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 ................................................4
2 Safety .......................................................6
3 Functional description ................................... 11
4 Description................................................ 12
5 Construction .............................................. 13
6 Pump hose ................................................ 14
7 Transport & storage ..................................... 14
8 Assembly, commissioning & installation ................ 16
9 Maintenance ............................................. 26
10 Troubleshooting
.......................................... 34
11 Spare parts ................................................ 36
12 End of life ................................................. 58
13 Declaration of Conformity ............................... 59
14 Warranty .................................................. 60
15 Where to buy ............................................. 61

Operating instructions Peristaltic Pump IP Series
4
1 INTRODUCTION
This instruction manual must accompany the pump at
all times for as long as it is in use.
The IP 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 IP 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 of the 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.

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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 IP Series
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the front cover. Depending on the specic working conditions or accesso-
ries 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
standards.
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 IP 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 IP 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 3 bar
(45 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 IP Series
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- (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 IP Series is a positive displacement pump. The feed liquid is conveyed
by the rotor squeezing the hose 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 3 bar (45 psi approx.)
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 viscous
media.
Typical areas of use include processes where only a low discharge pressure
is required (max. 8 bar).
3.1 Main modules
1. Drive unit | 2. Pump housing | 3. Base frame

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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 IP 30 IP 40 IP 50 IP 60 IP 70 IP 80
Max. Capacity
Continuous Duty
m3/h 1.55 3 7 9.5 16 28.08
GPM 6.82 13.2 30.82 41.83 70.45 123.63
Max. Capacity
Intermittent Duty
m3/h 2.05 4.1 5.2 8 20 42.12
GPM 9.03 18.05 22.89 35.22 88.06 185.45
Capacity per
Revolution
l/rev 0.43 0.86 1.47 2.69 6.72 11.7
Gal/rev 0.11 0.23 0.39 0.71 1.78 3.09
Max. Permissable
Working Pressure bar 8
Permissable Ambient
Temperature ºC -40 to +40
Permissable Product
Temperature ºC -10 to +80
Sound Level at 1m dB (A) 70
Key performance data and noice levels

Operating instructions Peristaltic Pump IP 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. Two rollers attached to the rotor
serve to press the pump hose against the pump housing.
The rotary movement of the rotor alternately presses and releases the
rollers against the pump hose. 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. Roller | 4. Hose
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.

Operating instructions Peristaltic Pump IP Series
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6 PUMP HOSE
6.1 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. Dependent on the specic
requirements of your application a corresponding pump hose must be
selected. For each pump model various hose types are available.
The material of inner layer is the part in contact with the media.
HOSE TYPE MATERIAL INNER LAYER COLOUR STRAP
NR Natural rubber No one (black)
NBR Nitrile rubber Red
EPDM EPDM Blue
CSM Hypalon Green
NBR-A Nitrile rubber (food grade) White
NR-A
(Available for IP 50, IP 60 and IP 70) Natural rubber (white) Black
TUBE TYPE TUBE MATERIAL COLOUR STRIPE
NORPRENE
(Available for IP 30, IP 40, IP 50 and IP 60) Norprene (food) N/A
7 TRANSPORT AND STORAGE
7.1 Transport
- The pump is protected by cardboard packaging or a wooden
crate.
- The packaging materials are recyclable.
A
B C

Operating instructions Peristaltic Pump IP Series
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7.2 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 hoses should be stored in a dry place away from direct light.
7.3 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 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
remaining roller is not pressing against the pump hose
‐ 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 hoses should be stored in a dry place away from direct light.
7.4 Elevation
Models IP 30, IP 40 and IP 50: Use the
eye bolt to elevate the pump.
WEIGHTS IP 30 IP 40 IP 50
Total pump
weight
82 kg
108 lbs
122 kg
268 lbs
182 kg
401 lbs
Max rating
of the lifting
point
170 kg
374 lbs
240 kg
529 lbs
Safety factor > 6 6

Operating instructions Peristaltic Pump IP Series
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Models IP 60, IP 70 and IP 80:
Use lifting equipment to elevate the pump.
WEIGHTS IP 60 IP 70 IP 80
Total pump
weight
253 kg
557 lbs
574 kg
1,265 lbs
1,150 kg
2,535 lbs
Max rating of
the lifting point
400 kg
881 lbs
750 kg
1,653 lbs
1,150 kg
2,535 lbs
Safety Factor > 6 6
8 ASSEMBLY, COMISSIONING AND INSTALLATION
8.1 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
Material Hose
Min. Temp.
(ºC)
Feed liquid
Max. Temp
(ºC)
Feed liquid
Min. Temp
(ºC)
Environment
Max.
Pressure
(bar)
NR, NBR, EPDM, CSM,
NBR-A, NR-A -10 80* -20 8
NORPRENE190* 2
1Only availlable for IP 40.
* At max. temperature., the life of hose is drastically reduced. Please contact authorized distributor for
applications in temperature range higher than 60 oC.

Operating instructions Peristaltic Pump IP Series
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8.2 Commissioning
8.2.1 Testing prior to commissioning the pump
The following tests are to be carried out:
- Check that the rollers are correctly tted and fastened.
- Check that the drive and the pump housing are properly
lubricated. The specially formulated lubricant can be obtained
from the authorized distributor.
- 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.
8.3 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 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.
- 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.

Operating instructions Peristaltic Pump IP Series
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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.
- 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
pump hose. 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 op-
tion is selected which is best suited to the physical conditions
of the rest of the installation.
- It is recommended to use exible piping between the xed
pipes and the hydraulic connections of the pump, in order to
avoid the transmission of vibrations.
8.3.2 Maximum permissible loads on the pump ange
Pump must be bolted to oor before applying loads to connections/
anges.
F1
F2
F3

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Maximum permissible loads on the pump ange
FORCE UNIT IP 30 IP 40 IP 50 IP 60 IP 70 IP 80
F1 N 600 1,000 1,200 1,300 1,500
lb-f 135 225 270 292 337
F2 N 300 500 550 600 750
lb-f 67 112 123 135 168
F3 N 300 500 550 600 750
lb-f 67 112 123 135 167
8.3.3 Discharge side
- The discharge line is to be kept as straight and short as pos-
sible, 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.
- It is recommended to use exible piping between the xed
pipes and the hydraulic connections of the pump, in order to
avoid the transmission of vibrations.
- Install a pressure relief valve or a pressure switch (or similar
device) 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.

Operating instructions Peristaltic Pump IP Series
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Shims placement
Hose compression
1 Hose without compression
2 Insufcient compression (back owing media in the cavity will destroy the hose
within a short period of time)
3 Optimum compression
4 Excessive compression (increased wear and tear to the pump and the hose)
8.4 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).
- In order to achieve optimal life of the pump hose, the
compression force of the pump hose can be adjusted by
placing a number of shims under the pressing rollers. The
shims (2) are tted between the rotor (1) and the pressing
roller (3). The number of shims will vary for each counter
pressure situation.