Metering Pumps SXDA/SXWA/SYDA/SYWA User's Manual —Before beginning operation, read this manual carefully!— • Thank you for purchasing this TACMINA product. Please read this manual carefully in order to ensure that you use the appliance safely and correctly. • Be sure to keep this manual in a place where it will be easily available for reference. WARNING • Install the pump in a location where it will not come into contact with other people besides the operator. • Be sure to always turn OFF the power supply before performing installation, maintenance, or other work. Failure to do so could result in electrical shock. CAUTION • Do not use this product for applications outside of the product specifications. Improper usage could result in electrical shock or breakdown of the pump. • TACMINA will accept no responsibility nor be liable for product modifications made by the customer. • The wiring work should be done by an electrician or other qualified engineer. • Be sure that the P.E. is firmly connected. Improper connection could result in electrical shock. • If anything unusual occurs during operation (smoke, burning smell, etc.), immediately shut down operation and contact TACMINA or your sales dealer. Failure to do so could result in fire, electrical shock, or breakdown of the pump. • When handling the liquid-end parts, be sure to always wear the suitable protective coverings (rubber gloves, mask, protective goggles, chemical-resistant overalls, etc.) appropriate for the chemicals being transferred. • Before performing maintenance or repair of the pump, first release the pressure from the discharge piping, drain the chemicals from the liquid-end parts and wash the pump. www.tacmina.com Contents —Read This First— 1 Using the Pump Safely ............................ 1 1-1 How to Use This Manual ................... 1 1-2 Conditions of Use.............................. 1 1-3 Notes on Handling ............................ 2 2 Checking the Product .............................. 3 2-1 Accessory List ................................... 3 —For Better Product Understanding— 3 Outline ..................................................... 4 4 Structure ................................................. 4 4-1 Drive Box Section ............................. 4 4-2 Pump Head with Relief Valve ............ 5 5 Operating Principle ................................. 6 6 Model Code ............................................. 7 7 Specifications (Standard) ........................ 9 8 Materials of Liquid-End Parts ................ 11 8-1 Pump Head Section ........................ 11 8-2 Anti-Siphon Check Valve ................. 12 9 Performance Curves ............................. 13 10 External Dimensions ............................. 15 —For Correct Handling— 11 Installation ............................................. 17 11-1 Place of Installation ...................... 17 11-2 Installing the Motor (w/out motor specifications only) ....................... 18 11-3 Pulsation ....................................... 21 11-4 Hose-Type Piping ......................... 22 11-5 Installation with TACMINA Exclusive Tank .............................................. 24 11-6 Flange-Type and Union-Type Piping ...................................................... 25 11-7 Concerning Slurry Transfer ........... 26 12 Electrical Wiring .................................... 27 12-1 Power Supply and P.E. Cable ....... 27 13 Operation .............................................. 28 13-1 Cautions for Use ........................... 28 13-2 Preparing for Operation ................ 30 13-3 Beginning Operation ..................... 31 13-4 Air Release SX(Y) DA-31.61.22.32 (VTC.VEC) .................................... 32 13-5 Adjusting the Injection Amount ..... 33 13-6 Disassembling the Flow Regulator and Adjusting the Zero Point ........ 34 14 Maintenance ......................................... 34 14-1 Checking During Operation (Daily Checking) ..................................... 35 14-2 Stopping Operation for an Extended Period ........................................... 35 14-3 Preparing to Re-Start Operation ... 35 14-4 Lubrication .................................... 36 15 Replacement of Parts............................ 36 15-1 Replacing the Valve Seats and Check Balls ................................... 36 15-2 Replacing the Pump Head ............ 39 15-3 Parts Replacement: Models SXDA-31/61/12/22/32, SYDA-31/61/12/32 ........................ 39 15-4 Parts Replacement: Models SXDA-62/82/13/23/33/43, SYDA-62/82/13/23/43 ................... 40 15-5 Parts Replacement: Models SXWA61/12/32, SYWA-31/61/12/32 ....... 41 15-6 Parts Replacement: Models SXWA-62/82/13/23/33/43, SYWA-62/82/13/23/43 .................. 42 15-7 Buffer Solution (Glycerin) Injection Method ........................... 43 16 Troubleshooting ..................................... 44 —Customer Services— 17 Warranty ................................................ 45 18 Repair Service ...................................... 45 19 Getting in Touch .................................... 46 20 Consumables and Spare Parts ............. 47 20-1 Consumables ................................ 47 20-2 Parts Recommended to be Kept at Hand ................................. 47 20-3 Spare Parts ................................... 48 21 Options and Related Equipment ........... 48 22 Maintenance Service Tool List .............. 49 —Other Information— 23 Explanation of Terms ............................. 50 24 Maintenance Data ................................. 51 1 Using the Pump Safely 1-1 How to Use This Manual This manual is intended to help the operator to handle the product safely and correctly. In support of this aim, important safety-related instructions are classified as explained below. Be sure to follow them at all times. WARNING • If the product is operated incorrectly in contravention of this instruction, it is possible that an accident resulting in death or serious injury will occur. CAUTION • This indicates that improper operation can result in an injury or physical damage to the product. IMPORTANT • This indicates information that should always be followed to maximize the product’s performance and service life. NOTE • This indicates supplementary explanations. 1-2 Conditions of Use CAUTION • Do not use this pump for applications other than injecting liquids. Use of the pump for other purposes can result in an accident or breakdown of the pump. • Do not use this pump outside of the operating conditions below. Improper use of the pump can damage it. Ambient temperature : 0 to 40°C Humidity : RH35 to 85% Liquid temperature : 0 to 40°C (PVC type) : 0 to 60°C (SXDA/SYDA-SUS,PVDF type) : 0 to 80°C (SXWA/SYWA-SUS,PVDF type) Liquid viscosity : Less than 50 mPa.s (Standard type) In the case of high-viscosity joint use, liquids with viscosities between 50 and 2000 mPa.s can be transferred. However, for models SX(Y)DA/WA13—43, the maximum viscosity is between 50 and 1000 mPa.s. Max. discharge pressure SXDA/WA-31 to 82 :1.0 MPa (10bar) SXDA/WA-13 • 23:0.5 MPa (5bar) SXDA/WA-33 • 43:0.3 MPa (3bar) SYDA/WA-31 to 82 :1.0 MPa (10bar) SYDA/WA-13 • 23 :0.5 MPa (5bar) SYDA/WA-43 :0.3 MPa (3bar) Height of installation site above sea level: 1000 m max. • The max. discharge pressure for the PTFE-hose connection (STS-FTC) types is 0.5 MPa. • The max. discharge pressure for the models SXDA & SYDA-43, PTFE-diaphragm types (VTC, STS, FTC) is 0.25 MPa. –1– • This pump is unsuitable for transferring slurry. Please consult TACMINA before attempting to transfer slurry. • If the pump is operated beyond the normaluse range of the soft PVC hose, replace with a heat-resistant PVC hose. Failure to do so may result in damage to the hose leading to chemical solution leaking or spurting from the hose. • Applicable Range of Soft PVC Hose 1.0 di Pressure: MPa 0.8 0.6 dia Normal operating range .12 a. 6 xd x ia. di 18 a. 11 0.4 0.2 0 10 20 30 Temperature (˚C) 40 50 1-3 Notes on Handling WARNING * A hose (dia. 4 mm x dia. 9 mm) supports an output of 1.0 MPa at a temperature of 50˚C. • Install the appliance in a location where it will not come into contact with other people besides the operator. • Do not operate the pump when your hands are wet. This could result in an electrical shock. CAUTION • If the pump is dropped or damaged, please contact TACMINA or your supplying agent. It may result in an accident or in damage to the product. • Do not install this pump in a humid or dusty location, as this may lead to electrical shocks or result in damage to the appliance. • If anything unusual occurs such as smoke or a burning smell during operation, immediately stop operation and contact TACMINA or your supplying agent. Failure to do so could result in fire, electrical shock or damage to the product. • Do not touch the motor section during operation as its high temperature may burn the skin. • Before disassembling the pump for maintenance or repair, make sure to turn OFF the power and confirm that no voltage is supplied to the pump. Also, make sure that the power switch is not turned ON again during the maintenance or repair work. • When handling the liquid contact section, be sure to wear protective coverings (rubber gloves, mask, protective goggles, chemical-resistant overalls etc.) appropriate for the chemicals being transferred. • Before maintaining or repairing the pump, release the discharge-side pressure, drain the chemicals from the liquid-contact section and wash the pump. • For the joints, hose nuts and hoses, be sure to use only those accessories provided with the pump or otherwise recommended by TACMINA. The use of unauthorized accessories may result in an accident or in damage to the product. • If you forget to open the discharge-side valve or if foreign matter becomes stuck in the discharge-side piping, the pressure in the piping and pump head may increase beyond the range indicated in the pump specifications. This may result in the chemicals leaking or spurting, or in damage to the pump or the piping. IMPORTANT • We recommend the installation of a relief valve in the discharge-side piping so that excess pressure can be released automatically. • A relief valve-equipped pump head is also available. –2– 2 Checking the Product When unpacking, please confirm the following points: (1) Is the enclosed product the same model you ordered? (2) Do the details on the pump nameplate match your order? (3) Are all the accessories present and correct? Please refer to the accessory list in Section 2-1, below. (4) Was the pump damaged due to vibration or shock during transportation? (5) Are there any loose or disconnected screws? All TACMINA products are carefully checked prior to shipment. If, however, you find a defect, please contact TACMINA direct or your local agent. 2-1 Accessory List Part name Hose Strainer Anti-siphon check valve Pump installation bolts / nuts Operation manual Hose type 4m 1 set 1 4 sets 1 Flange type Union type 4 sets 1 4 sets 1 1) A pump stand and pump cover are optionally available. 2) The strainer and the anti-siphon check valve are not provided with the high-viscosity models. 3) The quantities in the above chart refer to the case of simplex and standard duplex (1-box type) models. 4) In the case of a duplex (2-box type), triplex and other models, multiply the installation quantity by the number of pump heads. (excluding the operation manual) 5) The pump installation bolts / nuts are not provided with SYD(W)A types. • Accessories Exclusively for the W-Type Models Buffer solution syringe 31 61 12 22 32 62 82 13 23 33 43 1 pc. 50mL Glycerin 100mL 200mL 1) The quantities in the above chart are for simplex models. 2) In the case of duplex and other models, multiply the quantity by the number of pump heads. –3– 3 Outline TACMINA’s S series diaphragm type metering pumps are classified as follows according to the type of diaphragm and the reduction method employed. Type SXDA SXWA SYDA SYWA Diaphragm type Reduction method Direct diaphragm Worm.wheel gear Double diaphragm Worm.wheel gear Direct diaphragm Planetary gear Double diaphragm Planetary gear Motor connection Directly coupled with an dexclusive vertical motor Directly coupled with an exclusive vertical motor Coupling connection for a motor with universal legs Coupling connection for a motor with universal legs 4 Structure 4-1 Drive Box Section 4-1-1 SX Type The SX type pump is composed of the drive box equipped with a vertical four-pole exclusive motor which is assembled together with the reduction mechanism and the pump head section. Exclusive motor Pump head Drive box Within this structure, the following parts are assembled. (1) Worm.wheel Gear (2) (3) (4) Reduces the motor rotation to 1/14 or 1/28 of its original value. Eccentric Shaft Converts rotary motion into reciprocal motion. Pump Shaft Transmits reciprocal motion to the diaphragm. Spring-Return Mechanism On the suction stroke, this mechanism forces the pump shaft back to ensure that a constant discharge volume is maintained. Feed Flow Adjusting Mechanism Adjusts the feed flow between 0 and 100% during operation. * In the case that dial scale indication is less than “1”, the discharge amount may become unstable. (5) –4– 4-1-2 SY Type The SY type is composed of a drive box which consists of a four-pole general purpose motor with legs and planetary gear and the pump head section. * The figure is for a simplex (single head) pump. Features of the Planetary Gear (1) High transmission efficiency (2) Low noise and low vibration (3) Wide selection range of the reduction ratio combination Pump head Drive box Planetary gear General purpose motor Within this structure, the following parts are assembled. (1) Eccentric Shaft Converts rotary motion, reduced by the planetary gear, into reciprocal motion with the specified amplitude. (2) Pump Shaft Transmits reciprocal motion to the diaphragm. (3) Spring-Return Mechanism On the suction stroke, this mechanism forces the pump shaft back to ensure that a constant discharge volume is maintained. (4) Feed Flow Adjusting Mechanism Adjusts the feed flow between 0 and 100% during operation. * In the case that dial scale indication is less than “1”, the discharge amount may become unstable. 4-2 Pump Head with Relief Valve If a diaphragm pump (or any reciprocating pump) is operated while the discharge-side piping is closed, the pressure in the pump head rises to above the rated pressure. If operation continues in this state, the pump drive mechanism may be damaged or the discharge-side piping ruptures. In such a case, if a pump head with a relief valve is used, the pump, piping and peripheral parts can be protected without the need to install a relief valve in the discharge-side piping. 4-2-1 Structure 12 Relief port –5– 4-2-2Pressure Adjustment Remove the cap 1 and turn the pressure adjusting nut 2 clockwise with a screwdriver. The set pressure of the relief valve will increase. CAUTION • The pressure at which the relief valve operates should be set at about 120% of normal discharge pressure. Avoid setting at above 120% of the rated maximum pressure of the pump since this may cause the pump to become overloaded. IMPORTANT • In order to set the pressure of the relief valve, furnish the pump discharge side with a pressure gauge and stop valve (as shown below). Pressure gauge Discharge-side piping Stop valve Screwdriver Pump head 5 Operating Principle (1) The motor rotation is reduced by the worm.wheel gear (SX models) or the planetary gear (SY models). (2) Through the action of the eccentric mechanism, the motor’s rotation is converted into a reciprocal motion of the pump shaft. (3) When the diaphragm at the end of the pump shaft moves reciprocally, the volume of pump head alternately increases and decreases. This causes the pressure in the pump head to rise and fall alternately, and this pressure change causes the suction and discharge of chemical. (4) When the pump shaft moves back, negative pressure occurs in the pump head. At this moment, the discharge side check ball closes to prevent any of the liquid being transferred along the discharge side piping from flowing back into the pump head (Fig. 1). On the other hand, the suction side check ball opens the valve to allow liquid to flow into the pump head from the suction side. (5) When the diaphragm moves front, positive pressure occurs in the pump head. The suction side check ball closes and the discharge side check ball opens to allow the liquid to be discharged (Fig. 2). –6– Check ball Closed Closed Opened The shaded part is discharged. Fig. 1 Opened Fig. 2 (6) On the double diaphragm type, in addition to the drive diaphragm, a corrugated PTFE diaphragm is provided at the liquid end. The space between these two diaphragms is filled with buffer solution (glycerin, purified water or silicone oil), in order to transmit the reciprocal motions of the drive diaphragm accurately and uniformly to the PTFE diaphragm (front diaphragm). As a result, the diaphragm’s working life is dramatically extended. Buffer solution (glycerin, purified water, silicone oil, etc.) Drive diaphragm Front diaphragm Fig. 3 Double Diaphragm Type: SXWA, SYWA 6 Model Code S (1) (2) (3) (4) (5) a b (6) (1) Drive box type X: Vertical type Y:Horizontal type (2) Pump head DA:Direct-drive diaphragm WA:Double diaphragm MA:Hydraulic diaphragm MWA:Hydraulic double-diaphragm PA:Plunger (3) Number of pump heads 1:Single 2:Duplex (4) Model type (5) Relief valve R:with Relief valve Blank:without Relief valve –7– c (7) (8) (9) (10) (11) (6) Liquid-end materials a:Pump head S:SUS304 V:PVC F:PVDF 6:SUS316 or SCS14 CL:Acrylic H:Hastelloy C I:Titanium b:Diaphragm or Plunger seal E:EPDM T:PTFE Blank:In case of CL N:NBR c:Check ball C:Ceramic S:SUS304 6:SUS316 T:PTFE I:Titanium Blank:In case of CL (7) Connection type U:Union F:Flange H:Hose S:Female thread (8) Valve structure W:Standard V:High viscosity H:Special high viscosity (9) Connection standard G:Straight pipe thread R:Taper pipe thread D:DIN A:ANSI J:JIS (10) Motor M:standerd N:without motor A:without motor,with adaptor B:with special motor,with Adaptor (11) CE standard NOTE • There are restrictions on the combinations of liquid-end materials. For more information, refer to the Materials Table for Standard Liquid-end Parts and Specifications and Performance Table for each model. –8– 7 Specifications (Standard) * It is useful to use the table if you mark the related items. . SXDA/SXWA Models SXDA SXDA SXDA SXDA SXDA SXDA SXDA SXDA SXDA 1-31 1-61 1-12 1-22 1-32 1-62 1-82 1-13 1-23 SXWA SXWA SXWA SXWA SXWA SXWA SXWA SXWA 1-61 1-12 1-22 1-32 1-62 1-82 1-13 1-23 200 300 600 Max. discharge 50Hz 30 50 100 830 1000 1500 60 120 240 360 720 1000 1200 1800 volume (mL/min.) 60Hz 36 Max. discharge 1.0 0.5 pressure (MPa) Stroke number 50Hz 53 105 (spm) 60Hz 126 63 Stroke length (mm) 2 4 6 8 6 8 PVC hose dia. 6 x dia. 11 dia. 12 x dia. 18 HW dia. 4 x dia. 9 dia. 10 x dia. 12 PTFE hose dia. 12 x dia. 15 HW JIS 10K 15A Flange joint FW ANSI / 50Lb 1/2B DIN 250 / PN10 15 Model Specifications Union joint for piping PVC hose for high viscosity Flange joint for high viscosity UW HV FV Stainless steel (R 3/8) dia. 12 x dia. 18 JIS 10K 15A dia. 19 x dia. 26 JIS 10K 20A JIS 10K 25A SXDA 1-33 SXWA 1-33 2500 3000 0.3 SXDA 1-43 SXWA 1-43 3000 3600 0.3 Connection type & aperture 8 JIS 10K 25A ANSI / 50Lb 1B DIN 250 / PN10 25 - 6 Motors pecifications (standard) Paint color Noise level Totally-enclosed self-cooling outdoor type Totally-enclosed fan-cooling outdoor type 3-phase, 200V, 0.1kW 3-phase, 200V, 0.2kW 4P 4P 50/60Hz 1.3/1.1A 50/60Hz 0.71/0.63A Acrylic urethane resin paint (Munsell 10 B5/10) 85 dB or less ✽ Values in the above table show a case when the standard motor is used. Values vary when other motor is used. –9– . SYDA/SYWA Models SYDA SYDA SYDA SYDA SYDA SYDA SYDA SYDA 1-31 1-61 1-12 1-32 1-62 1-82 1-13 1-23 SYWA SYWA SYWA SYWA SYWA SYWA SYWA SYWA 1-31 1-61 1-12 1-32 1-62 1-82 1-13 1-23 Max. discharge 50Hz 30 60 100 300 600 830 1000 1500 36 72 120 360 720 1000 1200 1800 volume (mL/min.) 60Hz Max. discharge 1.0 0.5 pressure (MPa) Stroke number 50Hz 33 63 105 (spm) 75 60Hz 40 126 Stroke length (mm) 4 6 8 6 dia. 6 x dia. 4 x dia. 9 dia. 12 x dia. 18 HW PVC hose dia. 11 dia. 10 x dia. 12 dia. 12 x dia. 15 HW PTFE hose Model Specifications Flange joint FW JIS 10K 15A ANSI / 50Lb 1/2B DIN 250 / PN10 15 Stainless steel (R 3/8) dia. 12 x dia. 18 JIS 10K 15A dia. 19 x dia. 26 JIS 10K 20A JIS 10K 25A SYDA 1-43 SYWA 1-43 3000 3600 0.3 8 JIS 10K 25A ANSI / 50Lb 1B DIN 250 / PN10 25 - Connection type & aperture Union joint for UW piping PVC hose for HV high viscosity Flange joint for FV high viscosity Motors pecifications (standard) Paint color Noise level Totally-enclosed fan-cooling outdoor type 3-phase, 200V, 0.2kW 4P 50/60Hz 1.3/1.1A Acrilic urethane resin paint (Munsell 10 B5/10) 85 dB or less ✽ Values in the above table show a case when the standard motor is used. Values vary when other motor is used. NOTE 1) The indicated maximum discharge volume is in the case of maximum discharge pressure. 2) To obtain the maximum discharge volume for duplex or other multi head pumps, multiply the value for the simplex model accordingly. 3) In the case of triplex or greater pump head arrangements, model 33 and 43 are not available. 4) In the case of model SX(Y)DA-82, the PTFE diaphragm is not available. 5) In the case of models SXDA & SYDA-43, PTFE diaphragm types (VTC, STS, FTC), the maximum discharge rate at 50/60Hz is 3,000/3,600mL/min., and the maximum discharge pressure is 0.25MPa. 6) In the case of models 13—43, the high-viscosity flange joint is not available for the 1-box, duplex or larger types. 7) In the case of a pump head equipped with a relief valve, the letter “R” is added to the model number. Eg: SXDA1-32R, SYWA1-82R, etc. 8) Please consult TACMINA separately regarding other special specifications. 9) Specifications are subject to change without notice for the purpose of product improvement. – 10 – 8 Materials of Liquid-End Parts 8-1 Pump Head Section D-Type (Direct Drive Diaphragm Type) 1 2 6 5 4 3 1 Discharge-side upper joint 2 Discharge-side lower joint 3 Suction-side joint 4 Check ball 5 Valve stopper 6 Pump head 7 Diaphragm 7 W-Type (Double Diaphragm Type) 7 8 1 2 4 6 1 Discharge-side upper joint 2 Discharge-side lower joint 3 Suction-side joint 4 Check ball 5 Valve stopper 6 Pump head 7 Front diaphragm 8 Buffer solution 9 Drive diaphragm 0 Plug q O-ring w Retaining ring 5 3 w 0 q 9 – 11 – • Materials Table for Standard Liquid-end Parts Model Liquid end type VEC Part name Pump head Diaphragm Check ball Joint PVC EPDM PVC SXDA • SYDA VTC STS FTC*1 FTCT*2 FTCF*2 FTCE*2 PVDF PTFE PVDF PTFE CL 6T6*3 VTC SXWA • SYWA VTS STS FTC PVC SUS304 PVDF PTFE PTFE PTFE PVDF Acrylic SUS316 PVC PTFE PTFE PTFE PTFE PVC SUS304 PVDF PTFE PTFE PTFE Ceramic Ceramic SUS304 Ceramic Ceramic Ceramic Ceramic Ceramic SUS316 Ceramic SUS304 SUS304 Ceramic PVC SUS304 PVDF PVDF PVDF PVDF PVC SUS316 PVC PVC SUS304 PVDF Fluoro- PTFE PTFE Special Fluoro- EPDM Fluoro- PTFE Fluoro- Fluoro- PTFE PTFE FluoroO-ring for joint EPDM rubber rubber rubber rubber rubber rubber *1 Only for SX(Y)DA-62 ∼ 43 and SX(Y)DA31R ∼ 32R(with relief valve) *2 Only for SX(Y)DA-31 ∼ 32(not available for 31R ∼ 33R with relief valve) *3 Custom-made 1) In the case of model SX(Y)DA-82, only the EPDM diaphragm is available. 2) Fluororubber (brandname: Vaiton), is a copolymer of fluoride vynlidene and hexafluoride propylene which has been approved by the food sanitation test performed according to Notice No. 434 of the Japanese Ministry of Health and Welfare. 3) EPDM is a copolymer of ethylene, propylene and diene which has been approved by the food sanitation test performed according to Notice No. 434 of the Japanese Ministry of Health and Welfare. 4) PVDF (polyvinylidene fluoride) is a difluoride resin which has been approved by the food sanitation test performed according to Notice No. 434 of the Japanese Ministry of Health and Welfare. 5) Please consult TACMINA separately regarding other special materials. 6) Only for SX(Y)DA 31, 61 and 12 are available for the CL type(not available for 31R ∼ 12R) 8-2 Anti-Siphon Check Valve • For SXDA (SYDA) -31 • 61 • 12 • 22 • 32 2 1 3 4 5 2 6 7 1 2 3 4 5 6 7 Nozzle O-ring Main body Spring Poppet valve Retaining ring Hose nut 1) Illustration shows VEC and VTC types. The shapes for the STS•FTC differ from the figure above. Materials Table for Standard Liquid–end Parts Part code VEC VTC CL STS FTC Main body PVC SUS 304 PVDF Hose nut PVC SUS 304 PVDF – 12 – O-ring EPDM Fluoro-rubber PTFE Spring Hastelloy C SUS 304 WPB • For SXDA (SYDA) – 62 • 82 • 13 • 23 8 3 7 6 5 4 3 2 1 1 Hose union 2 Hose press ring 3 Union nut 4 Washer-equipped cross-recessed head screw 5 Bonnet 6 Compressed coil spring 7 Check ball 8 Nozzle 9 O-ring 0 Main body q Diaphragm 8 Outlet side Inlet side q 0 9 1) Illustration shows VEC and VTC types. The structure of the valve differs in the case of the STS and FTC types. • Liquid-End Materials Chart Part name Liquidend type Main unit PVC PVC Joint PVC PVC Diaphragm Check ball O-ring Special Special fluoro-rubber fluoro-rubber Fluororubber Compression spring SUS304 SUS304 SUS304 SUS304 VTC VEC STS FTC EPDM — — EPDM High-purity ceramic High-purity ceramic EPDM PTFE PTFE SUS304 SUS304 PVDF PVDF 9 Performance Curves CAUTION • In the case that dial scale indication is less than “1”, the discharge amount becomes unstable. IMPORTANT • Measure the discharge volume under the actual conditions in which the pump is used, and set the dial according to the appropriate performance curve. NOTE • The following performance curves are the results of measurements performed under controlled conditions at our testing facilities. The actual performance curve of your pump may differ slightly from our measurement according to the actual conditions under which the pump is used. Conditions: Room temperature, clean water. – 13 – 50Hz - - - 60Hz— SXDA1-31 SYDA1-31、SYWA1-31 SXDA1-61、SXWA1-61 SYDA1-61、SYWA1-61 80 60 Discharge volume Discharge volume 50 0.1MPa 0.10MPa 60 Discharge volume 0.10MPa 70 Discharge volume 0.10MPa 50 40 30 20 40 30 20 50 40 1.0MPa 60 50 40 1.0MPa 30 20 1.0MPa 30 20 10 0 1 2 3 4 Dial graduation 1.0MPa mL/min10 0 0.5 1 1.5 Dial graduation 2 mL/min 10 0 1 2 3 4 Dial graduation mL/min 10 0 1 2 3 4 Dial graduation mL/min SXDA1-12、SXWA1-12 SYDA1-12、SYWA1-12 120 Discharge volume SXDA1-22 SXWA1-22 300 Discharge volume Discharge volume SXDA1-32、SXWA1-32 SYDA1-32、SYWA1-32 500 0.10MPa 100 80 60 40 20 0 1 2 3 4 Dial graduation 1.0MPa 250 200 150 100 50 0 0.1MPa 400 300 200 0.10MPa 1.0MPa mL/min mL/min 1.0MPa 1 2 3 Dial graduation 4 mL/min 100 0 1 4 5 2 3 Dial graduation 6 SXDA1-62、SXWA1-62 SYDA1-62、SYWA1-62 900 800 Discharge volume Discharge volume 0.10MPa SXDA1-82、SXWA1-82 SYDA1-82、SYWA1-82 SXDA1-13、SXWA1-13 SYDA1-13、SYWA1-13 1500 0.10MPa Discharge volume 700 600 500 1200 0.10MPa 1000 800 600 400 200 1.0MPa 1200 900 0.5MPa 1.0MPa 400 300 600 300 mL/min 200 100 0 1 2 3 4 5 Dial graduation 6 mL/min mL/min 0 1 2 3 4 5 6 Dial graduation 7 8 0 1 2 3 4 5 Dial graduation 6 SXDA1-23、SXWA1-23 SYDA1-23、SYWA1-23 SXDA1-33、SXWA1-33 SXDA1-43、SXWA1-43 SYDA1-43、SYWA1-43 3600 0.10MPa Discharge volume 2000 Discharge volume 3200 2800 2400 2000 1600 1200 800 400 0 0.1MPa Discharge volume 5000 0.10MPa 1500 1000 0.5MPa 4000 3000 2000 1000 0 1 2 3 4 5 6 7 Dial graduation 8 0.3MPa 0.3MPa 500 mL/min 0 mL/min 1 2 3 4 5 6 Dial graduation 7 8 mL/min 1.5 3 4.5 Dial graduation 6 Please note that the maximum discharge volume at 50/60Hz is 3,000/3,600 mL/min for models employing SX(Y)DA PTFE type diaphragms (VTC, VTS, STS). – 14 – 10 External Dimensions SXDA Models 183☆ 123☆ A SXWA Models 188.5 123 A G3/4 F☆ UP G3/4 C 50 E C D 90 110 74 104 B 4-dia. 7 90 110 E • Hose Type (PVC type) Pump type 74 104 B 4-dia. 7 -31 -61 -12 -22 -32 -62 -82 -13 -23 A 239.5 241.5 241.5 243 245 240.5 242.5 251.5 253.5 B 68 68 68 69.5 69.5 70.5 70.5 82.5 82.5 C 153 153 153 153 153 176 176 192 192 D 76.5 76.5 76.5 76.5 76.5 97 97 105 105 E 76.5 76.5 76.5 76.5 76.5 79 79 87 87 F 269.5 269.5 269.5 269.5 269.5 269.5 307 307 307 • Hose Type (PVC type) Pump type ☆ When using a 0.2 kW motor, the dimensions differ slightly. Contact your dealer or TACMINA. -61 -12 -22 -32 -62 -82 -13 -23 A 265.5 265.5 264.5 266.5 276.5 278.5 284 286 B 99 99 98 98 102.5 102.5 110 110 C 154 154 154 154 184 184 196 196 D 77 77 77 77 101 101 107 107 E 77 77 77 77 83 83 89 89 ※ There is no hose type for model 33 and 43. 183☆ 123☆ A ※ There is no hose type for model 43. 188.5 123 A D UP G3/4 C 50 E C D 74 104 E 4-dia. 7 74 104 4-dia. 7 90 110 Pump type 51 B 90 110 B • Flange Type (PVC type) -31 -61 -12 -22 -32 -62 -82 -13 -23 -33 -43 A 259.5 261.5 261.5 263 265 266.5 268.5 278.5 280.5 B C D E F 68 334 119.5 119.5 269.5 68 334 119.5 119.5 269.5 68 334 119.5 119.5 269.5 69.5 334 119.5 119.5 269.5 69.5 334 119.5 119.5 269.5 70.5 361 142 124 269.5 70.5 361 142 124 307 82.5 377 150 132 307 82.5 377 150 132 307 The shape differs. Contact your dealer or TACMINA. • Flange Type (PVC type) Pump type -61 -12 -22 -32 -62 -82 -13 -23 -43 A 292.5 292.5 291.5 293.5 294.5 296.5 302 304 B 99 99 98 98 102.5 102.5 110 110 C 334 334 334 334 272 272 284 284 D 119.5 119.5 119.5 119.5 145 145 151 151 E 119.5 119.5 119.5 119.5 127 127 133 133 The shape differs. Contact your dealer or TACMINA. ☆ When using a 0.2 kW motor, the dimensions differ slightly. Contact your dealer or TACMINA. ※ The suction parts of model 61-32 differ from this drawing. – 15 – 50 307 G3/4 F☆ 50 307 D SYDA Models SYWA Models 140 110 140 110 A B D C C E 150 E D B 150 4-dia. 12 75 75 440 470 440 470 • Hose Type (PVC type) Pump type • Hose Type (PVC type) Pump type -31 -61 -12 -32 -62 -82 -13 -23 A B C D E 280.5 62.5 226.5 76.5 76.5 280.5 62.5 226.5 76.5 76.5 280.5 62.5 226.5 76.5 76.5 282 64 226.5 76.5 76.5 277.5 65 247 97 79 277.5 65 247 97 79 288.5 77 255 105 87 288.5 77 255 105 87 -31 -61 -12 -32 -62 -82 -13 -23 A 304.5 304.5 304.5 303.5 313.5 313.5 321 321 B 93.5 93.5 93.5 92.5 97 97 104.5 104.5 C 227 227 227 227 251 251 257 257 D 77 77 77 77 101 101 107 107 E 77 77 77 77 83 83 89 89 There is no hose type for model 43. There is no hose type for model 43. 140 110 140 110 A A 4-dia.12 B F JIS 10K 15A D D B JIS 10K 15A C 150 E C 4-dia. 12 JIS 10K 15A 440 470 150 E 4-dia. 12 JIS 10K 15A 440 470 75 75 • Flange Type (PVC type) Pump type • Flange Type (PVC type) F 51 51 51 51 51 51 51 51 Pump type -31 -61 -12 -32 -62 -82 -13 -23 A B C D E 300.5 62.5 268.5 118.5 119.5 300.5 62.5 268.5 118.5 119.5 300.5 62.5 268.5 118.5 119.5 302 64 268.5 118.5 119.5 303 65 291 141 124 303 65 291 141 124 315 77 299 149 132 315 77 299 149 132 -31 -61 -12 -32 -62 -82 -13 -23 A 328 328 328 327 331.5 331.5 339 339 B 93.5 93.5 93.5 92.5 97 97 104.5 104.5 C 269 269 269 269 295 295 312 312 D 119 119 119 119 145 145 162 162 E 119 119 119 119 127 127 144 144 For model 43 and the high-viscosity types, the shape and dimensions differ slightly. For details please contact TACMINA separately. For model 43 and the high-viscosity types, the shape and dimensions differ slightly. For details please contact TACMINA separately. – 16 – A 11 Installation 11-1 Place of Installation Take care to install the pump and peripheral piping in an appropriate location, bearing the following in mind. Pay attention to the following points for the pump (including piping) installation location. WARNING • Install the pump in a location where it will not come into contact with children or other people besides the operator. CAUTION • If this pump is installed in a cold location where there is a possibility that the solution may freeze in the winter, this may result in damage to the pump. In such a case, be sure to install heat insulation or heating equipment. IMPORTANT • Avoid locations exposed to direct sunlight, rain or wind. Although this pump is designed for outdoor use, exposure to direct sunlight may cause deterioration of metal parts due to increased temperature or in plastic parts due to reaction with ultraviolet rays. Also, atomospheric dust and rain water may cause flaws or rusting. So if installing outdoors, we recommend that you install a roof or protective cover (option) in order to maximize the pump’s working life. • The pump should be installed in a place with good ventilation in summer and not cold enough for the liquid to freeze in winter. If used in a closed room in which the humidity is high in summer, the heat generated by the motor can cause accelerated rusting of the pump’s metallic parts. • Leave enough space to allow easy access for maintenance. A wide range of tools are required to disassemble the pump, so be sure to leave sufficient space around the pump to allow maintenance and engineers to work freely and effectively. – 17 – IMPORTANT • Install the pump on a flat horizontal surface and fix it securely to prevent it from vibrating during operation. If the pump is installed on an inclined surface, the pump may not be able to discharge properly or at all. Provide the bolts, nuts, anchor bolts, etc. and use them to fix the pump securely. • Adopt preventative measures such as a chemical drain ditch in case chemicals flood out. • Installing the SX Type (Simplex/standard duplex 1-box type) 10mm is appropriate 74 M6 Pump head side SX drive box leg 25 8 4-dia. 7 90 (200) SX-type installation pitch *Figures in parentheses are for duplex (1-box type) setup. Steel plate SX-type bolt installation dimensions • Installing the SY Type Provide the anchor bolts shown in the figure for installation on a concrete base. (Simplex/standard duplex 1-box type) M10 110 (180) 15 Pump head side 440 (490) 95 25 Concrete base SY-type installation pitch *Figures in parentheses are for duplex (1-box type) setup. Anchor bolt dimensions * In the case of 2-box type duplex or multi-head types, please consult TACMINA separately. (Installation varies depending on the drive box combination.) 11-2 Installing the Motor (w/out motor specifications only) Follow the procedure below when installing the motor at the user site. Recommended motors: 1LA7 063-4AB04 (SY type) 1LA7 073-4AB14 (SX type) – 18 – 10 4-dia. 12 Stand thickness • • • • • Contents of Package Drive unit set x 1 Adapter (w/ oil seal inside) x 1 Worm shaft x 1 Serrated edge hexagon socket head set screw (M6 x 6) x 1 Bolt set (M8 x 25), washers, plain washers x 4 sets ● Preparation at Customer Site Grease (small amount) Tools (1) Remove the bolts (4 pieces, M5 x 15) fastening the cover at the top of the drive unit set, and remove the upper cover. Recommended tool: Spanner (8 mm) IMPORTANT • Take care not to spill the oil inside the drive unit. (2) Remove the O-ring (G-55) at the upper cover, and fit the O-ring onto the adapter. O-ring removed from upper cover (3) Temporarily fasten the serrated edge hexagon socket head set screw (M6 x 6) onto the worm shaft. – 19 – (4) Coat the motor shaft with grease, insert the motor shaft into the worm shaft, and tighten the serrated edge hexagon socket head set screw (M6 x 6) with an Allen key. Recommended tool: Allen key (3 mm) ✽ Align the serrated edge hexagon socket head set screw with the notch on the motor shaft. ✽ Insert the worm shaft until it makes contact with the motor. The insertion length differs according to the type of motor. (Normally, insert the worm shaft as far as it can go.) - for 63M motor: 25 mm - for 71M motor: 32 mm (5) Fit the adapter into the drive unit from above, and fix the adapter with the bolts (4, M5 x 15) that were fastening the upper cover. ✽ Take care not to pinch the O-ring by the drive unit. Bolts removed in step (1) (6) Install the motor unit onto the drive unit adapter, and fasten with the bolts provided (4 pieces, M8 x 25). – 20 – IMPORTANT • Insert the motor unit gently and straight into the drive unit adapter taking care not to scratch the adapter oil seal. NOTE • The motor can be installed facing any direction. Install the motor in the direction that best facilitates electrical wiring. 11-3 Pulsation Reciprocating pumps pulsate as a natural consequence of their principle of operation. This pulsation exhibits sine wave characteristics, with the max. momentary flow rate 3.14 (π) times the average flow. For example, a reciprocating pump with an average flow of 1000mL/min. delivers a maximum momentary flow equivalent to 3140mL/min. In view of this fact, when selecting the piping, unlike in the case of a continuous flow pump such as a volute pump, a value of π- times the required discharge (in mL per min.) should be specified. – 21 – 11-4 Hose-Type Piping 11-4-1 Cautions Piping CAUTION • When the pump is operating, the resulting pulsation may cause the hose to vibrate. Fix and support the hose to prevent this problem from occurring. We recommend the installation of an air chamber in the discharge-side piping to reduce pulsation. Please contact TACMINA separately. • If the hose must be bent, keep the bends as gentle as possible to ensure that the hose is not folded (R40 or more). Also, do not sharply bend, rub, cut or step on the hose. Such actions may damage the hose or cause leakage. • If the pump is operated with the discharge-side valve closed or with foreign matter blocking the discharge-side piping, it is dangerous because the pump head pressure may increase to beyond the pump’s specification range, and the solution being transferred may spurt and the piping may be damaged. • If the hose piping is too long, pressure losses will increase beyond the pump’s allowable pressure and overfeeding will occur. (Refer to Section 23 “Explanation of Terms”.) • The maximum length of extension piping differs according to the solution viscosity and the piping diameter. Please pay attention to this point when exchanging or rearranging piping. Pulsation is explained in further detail in TACMINA’s Practical Metering Pump Introductory Course which is available free upon request to TACMINA. • To prevent the hose from becoming disconnected, fully insert it up to its specified position and firmly tighten the nut. Some models have a retaining ring and others do not. Do not excessively tighten the nut using a tool. Doing so might break the hose. • The tightening force on the hose sometimes weakens if the pump is used at a location where the chemical temperature and ambient operating temperature are higher than room temperature. Tighten the nut as required at start of pump operation. 4 x 9 mm dia. hose 6 x 11 mm dia. hose 12 x 18 mm dia. hose Hose nut Hose nut Hose nut Retaining ring Retaining ring IMPORTANT • We recommend the installation of a relief valve in the discharge-side piping to automatically reduce excess pressure. • Install a pressure gauge in the discharge-side piping to measure the pump’s discharge pressure. • Fully tighten the piping to prevent leaks. – 22 – NOTE • A relief valve-equipped head is available. For each pump, a 4m of hosing is provided as an accessory in the form of 3m for the discharge side 1m for the suction side. If you make the piping longer than 4m (especially in the case of a high-viscosity type pump), the pressure loss from the piping may in some circumstances increase to beyond the maximum discharge pressure and the piping should be made thicker. If you inform TACMINA’s staff of (1) the viscosity of the liquid being transferred, (2) the piping length, and (3) the liquid’s specific gravity, we will recommend a suitable piping size for your application. (Details are illustrated in TACMINA’s technical document, “How to Use a Metering Pump”, which is available upon request.) 11-4-2 Concerning the Anti-Siphon Check Valve An anti-siphon check valve is provided with the hose-type pumps. It should be used in the following situations. (1) When the injection point is open to the atmosphere and is at a level below the solution level in the supply tank, so that siphonage can occur. (Prevention of siphonage) (Refer to Section 23 “Explanation of Terms”.) (2) When the pump is used for injecting into the suction-side piping of a centrifugal pump. (3) When the pump’s actual discharge volume is significantly greater (more than 1.5 times) than its rated discharge volume. NOTE • Even in the case of rising piping, if the overall piping is too long, overfeeding can occur. (Refer to Section 23 “Explanation of Terms”.) 11-4-3 Installing the Anti-Siphon Check Valve CAUTION • The anti-siphon check valve is made of plastic and can be easily damaged by shock. Therefore install it in a location where other objects will not bump against it. (1) Install a 1/2 inch female screw section at the injection point. The anti-siphon check valve has been cut with a 1/2 inch male thread (or with 3/8 inch and 1/2 inch threads for models 62 to 13). The nozzle of the anti-siphon check valve for models 62 to 13 is provided with two flat sections measuring 19 mm across for a spanner or monkey wrench. (The suitable tightening torque of the nozzle is 19.6 to 29.4 N-cm.) (2) If attaching the hose while the anti-siphon check valve is attached to the main piping, turn the hose nut while holding onto the grip. Turning the hose nut without holding onto the grip can damage the threads on the nozzle side. (3) Before injecting into narrow piping, cut the edge of the injection nozzle to a suitable length and install it. If the injection nozzle is too The most appropriate position is where the end of the long for the piping bore, cut along the line before use. injection nozzle is in the center of the injection-side piping. (Refer to Section 23 “Explanation of Terms”.) – 23 – CAUTION • When a valve is installed, do not operate the pump with the valve closed, as the pump head or discharge piping pressure may increase to the point where chemicals spurt from the seal section of the valve. • If the diaphragm is damaged, chemicals may spurt from the seal section of the anti-siphon check valve. IMPORTANT • We recommend that you install a valve for maintenance. Install a RC1/2 female screw section and screw the valve into it. For this valve, use a material which is corrosionproof in the presence of the chemicals being transferred. Type -32 Type 62-23 Valve Valve Anti-siphon check valve Chemicals spurt direction when diaphragm is damaged Seal section mentioned in caution Chemicals spurt direction when diaphragm is damaged 11-4-4 Suction-Side Piping IMPORTANT • Install the pump as close as possible to the chemical tank. • If the suction-side piping is too long, cavitation may occur and a stable flow of solution may not be maintained. (Refer to Section 23 “Explanation of Terms”.) • Minimize obstructions to the flow such as bends or joints in the piping. 11-5 Installation with TACMINA Exclusive Tank Chemical tank Metering pump S Series (SX type shown) Anti-Siphon check valve Use a suction valve (option) Concrete base Suction hose IMPORTANT • Place the tank and the pump as close as possible. • In the case that the pump is to be installed on the tank, install the accessory strainer at the tip of the suction-side hose and at least 30mm above the tank bottom. (1) Pass the hose through the hose nut and connect it to the tank’s suction joint. Then, in the same way, connect the hose to the pump’s suction-side joint. (2) Pass the discharge-side hose through the hose nut, then connect the hose to the pump’s discharge-side joint. Attach the anti-siphon check valve to the injection point, then connect the hose to the valve. – 24 – 11-6 Flange-Type and Union-Type Piping 11-6-1 Cautions for Piping CAUTION • Before beginning pump operation, always ensure that the valves are open. IMPORTANT (1) Since the joint is detached in the shipping package, please install it before connecting the piping. Before mounting, make sure that the valve stopper and check ball are correctly set in place. (2) In order to simplify maintenance, attach a cutoff valve near the pump on both the suction and discharge sides of the piping. (3) Install the pump as close as possible to the chemical tank. If the suction-side piping is too long, cavitation may occur and the metering discharge volume cannot be guaranteed. (Refer to Section 23 “Explanation of Terms”.) (4) Minimize the flow resistance by minimizing bends or joints. As dust and foreign matter may get into the pump head, keep the suction-side piping as short as possible and install a Y-strainer midway. (5) When discharging into less than atmospheric pressure, keep the end of the piping higher than the tank liquid level in order to stop to continue discharging, and connect a ventilation pipe near the feed pipe. 11-6-2 Installing the Flange The standard flange is an FF (Flat Face) type. Insert a seat gasket between flange and counter flange and tighten equally using hexagonal head bolts. If the bolt holes do not match, the flange will move freely when the joint’s cap nut becomes loose. Align the bolt holes of both flanges then retighten the union nut. Union nut 11-6-3 Installing the Union (Stainless Steel Union) The end part carries a PT3/8 male thread. Wind the outer circumference with two or three turns of sealing tape, then drive into the opposite-side piping. Counter socket/pipe R3/8 – 25 – • Make sure that the pump and pipe joints will not be subjected to any excessive force which might be exerted by, for instance, the weight of the piping or the shifting of the pipe join out of position. Use of flexible joints is recommended in order to protect the pump and the pipe joints. 11-7 Concerning Slurry Transfer Structurally, this pump is not suitable for slurry transfer. If, however, this is necessary, the following conditions should be satisfied. (1) The maximum particle size of slurry should be no more than 100μm (0.1mm). (2) The slurry concentration should be less than 10wt% (supposing the specific gravity of the slurry to be about 2 or 3.) (3) Do not raise the pipe too far vertically after the pump discharge side joint. When stopped or flowing slowly, slurry may settle and accumulate near the joints of the pump. This can impair the pump’s ability to convey solution. P P Drain WRONG CORRECT (4) As far as pressure loss characteristics permit, use the smallest possible piping diameter in order to raise the flow velocity within the pipe. (5) Install a cleaning water line (pressurized water such as tap water) in the suction side piping. Before stopping operation, flow cleaning water through the pump to flush any slurry. (6) Don’t use an anti-siphon stop check valve or back pressure valve. If the slurry adheres to the seal part of the valve, the function of the pump may be lost or impaired. If there is a possibility of siphonage or overfeeding, counteract by raising the head difference as far as possible. Separate the piping here Δh P Drain Cleaning line – 26 – 12 Electrical Wiring WARNING • Wiring work should be performed by a qualified electrician. • Make sure that the P.E. cable is correctly connected to prevent electric shock. • Before starting electrical wiring, check the motor voltage, number of phases and capacity. • Use wiring and P.E. cable of thickness matching the rated current of the motor. • Prevent water from entering the piping ports on the terminal box by using a cable gland or piping, for example. 12-1 Power Supply and P.E. Cable (1) Electrical wiring on a standard motor is connected by a terminal box, and size G3/4 wiring ducts are used for connections. Pass electrical wiring through wiring ducts when wiring. • Wire electrical wiring so that the motor rotates clockwise when viewed from the top of the cooling fan. If the motor rotates in the reverse direction, swap two of the three leads. NOTE • The motor can be installed rotated in 90° increments in the horizontal direction. For details on special motors, contact your supplying agent separately. CAUTION • Since the 0.1 kW motor is a totally-enclosed self-cooling motor, it is not equipped with a cooling fan. • Look through the rotation direction observation window on the top of the motor, and connect the wires in such a way that the motor shaft will rotate clockwise. Rotation direction Motor shaft Top of motor – 27 – (2) The SX can be equipped with an exclusive vertical motor that can be mounted at every 90˚ turn in the horizontal direction. Moreover, the terminal box can be rotated in the same way, so fix it in the most convenient position for wiring. NOTE • The wiring of the single-phase motor and special motor may differ slightly. Please consult TACMINA separately. • Single-phase Stand-Alone Operation (AC 100V to 200V) ELB NFB Power suplly AC 100V to 200V MC TH U W E SX pump • Interlocking Operation with a Three-phase Main Pump (AC 200V) ELB NFB1 MC1 TH1 U1 V1 W1 E1 NFB2 MC2 TH2 U2 V2 W2 E2 SX pump Main pump ELB : NFB : MC : TH : CS : L: Operation signal Auto Earth leakage breaker No-fuse breaker Off Electromagnetic contactor Thermal relay CS1 Manual Selector switches Lamp Auto Off Manual CS2 MC1 MC 1 RL 1 TH1 MC 2 L 2 TH2 13 Operation 13-1 Cautions for Use CAUTION • Do not use this pump for application other than injecting liquids. This may result in accident or damage to the pump. • For the product,consumables such as diaphragms and others are available. • Periodical replacement of consumables is required. • Particularly in the application for disinfection, it exerts a strong influence on human health and life if the diaphragm failure took place. • Be sure to refer to the description in the operation manual and perform periodical maintenance. Ambient temperature: Humidity: Liquid temperature: 0 to 40˚C RH35 to 85% 0 to 40˚C (PVC type) 0 to 60˚C (stainless steel type) – 28 – Liquid viscosity: Less than 50 mPa.s In the case of high-viscosity joint use, liquids with viscosities between 50 and 2000 mPa.s can be transferred. However, for models SX(Y)DA/WA13—43, the maximum viscosity is 1000 mPa.s. Max. discharge pressure SXDA/WA -31 to 82 : 1.0 MPa (10bar) SXDA/WA -13.23 : 0.5 MPa (5bar) .43 SXDA/WA -33 : 0.3 MPa (3bar) SYDA/WA -31 to 82 : 1.0 MPa (10bar) SYDA/WA -13.23 : 0.5 MPa (5bar) SYDA/WA -43 : 0.3 MPa (3bar) Height of installation site above sea level: 1000 m max. However, the max. discharge pressure for the PTFE-hose connection (STS-FTC) types is 0.5 MPa (5bar) , and for the SXDA-43.SYDA-43 PTFE-diaphragm (VTC, STS, FTC) types is 0.25 MPa (2.5bar) . • This pump is unsuitable for transferring slurry. Please consult TACMINA before attempting to transfer slurry. • If the pump is operated beyond the normal-use range of the soft PVC hose, replace with a heat-resistant PVC hose. Failure to do so may result in damage to the hose leading to chemical solution leaking or spurting from the hose. Applicable Range of Soft PVC Hose 1.0 Pressure: MPa 0.8 0.6 dia Normal operating range di .12 a. 6 xd x ia. di 18 a. 11 0.4 0.2 0 10 20 30 Temperature (˚C) 40 50 * A dia. 4 x dia. 9 hose supports an output of 1.0 MPa and a temperature of 50˚C. – 29 – 13-2 Preparing for Operation CAUTION • When handling chemicals, be sure to wear protective covering (rubber gloves, mask, protective goggles, etc.) appropriate for the chemicals being transferred. • When diluting sodium hypochlorite (NaOCl), use tap water as much as possible. If ground water is used, its iron or manganese content can result in the generation of slurry or in causing gas locks (in which gas bubbles form inside a pump head, reducing discharge performance). • Sometimes, some water used in the pre-dispatch test may remain in the pump’s liquidcontact parts. If you plan to transfer a solution that coagulates or generates gas when in contact with water, take care to remove any water and dry the pump interior before beginning operation. IMPORTANT • When low-salt sodium hypochlorite is used, gas locks seldom occur. So use low-salt sodium hypochlorite as much as possible. Before beginning operation, carry out the following preparatory steps. (1) Check that the level in the chemical tank is sufficient for operation. If the level is insufficient, refill the tank. (2) Check that none of the piping lines are disconnected and that there is no visible damage, no leakage of liquid and no blockages in the pump or piping. (3) Check that the suction-side and discharge-side valves are both open. (4) Check that the pump motor is correctly connected to a specified power source. (5) Check that there are no mistakes in the electrical wiring and no possibility of a short circuit or earth leakage. (6) A rubber blind plug is fitted to the oil feed port of the drive box to prevent oil leakage during transportation. Remove this plug before beginning operation. If the pump is operated with the plug remained, the drive box temperature will rise and this may cause oil to spurt out. – 30 – •SX Type Rubber plug Oil feed port •SY Type *In the case of the simplex type. Rubber plug Oil feed port (7) Check the oil level on the oil gauge at the side of drive box. The oil level should be near the middle of the gauge. (8) Check for oil leaking from the drive box, and in the case of the SXWA and SYWA types, check also for buffer solution, pure water, or silicone oil leaking from the middle chamber. If a leak is found, retighten the bolt at that location. Especially in the case of excessive leakage of glycerin buffer solution, the discharge volume may be affected, so replace the entire volume of buffer solution. (Please refer to Section 15-7 “Buffer Solution (Glycerin) Injection Method”.) 13-3 Beginning Operation (1) Inch the pump and make sure that the motor rotates clockwise as seen from the cooling fan side. (2) Run the pump for a while with the dial at the “0” position to check for unusual noise or abnormal vibration in the motor or drive section. (3) Turn the dial to the maximum stroke, open the discharge side to the atmosphere and operate the pump. Make sure that the liquid being transferred is reaching the pump head, and then connect the discharge side joint and begin normal operation. When the Pump Doesn’t Draw Up Solution The valve seats on the suction side and discharge side (sealed by a check ball) may catch minute foreign matters. Remove the joint, wash the ball and valve seat with clean water and reassemble them onto the pump head while still damp. Take care to reassemble with the suction and discharge sides correctly oriented. Please refer to Section 15 “Replacement of Parts”. CAUTION • In the case that a liquid which is affected by water is to be transferred, please dry the pump and piping sufficiently. – 31 – 13-4 Air Release SX(Y) DA-31.61.22.32 (VTC.VEC) WARNING • The air release operation spurts out chemicals from the air release joint end with tremendous force. Always attach the air release hose. CAUTION • Before performing the air release operation, be sure to read “Air Release Procedure”. IMPORTANT • The air release procedure should be performed before starting pump operation when using the pump for the first time and when the chemical containers have been replaced. 13-4-1 Air Release Procedure (1) Insert the supplied air release hose (dia. 4 x dia. 6) into the end of the air release joint. Be sure to insert the hose all the way into the base of the valve. Return the other end of the hose to the chemical tank. Air release valve Air release hose (2) Set the stroke length adjustment dial to MAX. position. (3) Turn on the power. While the pump is running, rotate the air release valve by 1 to 1.5 turns counterclockwise. The residual air in the suction-side hose and pump head is discharged from the air release valve, and chemicals fill the pump head. Chemicals come out of the air release valve during this operation. Therefore, tighten the air release valve. 13-4-2 When Chemicals Are Not Drawn up Even After Air Is Released Foreign matters may have accumulated on the valve seats on the discharge or suction sides (section where the check ball is sealed). Turn off the power, remove the joints, and wash the check balls and valve seats with clean water. Then, reattach the valve seats into the pump head while they are still wet, being careful not to mistake the discharge and suction sides. – 32 – CAUTION • If you are planning to transfer chemicals that are sensitive to water, be sure to first dry the valve seats and check balls thoroughly before reattaching. • Be sure to always insert the air release hose before removing air. 13-5 Adjusting the Injection Amount The amount of discharge can be controlled via the Vernier scale dial. Do not turn the dial below the “0” (ZERO) position or above the MAX. Position. NOTE • The dial scale reads from 0 to 8 but the effective valve differs according to the model as follows. Model Effective graduation SXDA SXDA SXDA SXDA SXDA SXDA SXDA -31 -61 -12 -22 -32 -62 -82 SXWA SXWA SXWA SXWA SXWA SXWA SXWA 2 4 4 4 6 6 8 Model Effective graduation SXDA SXDA SXDA SXDA SYDA SYDA SYDA -13 -23 -33 -43 -31 -61 -12 SXWA SXWA SXWA SXWA SYWA SYWA SYWA 6 8 6 8 4 4 4 Model Effective graduation SYDA SYDA SYDA SYDA SYDA SYDA -32 -62 -82 -13 -23 -43 SYWA SYWA SYWA SYWA SYWA SYWA 6 6 8 6 8 8 NOTE • Do not turn the dial to below “0” or above the MAX. position on the effective scale. • Further increasing the dial setting past the MAX. position will not increase the discharge amount. 13-5-1 Procedure for Changing the Injection Amount CAUTION • Loosen the dial fixing bolt 5 before carrying out injection amount adjustment. If the dial is turned forcefully without first loosening the bolt, it will no longer be possible to fix the adjustment dial 1 in position and so the set value may change during operation. (1) Loosen the dial fixing bolt 5. (2) Turn the adjustment dial 1 slowly (during operation it turns very lightly), and then set the injection amount against the adjustment shaft scale and the dial’s numerical value. At this time, turn the dial and confirm the “0” position, then set to the desired position. In this way a more secure adjustment is possible. (One turn of the dial is equal to one scale.) (3) When dial setting is complete, tighten the dial fixing bolt 5 firmly to prevent the set value from shifting. – 33 – 13-6 Disassembling the Flow Regulator and Adjusting the Zero Point 5 Dial fixing bolt (thumbscrew) 6 Brake piece 3 Hexagonal socket head stop screw 4 O-ring 0 2 Adjusting shaft q Drive box 0 O-ring 7 Adjusting shaft bearing 8 Hexagonal socket head bolt 9 Washer 1 Control dial Align the zero point The flow regulator can be disassembled as shown above. Reassemble according to the following procedure. (1) Insert the control dial 1 into the adjusting shaft 2, and tighten the hexagonal socket head set screw 3 tightly. Don’t forget to replace the O-ring 4. (2) Fit the adjusting shaft bearing 7 to the drive box q using the hexagonal socket head bolt 8. Be sure to put back the O-ring 0 and the washer 9. (3) Drive the dial unit assembled in step (1) into the adjusting shaft bearing 7. (4) Insert the brake piece 6 and tighten lightly with the dial fixing bolt (thumbscrew) 5. (5) Turn on the power switch and run the motor. At this time, keep the piping detached from the joints. (6) While operating the motor and pump, continue to turn the control dial 1 clockwise. At this time, the clicking of the pump shaft 2 can be heard. When the dial is turned further, this clicking sound suddenly stops. This is the zero point. (7) Loosen the hexagonal socket head screw 3 and match the zero point of the adjusting shaft bearing 7 with that of the control dial 1. Then tighten the hexagonal socket head screw 3 firmly. (8) Return to the desired dial position and moderately tighten the dial fixing bolt (thumbscrew) 5. CAUTION • Take care not to over-tighten the dial fixing bolt (thumbscrew) or the adjusting shaft bearing 7 may break. IMPORTANT • Lubricate the adjusting shaft with grease at least once a year . 14 Maintenance WARNING • Do not operate the pump when your hands are wet. This could result in electrical shock. – 34 – CAUTION • When disassembling the pump, always turn off the power and check that no voltage is supplied to the pump. Make sure that power cannot be turned ON again during disassembly. • During checking, when you loosen or remove the discharge-side hose or piping connections, take precautions against chemicals spurting from the connections. Wear appropriate protective coverings (rubber gloves, mask, protective goggles, etc.) IMPORTANT • Check the inside and outside of the joint sections once every three months. In the case of 24-hour operation, check the joint sections monthly as a rule. • We recommend that you keep a complete set of consumable parts (diaphragms, check balls, etc.) on hand to simplify replacement or repair. 14-1 Checking During Operation (Daily Checking) (1) Check the chemicals level in the chemical tank. Refill if necessary. Pay special attention to chemicals and processes that require an air-free environment. (2) Check that there are no solution leakages from the gland flange. If leakage is found, check the diaphragm as there is a possibility that it is damaged. (3) Check that there is no chemicals leaking from the joints and other parts, and retighten if necessary. If the leaking still doesn’t stop, check the packing and the O-ring of each part and replace if damaged. (4) Check that no abnormal sounds are coming from the main pump unit and especially from the solenoid section. 14-2 Stopping Operation for an Extended Period (1) Wash out the inside of the pump head using suction, and discharge clean water or washing solution through the pump head for about 30 minutes. (2) After washing is completed, turn the power OFF. (3) Cover the pump with the protective cover in order to guard it against dust and corrosive environment. Set the stroke to an intermediate point to prevent deformation of the diaphragm. (4) Before operation begins again, check that no foreign matter has accumulated, especially on the check balls and valve seats. 14-3 Preparing to Re-Start Operation (1) Check that the chemicals level in the chemical tank is sufficient. If the level is insufficient, replenish the solution. (2) Make sure that there are no abnormalities such as sediment accumulating in the tank or cloudy solution. If the chemical solution appears to have deteriorated, empty and clean the tank, then replace with fresh chemical. (3) Check that the pipes are secure, undamaged, unblocked and free from leakage. (4) Check that the valves on the suction and discharge sides are open. (5) Check that the pump is correctly connected to a specified power source. (6) Check electrical wiring and confirm that there is no mistake, no possibility of short circuiting and no electrical leakage. – 35 – 14-4Lubrication The reduction gear of this pump is lubricated in an oil bath. Please change the lubricating oil after every 4,000 hours of operation. Resupply 190mL of oil for the SX type and 250mL for the SY type per pump head. (In the case of the 2-head box type, resupply a total of 380mL for the SX type and 440mL for the SY type.) The following oils are recommended for use with this pump. Manufacturer Idemitsu Kosan Co.,Ltd. ExxonMobil Yugengaisha. JAPAN ENERGY Corporation Showa Shell Sekiyu K.K. NIPPON OIL Corporation *Avoid mixing different brands. Brand Daphne Super Gear Oil320 Spartan EP320 Mobil Gear632 JOMO Reductus320 Shell Omara Oil320 Bonnoc M320 15 Replacement of Parts 15-1 Replacing the Valve Seats and Check Balls IMPORTANT • Do not forget to install the O-rings, valve stoppers and check balls. (1) When removing and replacing the upper and lower joints, take care not to mistake a lower joint for a upper joint. (2) Make sure that there is no damage to the O-rings or check balls, and no damage to or foreign matter on the valve seats. – 36 – • SXDA-31•61•12•22•32 • SYDA-31•61•12•32 VEC, VTC Types Hose nut Retaining ring CL Types Hose nut Retaining ring Hose joint Hose joint Spacer (only NCS-11,31,61) Ball stopper Check ball Valve seat Ball stopper Check ball Valve seat O-ring Air release joint Hexagonal head bolt Ball stopper Check ball Valve seat Ball stopper Check ball Valve seat O-ring Air release joint Hexagonal head bolt Packing O-ring Washer Hose joint Washer Ball stopper Check ball Valve seat Ball stopper Check ball Valve seat Spacer O-ring Retaining ring Hose nut Ball stopper Check ball Valve seat Ball stopper Check ball Valve seat Hose joint Retaining ring Hose nut VEC, VTC Types Lower joint CL Type Lower joint • SXWA-61•12•22•32 • SYWA-31•61•12•32 Ball stopper Check ball Valve seat Ball stopper Check ball Valve seat O-ring Hose nut Retaining ring Hose joint Hexagonal cap nut Head bolt Washer Hose joint O-ring Retaining ring Hose nut Ball stopper Check ball Valve seat Ball stopper Check ball Valve seat VTC, VTS Lower joint – 37 – Standard Types: SX(Y)DA•WA-62•82•13•23 High-Viscosity Types: SX(Y)DA•WA-31•61•12•22•32 Hose type Cap nut for joint Discharge-use upper joint Union type, flange type O-ring (P-12) Discharge-side upper joint O-ring (P-16, Teflon: P-18) Valve stopper *Asterisked parts are used only in high-viscosity models. * Spring for high viscosity Check ball Discharge-side lower joint O-ring (P-18) High-viscosity models Pomp head Washer Hexagonal head bolt Pomp head Head bolt Washer Hexagonal cap nut Suctionside joint Cap nut for joint Hose type O-ring (P-18) Valve stopper * Spring for high viscosity Check ball Suction-side joint O-ring (P-12) Union type, flange type Standard Types: SXDA•WA-33•43, SYDA•WA-43, High-Viscosity Types: SX(Y)DA•WA-62•82•13•23 Hose type Cap nut for joint Discharge-use upper joint Union type, flange type O-ring (P-20) Second joint Ball guide *Asterisked parts are used only in high-viscosity models. * Spring for high viscosity Check ball O-ring (P-25) First joint O-ring (P-18) Pomp head Head bolt Washer Hexagonal cap nut O-ring (P-18) First joint O-ring (P-25) Ball guide * Suctionside joint Cap nut for joint Hose type Spring for high viscosity Check ball Second joint O-ring (P-20) Union type, flange type – 38 – 15-2 Replacing the Pump Head (1) Remove the piping from the discharge side upper joint section. (In the case of models SXDA/SYDA/SXWA/SYWA-33 and 43, detach the piping from the second joint.) (2) Remove the hexagonal head bolts (DA) and hexagonal cap nuts (WA). It is not necessary to remove the head bolts. (3) Remove the pump head in the direction of the arrow as shown in the above figures. (4) For reassembly, carry out the above procedure in reverse. CAUTION • When tightening the cap nuts of the pump head, tighten in the numerical sequence shown on the right. Tighten each bolt by an equal amount little by little. For example, if you tighten the cap nuts in the order 1→3→2→4, one side may be tighter than the other, which can in turn result in leakage from the pump head. 1 3 4 2 15-3 Parts Replacement: Models SXDA-31/61/12/22/32, SYDA-31/61/12/32 5 Spacer ring 6 Oil seal CAUTION 1 Pump head 4 Drive diaphragm 3 Washer 2 Hexagonal head bolt 7 Oil seal retaining ring 8 Gasket 9 Gland flange Do not loosen the bolt used to secure the gland flange. 15-3-1 Diaphragm Replacement (1) Dismount the pump head 1 according to the procedure detailed in 15-2. (2) The drive (liquid end) diaphragm 4 is screwed into the pump shaft. When replacing the diaphragm, move the motor temporarily by inching or some other method so that the diaphragm will be pushed out as far as possible. Turn this diaphragm counterclockwise, then remove. (3) Replace the diaphragm with a new one. Reassemble in the reverse direction of disassembly. – 39 – 15-3-2 Oil Seal Replacement (1) Disassemble up to the diaphragm according to the procedure detailed in 15-2 and 15-3-1. (2) Pull out the spacer ring 5 to disclose the oil seal retaining ring 7. (3) The oil seal 6 is integrally combined with the oil seal retaining ring 7. Replace the parts with new ones. (4) Direct the oil seal so that the spring side is facing the oil side (drive box side). 15-4 Parts Replacement: Models SXDA-62/82/13/23/33/43, SYDA-62/82/13/23/43 8 Oil seal retaining ring 7 Oil seal 1 Pump head 3 Washer 2 Hexagonal head bolt 6 Washer 0 Gland flange 5 Hexagonal socket head bolt 9 Gasket 4 Drive diaphragm 15-4-1 Diaphragm Replacement (1) Dismount the pump head 1 according to the procedure detailed in 15-2. (2) The drive (liquid end) diaphragm 4 is screwed into the pump shaft . When replacing the diaphragm, move the motor temporarily by inching or some other method so that the diaphragm will be pushed out as far as possible. Turn this diaphragm counterclockwise, then remove it. (3) Replace the diaphragm with a new one. Reassemble in the reverse direction of disassembly. 15-4-2 Oil Seal Replacement (1) Disassemble up to the diaphragm according to the procedure detailed in 15-2 and 15-4-1. (2) Pull out the diaphragm 4 to disclose the oil seal retaining ring 8. (3) The oil seal 7 is integrally combined with the oil seal retaining ring 8. Remove the hexagonal socket head bolt 5 and the washer 6, then the oil seal retaining ring 8 can be drawn out. If it is hard to pull out, drive two M5 x 0.8 bolts into two bolt holes other than the one for the hexagonal socket head bolt 5. This allows the oil seal retaining ring to be removed easily. (4) Since the replacement oil seal and oil seal retaining ring are supplied as an integrally combined unit, both of these parts should be replaced with new ones at the same time. (5) It is recommended that the gasket and copper washers for the hexagonal socket head bolts also be replaced at this time. Hole for the hexagonal socket head bolt Oil seal Drive M5 x 0.8 bolts here. (6) Direct the oil seal so that the spring side is facing the oil side (drive box side). – 40 – 15-5 Parts Replacement: Models SXWA-61/12/32, SYWA-31/61/12/32 0 Plug 9 Middle chamber q Drive diaphragm 5 Holding ring e Oil seal retaining ring 1 Pump head 2 Head bolt 4 Washer 3 Hexagonal cap nut 7 Front diaphragm 8 O-ring 6 Hexagonal socket head bolt r Oil seal y Gland flange w Spacer ring t Gasket 15-5-1 Front Diaphragm Replacement (1) (2) (3) (4) (5) (6) Dismount the pump head 1 according to the procedure detailed in 15-2. Remove the plug 0 from the bottom of the middle chamber 9. Remove the plug 0 from the top of the middle chamber 9 and discharge the glycerin. Remove the hexagonal socket head bolts 6 of the holding ring 5. Draw out the holding ring 5 and then remove the front diaphragm 5. Draw out the middle chamber 9 and in particular make sure that the seal section (the part in contact with the diaphragm) is free from scratches or other damage. (7) If there is no damage, wipe all the oil off and then reassemble. (8) Put a new front diaphragm 7 into the middle chamber 9. At this time, take care not to forget to reassemble the O-ring 8. (9) Assemble up to the pump head in the reverse order of disassembly. 15-5-2 Drive Diaphragm Replacement After performing the procedure outlined in (1) to (6) of 15-5-1, follow the procedure outlined in (2) and (3) of 15-3-1. 15-5-3 Oil Seal Replacement After disassembling up to the drive diaphragm according to the procedures outlined in (1) to (6) of 15-5-1 and (2) and (3) of 15-3-1, follow the procedure outlined in (2) to (5) of 15-3-2. – 41 – 15-6 Parts Replacement: Models SXWA-62/82/13/23/33/43, SYWA-62/82/13/ 23/43 0 Plug 9 Middle chamber 6 Holding ring r Oil seal 1 Pump head y Gasket 4 Head bolt 3 Washer 2 Hexagonal cap nut 7 Front diaphragm t Oil seal retaining ring e Washer q Drive diaphragm u Gland flange 8 O-ring 5 Hexagonal socket head bolt w Hexagonal socket head bolt 15-6-1 Front Diaphragm Replacement Dismount the pump head 1 according to the procedure detailed in 15-2. Remove the plug 0 from the bottom of the middle chamber 9. Remove the plug 0 from the top of the middle chamber 9 and discharge the glycerin. Remove the hexagonal socket head bolts 5 of the holding ring . Draw out the holding ring 6 and then remove the front diaphragm 7. Draw out the middle chamber and in particular make sure that the seal section (the part in contact with the diaphragm) is free from scratches or other damage (If there is scratch, or other damage, replace it with a new one.). (7) If there is no damage, wipe all the oil off and then reassemble. (8) Put a new front diaphragm 7 into the middle chamber 9. At this time, take care not to forget to reassemble the O-ring 8. (9) Assemble up to the pump head in the reverse order of disassembly. (1) (2) (3) (4) (5) (6) 15-6-2 Drive Diaphragm Replacement After performing the procedure outlined in (1) to (5) of 15-6-1, follow the procedure outlined in (2) and (3) of 15-4-1. 15-6-3 Oil Seal Replacement After disassembling up to the drive diaphragm according to the procedures outlined in (1) to (5) of 15-6-1 and (2) and (3) of 15-4-1, follow the procedure outlined in (2) to (5) of 15-4-2. – 42 – 15-7 Buffer Solution (Glycerin) Injection Method (Fig. 3) (Fig. 1) Syringe 9 Drive diaphragm (Fig. 2) 7 Plug Surface tension Specified Volume of Buffer Solution (Glycerin) Specified injection Model volume (mL) SYWA1-31 21 SXWA1-61 SYWA1-61 21 SXWA1-12 SYWA1-12 21 SXWA1-22 24 * SXWA1-32 SYWA1-32 24 * SXWA1-62 SYWA1-62 55 SXWA1-82 SYWA1-82 55 SXWA1-13 SYWA1-13 78 SXWA1-23 SYWA1-23 78 SXWA1-33 137 SXWA1-43 SYWA1-43 137 ✽ In the case of duplex or multiple types, multiply the specified injection volume by the number of pump heads. * Sanitary type: 22mL. Backward Forward 6 Middle chamber 9 Drive diaphragm (1) (2) (3) (4) Remove the fan cover of motor. Turn the motor fan and shift the position of the drive diaphragm backward. Remove only the upper plug 7 of the middle chamber 6. Inject a specified volume of glycerin slowly using the syringe provided. (Be careful not to admit air bubbles.) If the specified volume cannot be fully injected, turn the flow adjusting dial counterclockwise. Then the entire volume can be injected. (Fig. 1) (5) After the specified volume has been supplied, turn the motor fan (or the flow adjusting dial) to move the diaphragm slowly forward. (6) When the buffer solution (glycerin) builds up at the feed port due to surface tension, as shown in Fig. 3, tighten the feed port plug firmly as in Fig. 2. (7) Attach the fan cover and make sure the head bolt and the plugs of the feed and drain ports are firmly tightened. This completes the feeding operation. NOTE • When replacing the glycerine, collect and dispose of the old glycerine by an appropriate method. – 43 – 16 Troubleshooting WARNING • Do not operate the pump when your hands are wet. This could result in electrical shock. CAUTION • Before disassembling the pump for maintenance or repair, make sure to turn OFF the power and confirm that no voltage is supplied to the pump. Also, make sure that the power switch is not turned ON again during the maintenance or repair work. • When handling on the liquid contact section, be sure to wear protective coverings (rubber gloves, mask, protective goggles, chemical-resistant overalls, etc.) appropriate for the chemicals being transferred. • Before maintaining or repairing the pump, release the discharge-side pressure, drain the chemicals from the liquid-contact section and clean it. IMPORTANT • In order to check whether the discharge is abnormal or insufficient, we recommend you to use a flow indicator or a discharge-checker. Trouble Cause Remedy (2) Tighten and check O-ring. (3) Refill tank then remove air. (1) Gas generated depending on the type (1) Dilute the chemical. of chemical pumped. The pump is working Air enters the (2) Leak from joint or seal. pump. but no chemical is (3) The tank is empty. discharged. Liquid is not raised. Strainer is clogged Clean the strainer and tank. (1) Replace the check valve or joint. (2) Replace the spring. (3) Replace the diaphragm. (1) Overhaul. (2) Replace the damaged or fatigued part. (1) Check that the power is operating and voltage is correct. (2) Check and correct wiring. (3) Repair or replace the power cord. (4) Turn on correctly. (5) Seek cause and replace the fuse. (6) Seek cause and dry the motor. (7) Replace the motor. (8) Replace the magnet switch. (1) Overhaul or replace. (2) Overhaul or replace. (1) Check discharge pressure and check for clogging of parts. (2) Add or remove oil to restore level. (3) Improve installation conditions. (4) Overhaul or replace. (5) Replace the spring. Discharge is poor or insufficient. Liquid leaks (1) (2) (3) (1) (2) Check valve or joint is worn. Spring is broken. Diaphragm is deteriorated or broken. Pressure increase due to blockage. Hoses, diaphragms are damaged due to fatigue. The pump does not work. The motor does not run. (1) Faulty power source or incorrect voltage. (2) Faulty pump wiring. (3) Power cord is disconnected. (4) Switch is off. (5) Fuse is blown. (6) Water has entered the motor. (7) Insulation is defective. (8) Magnet switch is defective. (1) Reduction mechanism is broken. (2) Eccentric bearing is broken. (1) Overload. The motor runs. Noise or abnormal heat generation from the drive box. (2) (3) (4) (5) Insufficient or excessive oil. Ambient temperature too high. Eccentric bearing is worn. Spring is broken. * When disassembling the pump, refer to the disassembly drawings and see “Replacement of Parts”. * If you have any further questions or inquiries, please contact your local sales agent or TACMINA. – 44 – 17 Warranty • Period and Range of Warranty (1) The warranty period is one year from the date of purchase. (2) If, during the warranty period, the product sustains damaged or breakdown during normal use as a result a design or manufacturing defect, TACMINA will promptly arrange for repair or replacement of the product at no charge to the customer. (3) This warranty is limited to normal use of the product in Japan. (4) The customer will be charged for repair of the product or replacement of consumable items in the event of damage or breakdown in the following cases. • Damage or breakdown occurring or reported after the guarantee period has expired. • Damage or breakdown resulting from careless handling or abnormal operating or maintenance procedures. • Damage or breakdown resulting from the use of parts not made or specified by TACMINA. • Damage or breakdown resulting from repair or remodelling not specified by or using parts not made by TACMINA. • Damage or breakdown resulting from fire, act of God, natural disaster or other unforeseeable circumstances. • If a service engineer is despatched to a remote location to service the product, travelling expenses will be charged. (5) The cause of the damage or breakdown will be determined by the TACMINA engineer in consultation with the customer. (6) TACMINA accepts no liability whatsoever for damages arising from malfunctioning of the product or other use of this product. 18 Repair Service • When Requesting Product Repair Before requesting repair, read the operation manual carefully and double check the cause of the problem. In the event that the abnormality requires outside repair, please contact the store where you purchased the product. (1) Within the warranty term— Present the warranty document to the store where you purchased the product. The store will arrange the repair according to the warranty contents. (2) After expiration of the warranty term— Consult the store where you purchased the product. Depending on the type of repair required and whether the pump’s functions can be maintained, the store will perform repair according to the customer’s request for a charge. (3) Caution when returning products for repair— In the interests of maintaining a safe working environment, please observe the following cautions. – 45 – CAUTION • TACMINA regrets that it cannot repair pump products that been used for the transfer any of the following types of liquid. (1) Liquids containing radioactive components. (2) Liquids containing viruses which pose a danger to human health. (3) Liquids containing chemical weapon components and other chemical substances which pose a danger to human health. • Wash the pump thoroughly before despatch, and return it together with the maintenance service data sheet or safety data sheet (MSDS). • If the maintenance service data sheet or safety data sheet (MSDS) does not accompany the product, repair work cannot be carried out. • Even if the maintenance service data sheet or safety data sheet (MSDS) are provided, TACMINA reserves the right to refuse to repair the product if we determine it to be too dangerous. Minimum Keeping Period for “Performance” Spare Parts for Repair It is TACMINA’s policy to keep on hand a stock of spare parts that are vital to the performance and functionality of our products for a minimum of five years after we stop producing a particular model. 19 Getting in Touch If you have any questions concerning repair work within the product guarantee period, aftersales service, etc., please feel free to enquire at the store where you purchased the product or to contact your nearest TACMINA sales office. Contact details are listed on the inside of the back cover. – 46 – 20 Consumables and Spare Parts 20-1 Consumables CAUTION • The replacement intervals given for consumable parts in the tables below are based on TACMINA in-house test operation using clean water at room temperature. The actual replacement intervals will vary according to the conditions of operation. Keeping in mind the target replacement intervals, please replace the consumables promptly as operating the pump with worn parts can result in faulty discharge or injection. • The durability of a hose/tube/relief valve/anti siphonal check valve/foot valve/air-release hose/differs significantly depending on the chemicals with which it is used, such as on the temperatures and pressures and on the presence of ultraviolet rays. Inspect them, and replace them if they have deteriorated. * The following replacement parts are not provided as accessories with the pump (impacting, sliding and bending parts that can become particularly worn during pump operation). Part name Check ball Drive diaphragm Front diaphragm (PTFE, W type only) O-rings for joint Springs for high viscosity (High-viscosity type only) Oil seal Glycerin (W type only) Hose Quantity 4 pieces (-32 type VEC, TVC, CL) 2 pieces (Excluding type above) 1 piece 1 piece 1 set 2 pieces 1 (SX type), 2 (SY type) 50-200mL 4m Recommended replacement interval 4,000 hours or 1 year 4,000 hours or 1 year 4,000 hours or 1 year 4,000 hours or 1 year 2,000 hours or 6 months 4,000 hours or 1 year When replacing diaphragm 4,000 hours or 1 year * (1) Please replace the parts in question at the recommended replacement interval when either the accumulated operating time (4,000 or 2,000 hours) or the period of use (1 year or 6 months) has been reached. (2) Quantities refer to simplex (single head) pump types. For duplex or multi-head pump types, multiply the quantities accordingly. (3) The diaphragm replacement intervals given above are for cases where water is handled. Depending on the characteristics of the solution being transferred, diaphragm durability may be rather less than the above figures. 20-2 Parts Recommended to be Kept at Hand (Because the following parts can be easily damaged or lost. • Joints (especially the valve seat) • Valve stopper (Excluding -33, -43 types) • Ball guide (High-viscosity type: SXDA/WA-33, SYDA/WA-33, SXDA/WA62/82/13/23, SYDA/ WA-62/82/13/23 types only) – 47 – • Gaskets • Bolts and washers and packings 20-3 Spare Parts (1) Spare parts to be maintained for approx. 3 years. • Bearings • Worm.wheel gears (2) Spare parts to be maintained for longer than 3 years. • Compression spring • Motor • Planetary gear (SY type only) • Eccentric shaft • Motor coupling (SY type only) • Pump shaft 21 Options and Related Equipment • Back Pressure Valve Depending on the piping conditions, the overfeeding phenomenon, in which the pump discharges more than the rated amount, may occur. The back pressure valve can be used to prevent overfeeding from occurring. • Relief Valve If foreign matter blocks the pump’s discharge-side piping or the discharge valve becomes blocked or jammed, excess pressure builds up in the pump head. In such a situation, the relief valve can prevent the pressure from reaching a dangerous level by automatically opening at a set pressure to release the excess pressure. • Air Chamber Reciprocating pumps generate a characteristic pulsating discharge which can lead to vibration of the piping or overfeeding. An air chamber installed in the discharge-side piping can suppress pulsation and restore a roughly continuous flow to prevent these problems from occurring. • Accumulator The accumulator is another device for reducing pulsation. Its principle is similar to that of the air chamber. However, it is especially effective when used at high pressures in excess of 1.0 MPa or for solutions that are influenced by contact with air. • Flow Indicator Installed on the discharge-side of the pump, the flow indicator allows the discharge operation to be easily monitored. It is an optional metering pump peripheral that is very useful for detecting and preventing trouble. • Defoaming Joint Chemicals prone to generating gas, such as sodium hypochlorite, often cause gas locks which prevent discharge from occurring. By installing a defoaming joint on the pump’s suction side, any gas bubbles can be separated from the liquid and prevented from entering the pump head, thereby reducing the possibility of a gas lock. • PTU-100 A chemical injection unit consisting of a metering pump and a PE tank (100 Liters). • Chemical Tanks PE-material (25—100 Liters), PVC-material (50—1000 Liters) • Pump Stand • Pump Cover • Remote Controller • Pulse Counter – 48 – 22 Maintenance Service Tool List To simplify maintenance and replacement of parts, we recommend the use of following tools. Location Joint Joint Pump head Joint Part name Pliers Tool used Spec. (mm) Applicable models SXDA/WA; SYDA/WA resin type Spanner or monkey wrench Spanner or monkey wrench 26 or 29 across SXDA/WA-33; SUS type except SYDA/WA-33 Gland flange Middle chamber Reduction gear (SX type) Reduction gear (SY type) SXDA/WA-33; SYDA/WA-33 SUS 38 across type; SXDA/WA/SYDA/WA-62/ 82/13/23 SUS high-viscosity type Spanner or SXDA/WA-12/32; Cap nut for head bolt 8 across SYDA/WA-31/61/12/32 monkey wrench SXDA/WA-62/82/13/23/33; Spanner or Cap nut for head bolt 10 across SYDA/WA-62/82/13/23/33 monkey wrench Hexagonal socket head bolt SXDA/WA-62/82/13/23/33; Hexagonal key wrench 3 across SYDA/WA-62/82/13/23/33 for oil seal retaining ring Hexagonal socket head Hexagonal key wrench 5 across SXDA/WA-31/61/12/22/32; bolt for gland flange SYDA/WA-31/61/12/32 Hexagonal head 10 across SXDA/WA-62/82/13/23/33/43; Wrench bolt for gland flange SYDA/WA-62/82/13/23/33 Plug Spanner or monkey wrench 10 across SXWA/SYWA all models Motor mounting bolt Spanner or monkey wrench 8 across SXDA/WA all models Motor fan cover screw Philips screwdriver SXDA/WA all models Hexagonal socket head 5 across SYDA/WA all models bolt for bearing housing Hexagonal key wrench Hexagonal socket head 4 across SYDA/WA all models bolt for bearing housing Hexagonal key wrench Spanner or Oil feed port cap 14 across SXDA/WA all models monkey wrench Spanner or Oil drain cap 14 across SXDA/WA all models monkey wrench Bearing Puller SXDA/WA all models For shaft SXDA/WA all models C-shaped snap ring Snap ring pliers Bolt for reduction gear cap Spanner or monkey wrench 8 across SYDA/WA all models Hexagonal head bolt for Spanner or 10 across SYDA/WA all models mounting frame monkey wrench Hexagonal socket head 5 across SYDA/WA all models bolt for bearing housing Hexagonal key wrench Hexagonal socket head 4 across SYDA/WA all models bolt for bearing housing Hexagonal key wrench Oil feed port cap Oil drain cap Bearing C-shaped snap ring Hexagonal socket head bolt Hexagonal socket head set screw Hexagonal socket head bolt for reduction gear cover Hexagonal socket head bolt for gear case Pan head machine screw Spanner or monkey wrench 14 across SYDA/WA all models Spanner or monkey wrench 14 across SYDA/WA all models Puller SYDA/WA all models Snap ring pliers For shaft SYDA/WA all models Hexagonal key wrench 4 across SXDA/WA, SYDA/WA all models Flow control unit Hexagonal key wrench Hexagonal key wrench Hexagonal key wrench Philips screwdriver 2.5 across SXDA/WA, SYDA/WA all models 4 across 5 across SYDA/WA all models SYDA/WA all models SYDA/WA all models SYDA/WA all models Planetary gear (SY type only) Bolt for coupling cover Common base (SY type only) Hexagonal socket set screw for coupling Motor mounting bolt Spanner or monkey wrench 10 across Hexagonal key wrench 3 across SYDA/WA all models SYDA/WA all models Spanner or monkey wrench 10 across – 49 – 23 Explanation of Terms • Overfeeding A phenomenon that liquid continues to discharge from the piping for a few seconds due to the momentum of discharge (inertia) after stop operating a pump. In case of pulsation flow, the actual discharge volume might be larger than rated one because of this phenomenon. • Siphonage When the outlet of the discharge piping is below the liquid level in the suction side tank, the liquid being transferred continues to flow even after the pump is stopped. This phenomenon is called “siphonage.” • Cavitation If negative pressure occurs in pump head, gas bubbles may form within the liquid being transferred. This “cavitation” effect leads to abnormal noise and vibration while reducing the discharge volume. For more detailed information on these phenomena and other metering pump-related matters, please consult TACMINA’s technical manual series “Metering Pump Introductory Course”, which is available free upon request. – 50 – 24 Maintenance Data If the pump requires repair, wash the interior thoroughly with water, make a copy of this sheet and fill out all relevant details. Then enclose a copy when you dispatch the pump for repair. No. Customer name: Telephone No.: Address: Department: Person in Charge: Name of sales agent: Model: Serial No.: Power source: 50 Hz 60 Hz 1-phase 3-phase 100 V 200 V Other ( V) Control method: ON-OFF Inverter Thyristor Servo Other ( ) Delivery date: ___ (D) ___ (M) _____ (Y) First operation date: ___ (D) ___ (M) _____ (Y) Operating hours: ______ hours/day Flow rate adjustment dial position: ( ) Pulse number: ( ) Stroke length: ( )% Installation conditions: Indoor Outdoor Ambient temperature ( ) °C Name/composition of chemicals transferred: Concentration ( )% Specific gravity: ( ) Temperature: ( )°C Viscosity: ( )mPa.s Slurry: No Yes Content ratio: ( )wt% Particle size: ( ) Layout (Flow sheet): Piping diameter: _______ A Piping length: Suction side m Discharge side m Discharge pressure: _____ Accessories used: MPa Failure explanation (summary) – 51 – EM-019(12)05 2010/7/DDD