IWAKI Bellows Pump

KBR SERIES Instruction Manual

Read this manual before use of product

Thank you for having selected Iwakis bellows pump KBR series. This manual deals with the correct handling and operation procedures and troubleshooting methods for the pump. To make maximum use of the pump and to ensure safe, long operation, please read this manual carefully prior to operating the pump. Pay special attention to the Warning and Caution sections as they relate to matters of safety and proper usage of the pump.

Important Instruction
For the Safe and Correct Handling of the Pump
Read the Safety Instructions sections carefully to prevent accidents involving your customers or other personnel and to avoid damage or loss of other assets. Always follow the instructions and advice found in these sections. Observe and abide by the instructions described in this manual. These instructions are very important for protecting pump users from dangerous conditions and situations related with the use of the pump system.

Contents
Chapter Page

Safety Instruction ............................................................................2 1. Before use ................................................................................ 3 2. Installation ...............................................................................4 3. Piping .......................................................................................4 4. Adjustment of flow rate ........................................................... 5 5. Troubleshooting ....................................................................... 7 6. Maintenance and inspection .....................................................8 7. Expendable parts ......................................................................8 8. Disassembling and assembling .................................................9 9. Name of parts and structure ................................................... 10

The symbols relate to the following meanings described below: Warning Caution
Nonobservance or misapplication of the contents of the Warning section could lead to a serious accident, including death or injury. Nonobservance or misapplication of the contents of the Caution section could lead to serious physical injury to the user or serious damage to the product.

Types of Symbols
Indicates that Warning or Caution must be exercised. Inside this triangle, a concrete and practical image provided as a warning or caution message is depicted. Indicates a prohibited action or procedure. Inside or near this circle, a concrete and practical image of the activity to be avoided is depicted. Indicates an important action or procedure which must be performed or carried out without fail. Failure to follow the instructions herein can lead to malfunction or damage to the pump.

-1-

Safety Instruction
Warning
Turn off the power supply.
Working without disconnecting the power supply may cause an electrical shock. Before engaging upon any working procedures involving the pump, make sure to turn the power supply switch off and to stop the pump and other related devices. When you detect or become aware of a dangerous sign or abnormal condition during operation, terminate the operation immediately and start it from the beginning again.

Operating site must be free of water and humidity.

Electrical Shock

The pump is not designed to be water-proof or dustproof. The use of the pump in places where water splashes or humidity is high may result in an electrical shock or short circuit. Do not operate the pump without connecting the grounding wire. Otherwise, an electrical shock may result. Make sure the grounding wire is connected with the grounding terminal. Do not install or store the pump in the following places: * Places where a flammable gas or material is used or stored. * Places where the ambient temperature is extremely high (40C or higher) or extremely low (0C or lower).

Prohibited

Terminate operation.

Arrange grounding.

Grounding

Caution
Do not wet or dampen.
If the motor or wiring cable becomes wet or dampened with the operating liquid by mistake, this may result in a fire or cause an electrical shock. Install the motor and wiring cable in positions which are not likely to become wet or dampened with any liquid. Poisoning may result during an operation which involves toxic or odorous liquid. Ventilate the operating site sufficiently. Protective measures should be taken against any accidental spill-out or leakage of the operating liquid as a result of unexpected damage on the pump or the related piping.
Caution

Limited operating site and storage.

Prohibited

Prohibited

Disposal of used pump.

Ventilate.

Disposal of used or damaged pumps must be done in accordance with the relevant local laws and regulations. (Consult a licensed industrial waste products disposing company.)

Caution

Spill-out accident.

-2-

1. Before use
Prohibited liquid Dangerous liquid such as strong acid/alkali solution. Harmful liquid Gasoline, Hydro carbon such as kerosene. Halogen hydro carbon such as trichloroethylene and carbon tetrachloride. Ethel and esther. Adjustment of flow rate (in case of adjustable cam) When the flow rate is adjusted, switch off the power to stop the pump. (Adjustment can not be done during the operation.) Caution
Do not turn the pump by hand but turn it by switching on the power. Motor may be broken if it is rotated in reverse by force.

Permissible pressure of the pump The pump can be operated at the pressure range of : -0.01 to +0.01 MPa When the suction is flooded suction, its height must be 50cm or less. Caution
If the pump is operated beyond the above mentioned range, it may happen that the motor does not rotate or other failure or damage.

-3-

2. Installation
(1) Place to be installed Install the pump at the place of ambient temperature of 5 - 40C, relative humidity 35 90%wt and at the place of easy maintenance. Install the pump at place well ventilated. (2) Fixing of base To mount the pump fix the base using two M4 screws. Mounting holes are at the bottom and side. Caution
Do not install the pump on the unstable plate. Holes for side mount

3. Piping
(1) To minimize the pipe resistance of the liquid, employ the plumbing as short as possible and as less bends as possible. Also, to avoid the cavitation phenomenon (phenomenon which the bubbles are generated), employ the suction hose which corresponds to pump suction port and the suction hose must be as short as possible. As reference, the suction hose must be less than 2 meters if ID 8 mm hose is used. (2) Employ the vinyl hose which is chemically resistible to the liquid and can endure the pressure which the pump makes.
For base mount

Caution

(3) Preparation of hose Before the installation of pump, cut the hose end flat.

It may possible that the suction hose is squashed by pump suction force. Use braided hose or like. (Especially, pay attention when the warm liquid is pumped.)

Applied hose: ID 8mm

-4-

(3) Connection of hose Insert the hose by force till the end of discharge and suction ports. If the suction side is wrongly connected, it may suck the air which may cause insufficient pump performance. (4) Securely fix the hoses using hose clamp to avoid the liquid leakage. Caution
Pay attention not to tighten excessively the suction and discharge ports because they are made of plastics.

4. Adjustment of flow rate (for adjustable cam)

Flow rate can be adjusted by changing the stroke length. Follow the procedure mentioned below. (1) Stop the pump so that the stroke adjusting screw can come to the right side of the pump frame. If the drive cam B can not stop at the desired position, run the pump again to stop the cam at desired position, or you can adjust it by insert a bar (2 mm set wrench or like) into the side hole of drive cam B to turn it clockwise till it comes to desired position. You can turn it by 45 degree by one turn. (Never turn drive cam B to counter-clockwise.) (2) Turn counterclockwise the stroke adjusting screw by 1/4 - 1/2 turns to loosen it. Pay attention not to turn excessively.
Stroke length adjusting screw Drive cam B

-5-

(3) Turn the cam of this side by hand to adjust the dial (%).

This side cam

(4) After the adjustment is finished, tighten the adjusting screw.

-6-

5. Troubleshooting
The handling, maintenance and inspection is limited to the extent written on this manual. Phenomenon
Liquid is not sucked in.

Cause
Wrong mounting direction of valve Foreign matters adhered to the valve Damaged or broken valve Cap A is insufficiently tightened. Pump head is insufficiently tightened. Broken bellows Pump is air locked. Air is sucked in through the suction port. Motor does not rotate. No liquid to be pumped Too short stroke length*

Countermeasures
Mount the valve in correct direction. Clean valve Replace valve Tighten Cap A. Securely tighten pump head mounting screws. Replace the pump Remove the discharge side hose, fill liquid in the bellows and connect the hose. Connect the hoses correctly. Check the power source or replace the pump. Fill the liquid in the tank. Operate the pump at full stroke length (100%) and then adjust the stroke length. Mount the valve in correct direction. Clean valve Replace valve Replace the pump Remove the discharge side hose, fill liquid in the bellows and connect the hose. Check the power source or replace the pump. Fill the liquid in the tank. Clean valve Tighten Cap A. Securely tighten pump head mounting screws. Connect the hoses correctly. Tighten Cap A. Securely tighten pump head mounting screws. Replace the pump

Liquid is not discharged. Wrong mounting direction of valve Foreign matters adhered to the valve Damaged or broken valve Broken bellows Pump is air locked. Motor does not rotate. No liquid to be pumped Too small flow rate. Foreign matters adhered to the valve Cap A is insufficiently tightened. Pump head is insufficiently tightened. Air is sucked in through the suction port. Cap A is insufficiently tightened. Pump head is insufficiently tightened. Broken bellows

Liquid leaks.

* For KBR -

-7-

6. Maintenance and inspection

Always pay attention to the operating condition and liquid leakage. Also disassemble and inspect the pump once a year. Switch off the power when any abnormality is found and check the cause referring to the Troubleshooting. When the time comes for the parts to be replaced or when the pump performance gets lowered considerably, replace the parts or pump.

7. Expendable parts
If the pump is continuously operated for a long period, it is recommended the following expendable parts are always stocked by the user. No. 7 8 9 10 Parts name Poppet valve A (*) Poppet valve B (*) Valve gasket (*) O ring Estimated time to be replaced

3,000 hours

When valve is replaced. 5 millions strokes or 3,000 hours

11

Bellows

12

Geared motor

3,000 hours

Note 1: Parts marked by * are available as a unit (valve unit). 2: Above mentioned estimated life time is obtained by continuous pumping of clear water of 20 ~ 25 deg. C temperature and the life time depends on characteristics, pressure, temperature and other conditions of pumped liquid.

-8-

8. Disassembling and assembling

In most cases, prior to the disassembly of a pump there is liquid remaining in it. Particularly when using dangerous liquids, clean the inside of the pump. Be careful not to loose the small parts. Replacement of poppet valve (1) Disconnect the hoses on both the discharge and suction sides. (2) Rotate cap A (2) counterclockwise, then take out outlet (5), inlet (1), and pump head (3). (3) Take out the valve set (consisting of poppet valve (7), poppet valve B (8) and valve gasket (9)). (This completes the disassembling process.) (4) Replace the old valve set with a new one, and assemble the parts in the reverse order of disassembly. Pay close attention to the direction of the poppet valve in the assembling process. (Refer to the Name of parts and structure section.) Replacement of bellows (1) Use a philips-head screwdriver to loosen the tapping screw (16) and remove the pump head (3). Be careful not to lose the O ring (10) attached tn the section where the bellows (1) come in contact with the pump head. (2) If there is liquid remaining in the bellows, get rid of it with the use of a syringe. (3) Rotate the bellows (11) 90 counterclockwise. (4) Turn ON the power switch, turn the geared motor (15), and stop the connecting rod (12) at the lower dead point. (5) Contract the bellows (11) and pull them out. (This completes the disassembling process.) (6) Assemble new bellows (11) in accordance with the following steps. Set the bellows on the connecting rod (12). Turn ON the power supply to the geared motor (15) to stop the connecting rod (12) at the upper dead point. With this condition maintained, push the bellows (11) toward the connecting rod slightly and rotate the bellows 90.

-9-

9. Name of parts and structure

No. 1 Inlet Cap A Pump head Frame Outlet Motor cover Poppet valve A Poppet valve B Valve gasket O ring Bellows Connecting rod Drive cam Cam shaft Motor Tapping screw Nut Element Quantity Remarks 1 2 1 1 1 1 2 2 2 1 1 1 1 1 1 2 2 M4 M4 P-11

16 8 7 9 1 2 10 9

3 5 8 7

2 3 4 5 6 7 8 9 10 11

17 11 13 13 12 Adjustable cam type 4 14 15

12 13 14 15 16 17

- 10 -

( )Country codes

IWAKI CO.,LTD. 6-6 Kanda-Sudacho 2-chome Chiyoda-ku Tokyo 101-8558 Japan

TEL:(81)3 3254 2935 FAX:3 3252 8892(http://www.iwakipumps.jp) U.S.A. Australia : IWAKI WALCHEM Corporation : IWAKI Pumps Australia Pty. Ltd. TEL : (1)508 429 1440 FAX : 508 429 1386 Germany TEL : (61)2 9899 2411 FAX : 2 9899 2421 TEL : (65)763 2744 FAX : 763 2372 TEL : (62)21 690 6607 FAX : 21 690 6612 TEL : (60)3 7803 8807 FAX : 3 7803 4800 TEL : (886)2 8227 6900 FAX : 2 8227 6818 TEL : (66)2 320 1303 FAX : 2 322 2477 TEL : (852)2 607 1168 FAX : 2 607 1000 Italy Denmark Sweden Finland Norway France U.K. : IWAKI EUROPE GmbH TEL : (49)2154 9254 0 FAX : 2154 1028 : IWAKI Italia S.R.L. : IWAKI Sverige AB : IWAKI Suomi Oy : IWAKI Norge AS : IWAKI France S.A. TEL : (39)02 990 3931 FAX : 02 990 42888 FAX : 48 24 2346 FAX : 9 2742715 FAX : 66 81 16 61 TEL : (46)8 511 72900 FAX : 8 511 72922 TEL : (358)9 2742714 TEL : (47)66 81 16 60 : IWAKI Pumper A/S TEL : (45)48 24 2345

Singapore : IWAKI Singapore Pte. Ltd. Indonesia : IWAKI Singapore (Indonesia Branch) Malaysia Taiwan Thailand China China China Korea : IWAKIm Sdn. Bhd. : IWAKI Pumps Taiwan Co., Ltd. : IWAKI (Thailand) Co.,Ltd.

TEL : (33)1 69 63 33 70 FAX : 1 64 49 92 73 FAX : 32 3226084 FAX : 2236 33469 FAX : 297 273902 FAX : 943 628799 FAX : 1430 7008

Hong Kong: IWAKI Pumps Co., Ltd.

: IWAKI PUMPS (UK) LTD. TEL : (44)1743 231363 FAX : 1743 366507 : IWAKI (Austria) GmbH TEL : (43)2236 33469 : IWAKI Holland B.V. TEL : (31)297 241121 : IWAKI Iberica Pumps, S.A. TEL : (34)943 630030 : IWAKI Belgium n.v. TEL : (32)1430 7007

: IGFTZ IWAKI Engineering & Trading Co., Ltd. TEL : (86)20 8435 0603 FAX : 20 8435 9181 Switzerland : IWAKI (Schweiz) AG TEL : (41)32 3235024 : IWAKI Pumps Co., Ltd. (Beijing office) TEL : (86)10 6442 7713 FAX : 10 6442 7712 Austria : IWAKI Pumps (Shanghai) Co., Ltd. : IWAKI Korea Co.,Ltd. TEL : (86)21 6272 7502 FAX : 21 6272 6929 Holland FAX : 2 843 3096 Spain Belgium TEL : (82)2 3474 0523 FAX : 2 3474 0221

Philippines : IWAKI Chemical Pumps Philippines, Inc. TEL : (63)2 888 0245

T.407-3 02/09