original instructions
The original instructions for this manual have been written in English.
Other language versions of this manual are a translation of the original
instructions.
1.3 Other supplied documentation
Documentation of components such as motors and inverters is normally
not included in this manual. However, if additional documentation
is supplied, you must follow the instructions in this additional
documentation.

Operating instructions Peristaltic Pump APY Series
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CAUTION
Always observe the local rules and regulations with
respect to processing (non reusable) parts of the
hose pump.
1.4 Service and support
For information with respect to specic 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.
1.5 Environment and disposal of waste
Enquire with your local government about the possibilities for reuse or
environment friendly processing of packaging materials, (contaminated)
lubricant.

Operating instructions Peristaltic Pump APY Series
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2 SAFETY
2.1 Explanation of the safety information
This symbol identies the instructions of this manual,
which must be observed to avoid failure to meet safety
standards.
This symbol identies the instructions of this manual,
which must be observed to avoid compromising
electrical safety.
This symbol identies the instructions of this manual,
which must be observed to guarantee the correct
operation of the pump.
!
CAUTION
In this manual the following symbols are used:
2.2 Intended use
The hose pump is exclusively designed for pumping suitable products.
Every other or further use is not in conformance with the intended use. In
case of doubt it is the use which appears to be its intended use judging from
the construction, execution and function of the product. Observing the
instructions in the user’s documentation also belongs to intended use.
Only use the pump in conformance with the intended use described above.
The manufacturer cannot be held responsible for damage or harm result-
ing from use that is not in conformance with the intended use. If you want
to change the application of your hose pump, contact your AxFlow repre-
sentative rst.
2.3 Responsibility
The manufacturer does not accept any responsibility for damage or harm
caused by not (strictly) observing the safety regulations and instructions in
this manual and the also supplied documentation, or by negligence during
installation, use, maintenance and repair of the hose pumps mentioned on

Operating instructions Peristaltic Pump APY Series
7
the front cover. Depending on the specic working conditions or accessories
used, additional safety instructions can be required.
2.4 User qualications
Pumps are machines that can present dangers due to moving parts and the
presence of a pressurised uid within the hose.
THE FOLLOWING CAN CAUSE SERIOUS DAMAGE AND INJURY
• Improper use
• Removal of the protections and/or disconnection of protective
devices
• Lack of inspections and maintenance
The person responsible for safety should therefore guarantee that the pump
is transported, installed, put in service, used, maintained and repaired by
qualied personnel who should possess:
• Specic training and sufcient experience for the tasks.
• Knowledge of the technical standards and applicable laws.
• Knowledge of the national and local safety and installation stand-
ards.
Any work carried out on the electrical part of the pump should be authorized
by the person responsible for safety.
Given that the pump is intended to form part of a system, it is the
responsibility of whoever supervises the installation of the entire system to
guarantee absolute safety, adopting the necessary measures of additional
protection.

Operating instructions Peristaltic Pump APY Series
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!
!
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.
Lack of emergency stop switch
Possible consequence: fatal or very serious injuries.
- An emergency stop switch must be connected
for the entire system. This should enable the
entire system to be shut down in the event of an
emergency in such a way that the overall System
can be brought into a safe condition.
Unauthorized access
Possible consequence: fatal or very serious injuries.
- Risk mitigation: ensure that there can be no
unauthorized access to the pump or to the system.
Hazardous media/contamination of persons and
equipment
Possible consequences: fatal/serious injuries. Material
damage.
- Ensure that the pump hoses are chemically
resistant against the media being handled.
- Always observe the safety data sheets for the
media to be handled. The system operator must
ensure that these safety data sheets are available
and that kept up-to-date.
- The safety data sheets for the uid being handled
are always decisive for initiating countermeasures
and/or rst aid in the event of leakage of the uid.
- Observe the general restrictions in relation to
viscosity limits, chemical resistance and density.
- Always switch the pump off before exchanging
the pump hose.
2.5 General safety information

Operating instructions Peristaltic Pump APY Series
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Incorrect and improper use
Possible consequence: fatal or very serious injuries.
- The unit is not intended to convey or regulate
gases or solid media
- Do not exceed the rated pressure, speed or
temperature for the pump
- Maximum pressure on suction/inlet side is 0.5 bar
(7 psi approx.).
- The unit may only be used in accordance with
the technical data and specications provided in
these operating instructions and in the operating
instructions for the individual components.
- 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.
- Only switch the pump on if it has been properly
fastened to the oor.
- Only switch the pump on if the front cover has
been attached.
- Do not carry out any maintenance operations or
dismantle the pump without rst making sure
that the pipes are not under pressure and are
empty or isolated.
- In the case of the hose becoming stuck during
extraction or tting it is necessary to reverse the
direction of the pump, re-lubricate, and then
repeat the operation.
- As the peristaltic pump is volumetric and
its functioning is positive displacement, it is
necessary to prevent a possible overload of
pressure, due to for example the accidental
closure of a valve. For this reason it is advisable to
t a safety device such as: a safety valve, pressure
limiter, etc.
Operational lifetime of the pump hoses
Possible consequence: fatal or very serious injuries.
- The hose has an indeterminate life and due to the
possibility of its breakage or deterioration, the
user is responsible for the prevention of a possible
CAUTION
CAUTION

Operating instructions Peristaltic Pump APY Series
10
(although most unlikely) incorporation of
particles from the hose into the product being
pumped. This can be achieved by means of
ltration, a hose rupture alarm or other means
suitable for the respective process.
CIP cleaning
- In the event of CIP cleaning, it is necessary to
obtain information from the manufacturer
about correct installation of the pump (a
special installation is required) as well as
regarding the compatibility of the cleaning
agents with the pump hoses and the hydraulic
connections.
- Cleaning should be undertaken at the
recommended maximum temperature.
Direction of rotation/ow direction
Possible consequence: material damage,
destruction of the unit.
- The pump’s direction of rotation in relation
to the desired ow direction must be checked
prior to every start.
Disconnect the pump from the mains
Possible consequence: personal injury.
- Work may only be carried out on the pump
after it has previously been switched off and
disconnected from the mains.
Environmental inuences
Possible consequence: material damage up to
destruction of the unit.
- The device is suitable for outdoor operation
once it is covered and protected from rain and
direct sunlight. Ambient conditions must also
be respected (see section 8.1).
- Take suitable measures to protect the device
from environmental inuences such as:
UV rays | moisture | frost | etc.
!
!
!

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3 FUNCTIONAL DESCRIPTION
The APY Series is a positive displacement pump. The feed chemical is
conveyed by the rotor squeezing the tube in the direction of ow. No
valves are needed for this. This ensures gentle handling of the metered
media.
Maximum pressure on suction/inlet side is 0.5 bar (7 psi approx.)
The APY Series has been designed for safe and uncomplicated operation,
as well as straightforward maintenance.
The APY Series can be used for many different media. However, this pump
type is often the optimal solution for abrasive, shear-sensitive and viscous
media.
Typical areas of use include processes where only a low discharge pressure
is required (max. 2 bar).
3.1 Main modules
1. Drive unit | 2. Pump housing | 3. Base frame
APY APY LAB
1
2
3
1
2
3

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4 DESCRIPTION
4.1 Identication of the product
A: Pump head
B: Gearbox
C: Electric motor
4.2 Identication of the pump
MOD: Type number
No: Serial number
YEAR: Year of manufacture
DESCRIPTION UNIT TUBE (Ø) APY APY/LAB
Max. Capacity
Continuous Duty l/h – 84 38.2
Max. Capacity
Intermittent Duty l/h – 84 38.2
Capacity per
Revolution ml/rev
1.6 mm 0.40 –
3.2 mm 1.66 0.75
4.8 mm 3.80 1.72
6.4 mm 6.26 2.54
8.0 mm 10.00 4.55
Max. Permissable
Working Pressure bar – 2
Permissable Ambient
Temperature ºC – ‐10 to +40
Permissable Product
Temperature ºC – ‐10 to +80
Sound Level at 1m dB (A) – 70
Key performance data and noice levels
APY APY LAB

Operating instructions Peristaltic Pump APY Series
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5 CONSTRUCTION
The pump housing is closed off with a bolted front cover in order to avoid
the risk of injury.
The motor serves to drive the rotor. Three rollers attached to the rotor
serve to press the tube against the pump housing.
The rotary movement of the rotor alternately presses and releases the
rollers against the tube. This serves to suck the media and convey it into
the metering line.
Fig. 1: Diagram of functional principle
1. Pump housing | 2. Rotor| 3. Tube
4.3 Identication 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.
4.4 Identication 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’ function such
as electric power.
APY APY/LAB
3
1
2

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6 TRANSPORT AND STORAGE
6.1 Transport
- The pump is protected by cardboard packaging or a wooden
crate.
- The packaging materials are recyclable.
6.2 Storage for less than 1 month
- The pump should be in a resting position, rotor in horizontal
position.
- Avoid areas open to harsh weather or excessive humidity and
temperatures lower than 0 °C or higher than 30 °C.
- Spare tubes should be stored in a dry place away from direct
light.
6.3 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 the tube from the housing (see
section 8.2)
- For storage periods of longer than 30 days, protect the
coupling surfaces (clamps, reducers, motors) with adequate
anti-rust protection.
- For storage periods longer than 6 months rotate the rotor a
few turns to prevent. damage to bearings and oil seals and to
prevent grease migration.
- Spare tubes should be stored in a dry place away from direct
light.
6.4 Elevation
APY pumps sizes can be lifted manually and can be lifted by one person.
It is the customer’s responsibility to adhere to local workplace legislation.
WEIGHTS APY APY/LAB
Total pump weight <11 kg
<24.25 lbs
Lifting 1 person

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7 ASSEMBLY, COMISSIONING AND INSTALLATION
7.1 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 inuences.
When positioning the pump, ensure that sufcient room for access is
provided for all types of maintenance work.
Limit values for hose temperature and pressure
Tube Material Min. Temp. (ºC)
Feed liquid
Max. Temp (ºC)
Feed liquid
Min. Temp (ºC)
Environment
Max.
Pressure (bar)
NORPRENE
-10 80* -10
2
SOLVA 3
SILICONE 2
* At max. temperature, the life of tube is drastically reduced. Please contact authorized distributor for
applications with feed liquid temperature higher than 60 °C.
7.2 Commissioning
7.2.1 Testing prior to commissioning the pump
The following tests are to be carried out:
- Only switch the pump on if the front cover has been properly
attached.
- Check that the mains voltage is suitable for the motor.
- Check that the thermal overload protection (not included in the
delivery scope) corresponds to the value specied on the motor
type plate.
- Conrm 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 qualied personnel.
- Check that the optional electrical components are connected
and are working properly.
- Check whether the direction of rotation is correctly adjusted.

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7.3 Correct installation of the pump
- Ensure that the pump has not been damaged during
transportation or storage. Immediately report any damage to
the supplier.
- Ensure that all the packaging has been removed.
- Check that the information printed on the identication plate
corresponds with the order.
- Check the operating instructions in order to ensure that the
ow values, pressures & power consumption of the motor do
not exceed rated values.
- Ensure that the tube is suitable for the uid to be conveyed
and that it is not damaged.
- Make sure that the temperature of the liquid does not exceed
the recommended temperature range.
- Ensure that there is enough space for free airow around the
motor.
- Ensure that no nearby objects or direct sunshine radiate
additional heat to the motor.
7.3.1 Suction side
- 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.
- The suction line must be absolutely airtight and made of a
suitable material, so that it does not collapse under vacuum.
- The diameter must correspond to the rated diameter of the
tube. A larger diameter is recommended in the event of viscous
liquids.
- The pump is self-priming and does not require an admission
valve.
- 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.

Operating instructions Peristaltic Pump APY Series
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7.4.1 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
tube. A larger diameter is recommended in the event of viscous
liquids.
- Do not close or block the outlet since, as it is a volumetric
pump, it would cause the tube to break or an electro-
mechanical overload.
8 TORQUE VALUES
8.1 Lubrication
APY pumps only require a thin lm of grease to reduce the friction
between the roller and the outer surface of the tube. No other lubrication
is necessary.
Lubricant quantity table
DESCRIPTION UNITS APY
ACover bolts – Manual,
no bolts
B
UNIT APY
Lubricant – realax
Silicone grease
quantity
gramme 10-20
ounce 0.35 – 0.71
A
B

Operating instructions Peristaltic Pump APY Series
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8.1.1 Changing oil in gearbox
The instructions manual of the gearbox are usually delivered with the IOM
of the realax pump.
Some models of gearbox are lubricated for life, other models of gear
reducers require regular maintenance according to the instructions
manual of the gear reducer manufacturer.
In case of doubt, please contact the gearbox manufacturer or their
authorised distributor in your country.
8.2 Exchanging the APY tube
8.2.1 Dismantling
Close off all valves, in order to prevent leakage of the feed chemical.
1. Dismantle the pipes from both discharge and suction sides.
2. Remove the front cover. Front covers of APY series can be removed
manually.

Operating instructions Peristaltic Pump APY Series
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3. Insert an allen key into bolt on the left of the housing to stop the bolt
from rotating and twist off the star knob on the right.
4. Slide off the removable housing.
5. Clean removable housing and rollers.

Operating instructions Peristaltic Pump APY Series
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6. Apply lubricant to the rollers and the removable housing with a small
brush.
7. Place new tube around the roller and through the slots in the
housing.
8. Place the allen screws in the removable housing and slide it on the
housing.