Realax IP Series User manual

Operating instructions
IP 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 representative
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 IP Series
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TABLE OF CONTENTS
1 Introduction ............................................... 2
2 Safety and Responsibility................................. 4
3 Functional description.................................... 7
4 Transport and Storage .................................... 8
5 Assembly and Installation ................................ 9
6 Commissioning...........................................14
7 Maintenance, repair, malfunctions
disposal and spare parts.................................15
8 Spare parts................................................21
9 Declaration of Conformity...............................33
10 Warranty ..................................................34

Operating instructions Peristaltic Pump IP Series
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1 INTRODUCTION
This manual forms an integral part of the pump and must accompany it
until its demolition. The series IP peristaltic pump is a machine destined
to work in industrial areas and as such the instruction manual must
form part of the legislative dispositions and the applicable technical
standards and does not substitute any installation standard or eventual
additional standard.

Operating instructions Peristaltic Pump IP Series
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1.1 Explanation of the safety information
The instructions of this manual, whose inobservance
is determined as a failure to meet safety standards, are
identied by this symbol .
The instructions of this manual, whose inobservance
compromises electrical safety.
The instructions of this manual, whose inobservance
compromises the correct working of the pump, are
identied with this symbol.
!
CAUTION
1.2 Users’ qualifications
Pumps are machines that due to their functioning under pressure and
moving parts can present dangers.
- Improper use.
- Removing the protections and/or disconnecting the protec-
tion device.
- The lack of inspections and maintenance.
They can cause serious damage or injury.
The person in charge of safety should therefore guarantee that the
pump is transported, installed, put in service, used, maintained and
repaired by qualied personnel who should therefore possess:
- Specic training and sufcient experience.
- Knowledge of the technical standards and applicable laws.
- Knowledge of the general national and local safety standards
and also of installation.
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
destined to form part of an installation, it is the responsibility of who-
ever supervises the installation to guarantee absolute safety, adopting
the necessary measures of additional protection.

Operating instructions Peristaltic Pump IP Series
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2 SAFETY AND RESPONSIBILITY
2.1 General safety information
Live parts
Possible consequence: Fatal or very serious injuries.
- Measure: 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.
Emergency stop switch
Possible consequence: Fatal or very serious injuries.
An emergency stop switch is to be connected for the en-
tire plant. This should enable the entire plant to be shut
down in the event of an emergency in such a way that
the overall plant can be brought into a safe condition.
Unauthorized access
Possible consequence: Fatal or very serious injuries.
- Measure: Ensure that there can be no unauthor-
ized access to the unit.
Hazardous media/contamination of persons and
equipment
Possible consequence: Fatal or very serious injuries
material damage.
- Ensure that the pump hoses are resistant against
the media being conveyed.
- Always observe the safety data sheets for the
media to be conveyed. The system operator must
ensure that these safety data sheets are available
and that they are kept up-to-date.
- The safety data sheets for the media being con-
veyed are always decisive for initiating counter-
measures in the event of leakage to the media
being conveyed.
- Observe the general restrictions in relation to
viscosity limits, chemical resistance and density.
- Always switch the pump off before exchanging
the pump hose.

Operating instructions Peristaltic Pump IP Series
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Correct and proper 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 tem-
perature for the pump.
- 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.
- The system is not designed for use in areas of risk
from explosion.
- Only switch the pump on if it has been properly
fastened to the oor.
- Only switch the pump on if it 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, relubricate, and then
repeat the operation.
- As the peristaltic pump is volumetric and its func-
tioning 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 operational lifetime of the pump hoses cannot be
precisely specied. For this reason, the possibility of
fracture and consequential leakage of liquids must be
accounted for. If the hose rupture alarm (optional) is
tted, then the pump can be stopped and / or an elec-
trical valve can be actuated.
CAUTION
CAUTION

Operating instructions Peristaltic Pump IP Series
In addition, as 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
(although most unlikely) incorporation of particles
from the hose into the product being pumped. This can
be achieved e.g. by means of ltration, a hose rupture
alarmorothermeans suitablefor therespective process.
CIP cleaning
In the event of CIP cleaning, it is necessary to obtain in-
formation from the manufacturer about correct instal-
lation 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 connec-
tions.
Cleaning should be undertaken at the recommended
maximum temperature.
Direction of rotation/flow direction
Possible consequence: Material damage right through
to 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.
You may only carry out work on the pump after it has
previously been switched off and disconnected from
the mains.
Environmental influences
Possible consequence: Material damage right through
to destruction of the unit.
- The device is not suitable for outdoor operation
- Take suitable measures to protect the device from
environmental inuences such as:
– UV rays.
– Moisture.
– Frost, etc.
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Operating instructions Peristaltic Pump IP Series
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3 FUNCTIONAL DESCRIPTION
The IP Series is a positive displacement pump. The process uid is con-
veyed by the rotor squeezing the hose in the direction of ow. No valves
are needed for this. This ensures gentle handling of the process uid.
The IP Series has been designed for safe and uncomplicated operation,
as well as straightforward maintenance.
The IP Series can be used for many different media. However, this
pump type is often the optimal solution for abrasive, shear-sensitive and
viscose media.
Typical areas of use include processes where only a low discharge
pressure is required (max. 8 bar).
3.1 Construction
Main modules: – Drive Unit, – Housing, – Base frame
The pump housing is closed off with a screwed front cover in order to
avoid the risk of injury.
The motor serves to drive the rotor. Two rollers at the ends of the rotor
serve to press the pump hose against the pump housing.
The rotary movement of the rotors alternately press and relax the
rollers in relation to the pump hose. This serves to suck the media and
convey it into the process line.
Fig. 1: Diagram of functional principle.
1 Casing 2 Rotor 3 Rollers 4 Hose

Operating instructions Peristaltic Pump IP Series
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4 TRANSPORT AND STORAGE
4.1 Transport
- The pump is protected by a cardboard packaging.
- The packaging materials are recyclable.
4.2 Storage
- The pump should be in a resting position. (The hose should
not be compressed).
- Avoid areas open to harsh weather or excessive humidity.
- For storage periods of longer than 60 days, protect the
coupling surfaces (clamps, reducers, motors) with adequate
anti-oxidant products.
- Spare hoses should be stored in a dry place away from direct
light.
4.3 Lifting
Models IP-30, IP-40, IP-50
- To lift the pump use the
eye bolt.
Models IP-60, IP-70, IP-70D
- To lift the pump, it’s
necessary to use lifting
slings.

Operating instructions Peristaltic Pump IP Series
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5 ASSEMBLY AND INSTALLATION
5.1 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 sun-
light 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
Material
Hose
Min. Temp.
(°C) Feed
chemical
Max. Temp
(°C) Feed
chemical
Min. Temp
(°C)
Environment
Max. Pressure
(Bar)
NR -20 80* -40 8
NBR -10 80* -40 8
EPDM -10 80* -40 8
NR-A -10 80* -40 8
NBR-A -10 80* -40 8
NORPRENE1-10 120* -40 2
1Only available for IP-40
* At max. temperature, the life of hose is drastically reduced. Please contact author-
ized realax distributor for high temperature application.
5.2 Correct installation of the pump
5.2.1 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 is not squeezed together under vacuum. The diameter must
correspond to the rated diameter of the pump hose. A larger diameter is
recommended in the event of viscose liquids. The pump is self-priming
and does not require an admission valve. The pump is reversible and
the suction connection can therefore comprise of one of two options.
Normally the option is selected which is best suited to the physical con-
ditions of the installation. It is recommended to use a exible transition
between two xed pipes and the hydraulic connection of the pump, in
order to avoid the transmission of vibrations.

Operating instructions Peristaltic Pump IP Series
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5.2.2 Discharge side
The discharge line is to be kept as straight and short as possible, in or-
der to avoid performance reduction. The diameter must correspond to
the rated diameter of the pump hose. A larger diameter is recommend-
ed in the event of viscose liquids. It is recommended to use a exible
transition between two xed pipes and the hydraulic connection of the
pump, in order to avoid the transmission of vibrations.
5.3 Adjusting the roller pressure
The peristaltic pump is equipped with shims, in order to adjust the pre-
cise pressure distance to the roller (dependent on speed and operating
pressure).
Fig 2:
1- Roller / 2- Shims

Operating instructions Peristaltic Pump IP Series
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1. Hose in normal shape.
2. Insufcient squeezing (back owing media in the cavity will destroy the hose within
a short period of time).
3. Perfect squeezing.
4. Excessive squeezing (increased wear and tear to pump and hose).
The shims are tted in the factory. You can adapt the number of shims
to the actual operating conditions according to the following table.
5.3.1 IP-30 Model (Number of shims of 0.5 mm thickness):
a) NR, NBR, EPDM, HYPALON, NR-A and NBR-A:
Bar 1/min
0-19 20-39 40-59 60-79 80-99
0.5 2 2 1 1 1
2.0 2 2 2 2 2
4.0* 3 2 2 2 2
6.0 3 3 3 2 –
8.0 4 3 3 – –
*Factoring default setting if working pressure is not informed.
Fig 3:
Squeezing the hose

Operating instructions Peristaltic Pump IP Series
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5.3.2 IP-40 Model (Number of shims of 1 mm thickness):
a) NR, NBR, EPDM, HYPALON, NR-A and NBR-A:
Bar 1/min
0-19 20-39 40-59 60-79 80-99
0.5 4 4 4 4 3
2.0 5 4 4 4 4
4.0* 5 5 5 4 4
6.0 6 5 5 – –
8.0 6 6 – – –
*Factoring default setting if working pressure is not informed.
b) Norprene:
Bar 1/min
0-19 20-39 40-59 60-79 80-99
0.5 14 14 14 14 14
2.0* 14 14 14 14 14
*Factoring default setting if working pressure is not informed.
5.3.3 IP-50 Model (Number of shims of 1 mm thickness):
a) NR, NBR, EPDM, HYPALON, NR-A and NBR-A:
Bar 1/min
0-19 20-39 40-59 60-79 80-99
0.5 1 1 1 0 0
2.0 2 1 1 1 1
4.0* 2 2 2 2 2
6.0 3 3 3 3 –
8.0 4 3 – – –
*Factoring default setting if working pressure is not informed.

Operating instructions Peristaltic Pump IP Series
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5.3.4 IP-60 Model (Number of shims of 1 mm thickness):
a) NR, NBR, EPDM, NR-A and NBR-A:
Bar 1/min
0-19 20-39 40-59 60-79 80-99
0.5 6 5 5 5 5
2.0 6 6 6 6 5
4.0* 6 6 6 6 6
6.0 7 6 6 6 6
8.0 7 7 7 7 –
*Factoring default setting if working pressure is not informed.
5.3.5 IP-70 Model (Number of shims of 1 mm thickness):
a) NR, NBR, EPDM, HYPALON, NR-A and NBR-A:
Bar 1/min
0-19 20-39 40-59 60-79 80-99
0.5 1 1 0 0 0
2.0 1 1 1 0 0
4.0* 2 2 2 1 1
6.0 3 3 2 – –
8.0 4 3 3 – –
*Factoring default setting if working pressure is not informed.

Operating instructions Peristaltic Pump IP Series
5.3.6 IP-70D Model (Number of shims of 1 mm thickness):
Each of the two pump bodies is tted with the following conguration:
a) NR, NBR, EPDM, HYPALON, NR-A and NBR-A:
Bar 1/min
0-19 20-39 40-59 60-79 80-99
0.5 1 1 0 0 0
2.5 1 1 1 0 0
3.0* 2 2 2 1 1
*Factoring default setting if working pressure is not informed.
6 COMMISSIONING
6.1 Testing prior to commissioning the pump
The following tests are to be carried out:
- Ensure that the pump has not been damaged during transportation or
storage. Immediately report any damage to the supplier.
- Check that the mains voltage is suitable for the motor.
- Ensure that the hose 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.
-
Only switch the pump on if it the front cover has been properly attached.
- Check that the rollers are correctly tted and fastened.
- Check that the pump drive and the inner of the rollers are correctly
greased. The specially formulated grease can be obtained the autho-
rised realax pump distributor.
- Check that the thermal overload protection (not included in the deli-
very scope) corresponds to the value specied on the motor type plate.
- Check whether the direction of rotation is correctly adjusted.
- Check that the optional electrical components are connected and are
working properly.
- Install a manometer in the pressure line if the back-pressure value is
unknown.
- Check the operating instructions in order to ensure that the ow
values, pressures and power consumption of the motor do not exceed
the rated values.
- Install a pressure relief valve in the pressure line in order to protect the
pump in the event that a valve is unintentionally closed off or the line
is blocked in another way.
14

Operating instructions Peristaltic Pump IP Series
15
7 MAINTENANCE, REPAIR, MALFUNCTIONS,
DISPOSAL AND SPARE PARTS
7.1 Lubrification
Check that the rollers and the hose are sufciently lubricated.
Use only the original realax silicone grease.
• Check every 300 operating hours.
Model Silicon grace quantity (gr)
IP-30 150
IP-40 200
IP-50 250
IP-60 400
IP-70 500
Gear reducers.
• Exchange the oil at regular intervals and make sure that the
gear is lubricated in accordance with the instructions in the
gearbox manual.
7.2 Exchanging the pump hoses
7.2.1 Exchanging the pump hoses
(refer to section 8 for parts lists and drawings)
7.2.1.1 Models IP-30, IP-40, IP-50, IP-70 and IP-70D
1 Close off all valves, in order to prevent leakage of the feed
chemical.
2 Dismantle the pipes from both discharge and suction sides
3 Remove the front cover.
4 Remove a roller (the roller that is not touching the pump
hose).
5 Mount the front cover.
6 Turn the rotor with the help of the motor so that the re-
maining roller is not pressing against the pump hose.
7 Dismount the front cover.
8 Remove the press ange and connections from the pump
housing.
9 Remove the press rings.
10 Remove the pump hose to be exchanged.

Operating instructions Peristaltic Pump IP Series
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7.2.1.2 Model IP-60
1 Close off all valves, in order to prevent leakage of the feed
chemical.
2 Dismantle the pipes from both discharge and suction sides
3 Remove the front cover.
4 Remove a roller (the roller that is not touching the pump
hose).
5 Mount the front cover.
6 Turn the rotor with the help of the motor so that the
remaining roller is not pressing against the pump hose.
7 Dismount the front cover.
8 Remove the connections.
9 Remove the press ange from the pump casing.
10 Remove the pump hose to be exchanged.
11 Dismantle the inserts from both pump hose ends.
7.2.2 Exchanging the pump hoses- installation
7.2.2.1 Models IP-30, IP-40, IP-50, IP-70 and IP-70D
1 Clean the interior surfaces of the pump housing.
2 Lubricate the internal surfaces of the pump housing at the
contact surfaces to the pump hose with original silicon
grease.
3 Check the rollers. Ensure that the roller surfaces are not
damaged.
4 Lay the pump hose into the pump housing.
5 Lay the press rings. Between the end of the hose and the
press ring, it has to be a distance of 3-7 mm.

Operating instructions Peristaltic Pump IP Series
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Fig 5:
Way to proceed
with the screws
tightening.
6 Fasten the press ange and the connections to the pump
casing, tightening progressive the bolts in clock wise (1,
3, 2, 4, 1, 3, 2, 4, etc.), until the ange becomes totally
tighten.
Torque setting
Model IP-30 IP-40 IP-50 IP-60 IP-70
Press ange 25 Nm 30 Nm 35 Nm 55 Nm 40 Nm
Connection 20 Nm 20 Nm 20 Nm 20 Nm 20 Nm
Fig 4:
Required distance
between the end
of the hose and
the press ring.

Operating instructions Peristaltic Pump IP Series
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7 Mount the front cover.
8 Turn the rotor with the help of the motor so that the
remaining roller presses against the pump hose.
9 Dismount the front cover.
10 Re-attach the second roller with shims back onto the rotor.
11 Lubricate the pump hose and the rollers.
12 Attach the front cover to the pump housing.
13 Mount the pipes from both discharge and suction sides.
14 Open all of the valves.
7.2.2.2 Model IP-60
1 Clean the interior surfaces of the pump casing.
2 Lubricate the internal surfaces of the pump casing at the
contact surfaces to the pump hose with original silicon
grease.
3 Check the rollers. Ensure that the roller surfaces are not
damaged.
4 Lay the pump hose into the pump casing.
5 Attach the inserts at both hose ends with the help of the
press ange.
6 Fasten the two parts of press anges us the base.
7 Fasten the press ange to the pump casing.
8 Fasten the connections to the press ange.
9 Mount the front cover.
10 Turn the rotor with the help of the motor so that the
remaining roller presses against the pump hose.
11 Dismount the front cover.
12 Re-attach the second roller with shims back onto the rotor.
13 Lubricate the pump hose and the rollers.
14 Attach the front cover to the pump casing.
15 Mount the pipes from both discharge and suction sides.
16 Open all of the valves.