JOWA

BIO - STP 2

SEWAGE TREATMENT PLANT

OPERATION AND TECHNICAL MANUAL

Jowa AB

TELEFON INTERNET

Tulebo 865

+46(0)31-795 00 40

www.jowa.se

S-428 34 KÅLLERED

GÖTEBORG TELEFAX

+46(0)31-795 45 40

info@jowa.se

Date: 2003-04-02

JOWA

Rev: A

BIO – STP 2

Sign: PB

Table of Contents

INTRODUCTION

1.1 G

ENERAL

SYSTEM DESCRIPTION

SPECIFICATIONS

3.1 S

HIP

ARTICULARS

3.2 S

EWAGE TREATMENT PARTICULARS

3.3 S

EWAGE TREATMENT TANK PARTICULARS

3.4 S

EWAGE TREATMENT ACCESSORIES

(1 SET/ 1 SHIP)

INSTALLATION INSTRUCTIONS

4.1 D

ELIVERY

4.2

JOWA BIO STP

LOCATION

4.3 E

XTERNAL PIPE CONNECTIONS

4.4 E

LECTRIC CONNECTIONS

4.5 E

ALARM CONNECTION

4.6 E

XTERNAL VALVES INSTALLED BY YARD

OT INCLUDED

)

4.7 V

ACUUM SYSTEM

( O

PTIOPNAL

)

OPERATIONS

5.1 S

TART UP

5.2 N

ORMAL OPERATION

5.3 D

ISCHARGE OF BIOREACTOR AND SETTLING TANK

5.4 M

AINTENANCE

TROUBLESHOOTING

P&I DIAGRAM

MECHANICAL GA DRAWINGS

ELECTRICAL WIRING DIAGRAMS

DISCHARGE PUMP

MACERATING PUMP

METERING PUMP

AIR BLOWER

LEVEL SWITCHES

PLC MANUAL

SPARE PART LIST

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CERTIFICATES

VACUUM SYSTEM (OPTIONAL)

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BIO – STP 2

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1 Introduction

The JOWA BIO STP (Sewage Treatment plants) are designed for automatic operation
onboard ships in accordance with

IMO MEPC2 (VI) and meets all the requirements in Marpol

73/78 annex IV.

The JOWA BIO STP is an aerated, submerged, fixed-film unit with a proprietary aeration
system that provides major advantages for the operators. The Bioreactor contains a cross-
fluted structured matrix, on which the degrading bacterial biomass adheres and rapidly grows.
The Bioreactor ensures maximum optimum biological treatment and the efficient aeration
system ensures that the Bioreactors produce no offensive odours.

1.1 General
To obtain all advantages operating the JOWA BIO STP, be assured all users have adequate
education for the equipment.
That the installation is correct maintained and operated in accordance with the instruction in
this manual.
Otherwise the functions of the equipment cannot be guaranteed.

Before installation and start up, read this manual carefully.

Supplier and manufacturer:

Jowa AB

Tulebo

865

S-428

Kållered,

Gothenburg

Sweden

Phone:

+46 31 795 00 40

Fax:

+46 31 795 45 40

E-mail:

info@jowa.se

www.jowa.se

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2 System description

The JOWA BIO STP is an aerated, submerged, fixed-film unit with a proprietary aeration
system that provides major advantages for the operator.

The raw sewage is led to the pre-treatment chamber. In the pre-treatment chamber there is a
submerged macerating pump. The pump macerates the raw sewage to very small pieces
before it enters the bioreactor. The macerating pump is constantly running and when there is
no inlet water it collects water and sludge from the bottom of the bioreactor. The macerating
of the bottom sludge in the bioreactor prevents the bioreactor matrix from clogging.

The Bioreactor contains a polypropylene, cross-fluted structured matrix, as its media, on
which the degrading bacterial biomass adheres and rapidly grows. This matrix is
manufactured so that constant inter-mixing of the wastewater occurs in each vertical column
of the media, ensuring maximum contact between the effluent and the surfaces on which the
biomass is fixed. The wastewater is driven upwards by strategically placed aerators over
alternate columns of the matrix and it flows downwards in the adjacent column. In this way,
the effluent moves in a serpentine fashion through the whole of the Bioreactor to ensure the
maximum contact time and optimum biological treatment.

There are no moving parts inside the Bioreactor, and the self-cleaning aeration system, fed by
the air blower, provides:

(i)

The required amount of dissolved oxygen for the biomass to feed on and degrade
the waste.

(ii)

The motive force for the serpentine passage of the wastewater through the aeration
chamber with maximum contact with the degrading bacteria.

(iii)

The removal of solids from the Bioreactor without the need for back washing or
desludging procedures.

(iv)

The efficient aeration system also ensures that the Bioreactors produce no
offensive odours, unlike other biological treatment plants.

Solids are produced in all biological degradation processes due to the development of the
bacterial biomass by absorption of organic materials, nitrogen and phosphorus nutrients,
micronutrients and oxygen to perform the organic degradation to carbon dioxide and water.
During this process, which removes the organic contamination from the water, the biomass
film thickens on the matrix and eventually this slime layer becomes too deep for nutrients and
oxygen to penetrate right through it. At this stage, it stops producing sticky polysaccharides,
loses its adhesion to the plastic matrix, is detached by the sheering force of the air and water
in a sloughing process, and passes into the water stream which gravity flows out of the
Bioreactor. These fully digested, odouress, biological solids, or dead cells, is settled in the
settling chamber. The solids will be recycled back to the inlet and degraded like any other
organic material, providing that sufficient biodegradation capacity and residence time has
been built into the system.

For sewage treatment, the Bioreactors need no nutrient addition or pH correction and
chemicals are not required, hence there are no added costs or environmental problems
associated with the use of chemicals. Primary settlement of sewage is not needed as the
Bioreactor can take the complete waste, via the perforated inlet pipe and the macerating
pump, removing the requirement for the handling of septic solids and their costly disposal. In

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addition, the Bioreactor can accept all normal kitchen greases and fats in the wastewater and
successfully degrade them, removing the requirement for a grease trap and its associated
smells and costly emptying and disposal. The intensive bacterial activity that takes place in
the Bioreactor ensures that pathogenic bacteria, originally present in the sewage, are
competitively inhibited. Thus, a discharge to surface waters meets stringent quality standards.

Should it be required, ultra-violet light (UV) disinfection of the discharged waters and the
solids can be achieved in a compact flow-through unit to remove all microbiological
contamination. Where it is permitted, chlorine disinfection of the discharged waters is an
alternative, if required.

The removal of any other contaminants from the water can also be achieved, either as a pre-
treatment step to the Bioreactor stage, such as by precipitation of heavy metals, or as a post
treatment stage by activated carbon adsorption for colour, pesticide residues and heavy
metals.

The Bioreactor based treatment systems is designed so that the discharged water is better in
quality than 50 mg/l BOD

(biochemical oxygen demand), 50 mg/l Suspended Solids and 250

faecal coliforms/100 ml.

Due to the high de-gradative power of the JOWA BIO STP, they are much smaller than
comparable biological degradation methods using suspended growth (rather than fixed-film)
systems. Such systems include activated sludge, extended aeration activated sludge, and
sequencing batch reactors (SBR). In these aerated systems, the biomass concentration cannot
be as high as in a fixed-film system, so the aeration volume has to be much larger. As a
consequence, the Bioreactor is much smaller than suspended growth systems and has a
smaller footprint. This makes the JOWA BIO STP very suitable for marine use. The
Bioreactors has a quick biological start period and is also non-sensitive to long shutdown
periods due to continuous sludge return.

In addition, because the Bioreactor is a submerged, fixed-film unit, the biomass is more stable
and able to tolerate both hydraulic and organic shock loadings better than the alternatives.
Low flows and loadings can, therefore, be accepted for extended periods. As a result, they are
not susceptible to having periodic failures of wastewater degradation and should continuously
achieve the required effluent consent levels.

The high stability of the Bioreactor means that it does not need regular attention. As there are
no sludge wasting and recycling procedures, which are required by suspended growth
systems, there is no need for a dedicated operator. It also has a low requirement for
maintenance and minimal spare parts usage.

Location on remote sites and unattended running is possible (optional), providing that there is
an electricity supply. All electromechanical equipment, including pumps and blowers, can be
supplied in duplex (optional), in duty and standby configuration, with automatic switchover
for even wear and, in the event of a failure of one of the dual units (optional), continuous
effluent treatment is assured.

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3 Specifications

3.1 Ship

Particulars

• Hull

No.

N/A

• Yard

Owner

N/A

• Type

JOWA

BIO

STP

• Quantity

SET/SHIP

• Drainage

system

Gravity

Vacuum

• Type of ship

Passenger / Merchant

• Number

crew

P.E

• Number of passenger

P.E

• Total Complement

25 P.E (at black water

gravity system)

3.2 Sewage treatment particulars

• Certified hydraulic load

1,75 m³/day

• Certified organic load

1,29 kg BOD

/day

• Power

consumption 4.1

3.3 Sewage treatment tank particulars

• Material

Mild

Steel

• Dimensions

See

chapter

Drawings

• Hydraulic

Test

2.2

m.v.c

• Weight (Empty / Full)

approx. 792 / 2172 kg

• Paint system

o Interior: Epoxy Phenolic

250

µm +/- 10%

o Exterior: Epoxy and Polyurethane

125

µm +/- 10%

3.4 Sewage treatment accessories (1 SET/ 1 SHIP)

• Discharge pump; Herborber Unipump 4/HK 50

1 set

• Macerating pump, ZENIT GRS 100/2G40HT

1 set

• Air blower; BECKER DT 4.25/K

1 set

• Metering pump; IWAKI ESB10VC

1 set

• Level

switches;

JOLA

set

• Control

Cabinet

set

• Spare parts

See Chapter 15

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4 Installation

instructions

4.1 Delivery
By deliverance this JOWA BIO STP Sewage Treatment Plant is tested and controlled.

4.2 JOWA BIO STP location
Locate the unit so there is enough space around it for maintenance and service, on top of the
tank it should be at least 500 mm to dismount the tank cover.
Mount the unit sufficiently by bolts or welding.

4.3 External pipe connections
The sewage treatment plant has the following external connections, which should be
connected to the vessels piping systems. We refer to

P&I Diagram, chapter 7

and

drawings, chapter 8

for more info. All pipes have flange connections.

4.3.1 Black, grey and galley water inlet
Location

Pre-treatment chamber,

Pipe dimension

DN100

Standard

DIN

PN16

Nos. of inlets

1 off

4.3.2 Grey water inlet (For system with black water treatment only)
Location

Clean water chamber

Pipe dimension

DN50

Standard

DIN

PN16

Nos. of inlets

1 off

4.3.3 Ventilation (to be connected to funnel)
Location

Bioreactor

chamber.

Pipe dimension

DN65

Standard

DIN

PN16

Nos. of inlets

1 off

4.3.4 Discharge
Location

After the discharge pump

Pipe dimension

DN50

Standard

DIN

PN16

Nos. of inlets

1 off

IMPORTANT!
If the discharge point is below the tank top, a swan neck must be installed and
its top should be at least 400 mm above the tank top.

4.3.5 Overflow (Not included, to be installed by yard)
Location

Direct to bilge tank or other dedicated tank. Install max. 400 mm
above tank top!

Pipe dimension

DN65

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4.4 Electric

connections

The electric power supply is 3 x 400 VAC / 50 Hz or 3 x 440 VAC / 60 Hz (should be stated
in the order) and it should be connected to the main switch and ground in the control cabinet,
see specifications

chapter 9, Electrical wiring diagrams

for more information.

Connections between control cabinet and pumps, UV etc are pre-wired at delivery, refer to

chapter 9, Electrical wiring diagrams

4.5 Ext. alarm connection
The external alarm has a normally closed contact or a normally open contact.
For more info we refer to

chapter 9, Electrical-wiring diagrams

4.6 External valves installed by yard (Not included)
The following valves to be installed by the Yard/Customer:

• Black, grey and galley water inlet

1 off sluice valve per inlet.

4.7 Vacuum system ( Optiopnal)
If the sewage treatment plant is connected to a vacuum system, see separate instructions from
the Supplier.

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5 Operations

For easy understanding please see

chapter 7, P&I Diagram and valve designation list

and

chapter 9, Electrical-wiring diagram

5.1 Start

• Close valves V01 (Tank II, Bioreactor chamber), V02 (Tank III, Settling tank), and

V08 (Bioreactor test cock).

• Open valve V03 (Tank IV, Clean water chamber).
• Fill up the unit with water.
• Open all valves between the water outlet and the overboard.
• Turn the main switch in position “ON”.
• Turn the switch S0 in position start.
• Turn the switch S1 in position Manual.
• Turn the switch S2 to start the discharge pump and check that the motor has the

correct rotation.

• Turn the switch S1 in position “AUTO”.

5.2 Normal

operation

• The valves V01 (Tank II, Bioreactor chamber), V02 (Tank III, Settling tank) and V08

(Bioreactor drain cock) should be closed.

• The valves V03 (Tank IV, Clean water chamber) should be opened.
• All valves between the water outlet and the overboard must be open.
• The main switch in position “ON”.
• The switch S1 in position “AUTO”.

Under normal operation are the P01 (macerating pump) and P03 (air blower) running
constantly. The level switches control the pump P02 (discharge pump); the discharge pump
starts when LS02 (high level) is indicated and stops when LS01 (low level) is indicated.

The solenoid valve V30 opens once every hour for 2 min (time set at delivery), when the
valves opens it will start the solids airlift from the settling tank back to bioreactor. The solids
airlift can be adjusted on the PLC inside the control cabinet. The frequency of the openings
and the opening time shall be so long so most of the sludge in the settling chamber is returned
back to the pre-treatment chamber, to avoid high concentration of suspended solids in the
discharge water.

5.3 Discharge of bioreactor and settling tank
Never discharge sewage and sludge when the ship is in harbour or in a restricted area. This
has to be done when the ship is in an unrestricted zone or to shore facilities via the Marpol
flange
To empty the bioreactor and the settling tank, proceed as follows:

• Set the switch S1 into “Manual”.
• Close valve V03 (Tank IV, Clean water chamber).
• Open valve V01 (Tank II, Bioreactor chamber) and V02 (Tank III, Settling tank).
• Turn the switch S4 to start the Discharge pump.
• Make the reverse of the points above before the start of filling up the plant.

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The degradation process in this plant is done mostly on the submerged plastic matrix on
which the degrading bacterial biomass adheres and rapidly grows. When the bioreactor tank is
emptied, there is therefore no total loss of the degradation process. The plant will work
normal just after a few hours after it has been filled again.

5.4 Maintenance
5.4.1 Daily

inspections

• Check that there are no alarm indications.

5.4.2 Weekly

inspection

• Check the sludge return from the settling chamber to the inlet through the plastic hose.

The manufacturer pre set this airlift of the solids to once every hour for 2 minutes.

o If there is still sludge in the water from the settling chamber, increase the

opening time with further 2 minutes of the solenoid valve V30, by changing
the time T2 in the PLC (Please check the PLC manual for information of how
to do this). The amount of sludge build up varies from time to time and from
ship to ship.

o If there is no water or sludge the airlift pipe or hose can be clogged. Clean the

pipe and hose with fresh water and check the airlift again.

• Check if there is or have been any leakage, in pipe, hose or tank connections.
• If the plant is supplied with a chemical dosing system, check that the chemical tank

has a sufficient amount liquid. If liquid is to be added, ensure that;

Gloves and safety goggles are used.
If any spilling of chemicals, wash away by using water.
If chemicals come in contact with skin, follow instructions in Safety

and Health Data Sheets.

• If the plant has duplicate Pumps, Air blowers etc. Change the stand by pump to

service pump, to get balance the running time.

5.4.3 Monthly

inspection

• Check the sludge content in the bioreactor.

o Fill an Imhof conical glass 0 – 1000 ml with 1000 ml sample from the test

cock V08.

o Leave the Imhof conical glass still for 30 minutes to let the sludge to settle.
o After 30 minutes check the level of sludge content.
o If the reading is below 500 ml the system is OK.
o If the reading is above 500 ml there is too much of sludge in the bioreactor, the

bioreactor needs to be emptied next time the ship is in an unrestricted zone.
Follow the steps in chapter 5.4.

5.4.4 Annual

inspection

Due to the build up of mineral sludge, the bioreactor needs to be emptied once every year.
This has to be done when the ship is in an unrestricted zone or to shore facilities via the
Marpol flange. Never discharge sludge when the ship is in harbour or in a restricted area.

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Follow the steps in chapter 5.4.

• When the bioreactor and the settling chamber are empty following can be done:

o Control the inner paint system.
o Control the diffusers, unscrew them and check if the membrane is all right.

They should be tightly fitted in both ends of the pipe.

5.4.5 Sewage treatment plant accessories maintenance

All the STP accessories needs different maintenance, read about their requirements in the
enclosed manuals. To check the condition of the macerating pump open the manhole for
the pre-treatment chamber. Pull the wire holding the pump check the condition of the
pump.

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Rev: A

BIO – STP 2

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6 Troubleshooting

The alarm indication lamp on the front of the control cabinet and the external alarm output is
affected by the high level alarm and if an over-current relays that have released. Open the
control cabinet and check the display on the PLC what have caused the alarm.

Inside control cabinet there is four glass fuses 5x20mm. Each fuse relate to it’s specific unit
as list below:

F1-F2:

1A:

Transformer

TR1

F3-F4:

1A: Internal manoeuvre voltage 220 VAC

The over current relays are adjusted as follows:

Q01:

2.05 A: Macerating pump

Q02:

6,3 A: Discharge pump

Q03:

2,8 A: Air blower

Procedure to reset: Open the control cabinet door and look visually at the Q01-Q03 and see
which of the over-current relay that is released, reset by push reset button. Check also if any
phase is missing by control the related terminals.

It could also be high level alarm in the unit, check what have caused the overflow in the
system.

At an overflow in the STP, check the following step.

• Check if the discharge pump P02 is working.
• Open the cover for the settling and clean water chamber (Tank III and IV).
• Empty the settling and clean water chamber (Tank III and IV).
• Check and clean the level switches.
• Flush and clean the clean water chamber (Tank IV) and the settling chamber (Tank

III).

• Restart the STP according to chapter 5.1.
• If the problem occurs again open the bioreactor and check if the plant is clogged.

If there is failure in specific units mounted on the skid. Consult the table of contents for each
unit’s specific manual in the binder.

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7 P&I

Diagram

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8 Mechanical GA drawings

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A-A

CHECK

REV

APPR.

DRAWN

FILE NAME

SIZE

ID NO

MODEL ID

SCALE

JOWA AB

TULEBO 865

Göteborg-SWEDEN

Teleph. +46 31 795 00 40

jowa bio stp2.iam

Per Blad

1 031001 PB

26-0002-01-

2003-02-10

JOWA BIO STP 2

1475

850

127

1605

130

150

315

834

CHECK

REV

APPR.

DRAWN

FILE NAME

SIZE

ID NO

MODEL ID

SCALE

JOWA AB

TULEBO 865

Göteborg-SWEDEN

Teleph. +46 31 795 00 40

jowa bio stp2.iam

Per Blad

1 031001 PB

26-0002-01-

2003-02-10

ISO

JOWA BIO STP 2

SINGLE DISCHARGE & AIR BLOWER

1 SETTLING LAMELLAS STP 2

1.500 kg

26-0002-01-09

1 BIOREACTOR MATRIX STP 2

5.000 kg

26-0002-01-10

1 AIR BLOWER DT 4.25

36.500 kg

26001-00004

1 CONTAINER 25L

0.5 kg

20054-25252

1 DRAIN COCK

BRASS 0.2 kg

26001-00007

1 DOSING PUMP

1.8 kg

26001-00006

3 Ball Valve DN50

5.530 kg

26001-00008

1 CONTROL CABINET

15.0 kg

26000-00201

1 DISCHARGE PUMP

GG-25

49 kg

26001-00001

1 MACERATING PUMP

GG-25

21.120 kg

26001-00002

2 DIFUSOR

1.518 kg

26-0002-01-27

1 JOWA BIO TANK STP2

S235

659.944 kg 26000-20120

ITE QT

DESCRIPTION

MTRL

MASS

ID NUMBER

GRAVITY WATER INLET DN100

VACUUM WATER INLET DN50

HOSPITAL WATER INLET DN50

VENTILATION DN65

GREY WATER FOR STERILISATION ONLY INLET DN50

DISCHARGE DN50

INSTRUMENT AIR INLET

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BIO – STP 2

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9 Electrical wiring diagrams

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10 Discharge pump

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11 Macerating Pump

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General

Available

Options

Liquids -

Dest. Market

Curve -

Graphs

Dimensions

GRS 100/2/

General Product Information
Impeller Type:

High head impeller and grinder on

Motor Power:

0.9 kW

Motor Revolutions:

2900 1/min

Diameter of Outlet:

1 ½" horizontal gas threaded open

Motor Phases:

Three-phase

Explosion-proof
Product:

Pump in NOT ex-proof version

Exploded drawing

Explain Name

Hydraulic Product Information

Max. Head: 20 m

Max. Capacity: 4 l/sec

Free Passage: Not applicable

Max. Temp. of Liquid Handled: 40 °C

PH of liquid handled: 6 to 10

Density of liquids handled: 1 kg/dm³

Viscosity of liquid handled: 1 mm²/s

Electrical / Motor Information

Rated Supplied Power: 0.9 kW

Rated Absorbed Power: 1.28 kW

Rated Absorbed Current 2.05A

Starting Current: Not available

Starting torque: Not available

Rated Cos Ø: 0.9

Max number of start-ups/hours: 20

Service Type: S1 submersible or w/sleeve

Motor Protection: IP 68

Insulation Class: F

Winding Type: Induction motor with dry winding and automatic overload

Impregnation Type: Doubly impregnated humidity-resistant winding

Direction of Rotation: Clockwise seen from top of electric pump

Rated yield: 70%

Number of ball bearings

installed:

Upper and lower permanently lubricated ball bearings

Lifting: With handle on motor cover

Cable type in Standard version: H07RN-F 4G1

Capacitor capacity: 0 mF

EX Certification Type:

Nr. EX Certificate:

Material of Manufacture

Motor Wrapping Material: EN-GJL-250 cast iron

Hydraulic Unit Mat.: EN-GJL-250 cast iron

Bolts and Screws Material: INOX A2 steel

OR Material: NBR-SBR rubber

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Gate Valves
Outlet Bends
Inlet Bends
Cables
Chains
Float Switches
Relays
Ejectors
Electrical Panels
Flow Valve

Sida 1 av 2

Zenit - Products

2002-12-18

http://www.zenit.net/products/AlberoProdottiG.asp?Page=Pompe&IDArticolo=02030...

Grinder Material: X102CrNiMo17Ku steel

Motor Shaft Material: X30Cr13 (AISI420) steel

Cooling jacket Material: Not applicable

General / Commercial Information

Motor Wrapping Material: EN-GJL-250 cast iron

Hydraulic Unit Mat.: EN-GJL-250 cast iron

Bolts and Screws Material: INOX A2 steel

OR Material: NBR-SBR rubber

Grinder Material: X102CrNiMo17Ku steel

Reference standards

EN 292-1; EN 292-2; CEI EN 60529; ISO 9906; CEI EN 60034-1.
CEI EN 60204; UNI ISO 6009; UNI EN 1561-1563; UNI EN 10098.
Low voltage directive 73/23/CEE.
Procedures specified by Zenit S.p.a. Quality System, UNI EN ISO 9001 (ISO 9001) certified,
certified.
Machines directive 89/392/CEE and successive amendments thereto (directives 91/368/CEE
electromagnetic compatibility directive 89/336/CEE

Sida 2 av 2

Zenit - Products

2002-12-18

http://www.zenit.net/products/AlberoProdottiG.asp?Page=Pompe&IDArticolo=02030...

HANDLE

CABLE

CABLE CLAMP PLUG

CABLE GLAND

RUBBER GASKET

MOTOR COVER

BEARING SUPPORT

UPPER BALL BEARING

SHAFT WITH ROTOR

10 O-RING
11 WINDING
12 STATOR
13 MOTOR CASE
14 LOWER BEARING HOLDER

15 O-RING
16 SUPPORT WASHER

17 SEEGER
18 LOWER BALL BEARING

19 LIP SEAL
20 O-RING
21 SEALING FLANGE

22 SEEGER
23 SEEGER
24 GASKET
25 MECHANICAL SEAL

26 O-RING
27 INTERMEDIATE SUPPORT

28 PUMP BODY
29 IMPELLER
30 KEY
31 FOOT BASE SUPPORT

32 REGISTERING GRUB SCREW

33 CUTTING DISK
34 CUTTER
35 BOX NUT
36 IMPELLER BUSH

37 STRAINER
38 WASHER

Sida 1 av 1

Famiglia Dreno

2002-12-18

http://www.zenit.net/html/Esplosi/EN/Esploso28.htm

Date: 2003-04-02

JOWA

Rev: A

BIO – STP 2

Sign: PB

12 Metering pump

K:\1-NYA K\1-JOWA PROJEKT\Sewage unit\JOWA BIO STP\Manual\JOWA Bioreactor
STP manual STP 2.doc

Read this manual before use of product

IWAKI

Electromagnetic Metering Pump

ES Type

Instruction Manual

T324-2 02/06

( )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)

Germany

: IWAKI EUROPE GmbH

Italy

: IWAKI Italia S.R.L.

Denmark

: IWAKI Pumper A/S

Sweden

: IWAKI Sverige AB

Finland

: IWAKI Suomi Oy

Norway

: IWAKI Norge AS

France

: IWAKI France S.A.

U.K.

: IWAKI PUMPS (UK) LTD

Switzerland : IWAKI (Schweiz) AG
Austria

: IWAKI (Austria) GmbH

Holland

: IWAKI Holland B.V.

Spain

: IWAKI Iberica Pumps,S.A.

Belgium

: IWAKI Belgium n.v.

TEL : (49)2154 9254 0 FAX : 2154 1028
TEL : (39)02 990 3931 FAX : 02 990 42888
TEL : (45)48 24 2345

FAX : 48 24 2346

TEL : (46)8 511 72900 FAX : 8 511 72922
TEL : (358)9 2742714

FAX : 9 2742715

TEL : (47)66 81 16 60

FAX : 66 81 16 61

TEL : (33)1 69 63 33 70 FAX : 1 64 49 92 73
TEL : (44)1743 231363 FAX : 1743 366507
TEL : (41)32 3235024

FAX : 32 3226084

TEL : (43)2236 33469

FAX : 2236 33469

TEL : (31)297 241121

FAX : 297 273902

TEL : (34)943 630030

FAX : 943 628799

TEL : (32)1430 7007

FAX : 1430 7008

U.S.A.

: IWAKI WALCHEM Corporation

Australia

: IWAKI Pumps Australia Pty. Ltd.

Singapore : IWAKI Singapore Pte. Ltd.
Indonesia : IWAKI Singapore (Indonesia Branch)
Malaysia

: IWAKIm Sdn. Bhd.

Taiwan

: IWAKI Pumps Taiwan Co., Ltd.

Thailand

: IWAKI (Thailand) Co.,Ltd.

Hong Kong : IWAKI Pumps Co., Ltd.
China

: IWAKI Pumps Co., Ltd. (Guangzhou office)

China

: IWAKI Pumps Co., Ltd. (Beijing office)

China

: IWAKI Pumps (Shanghai) Co., Ltd.

Philippines : IWAKI Chemical Pumps Philippines, Inc.
Korea

: IWAKI Korea Co.,Ltd.

TEL : (1)508 429 1440 FAX : 508 429 1386
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
TEL : (86)20 8130 0605 FAX : 20 8130 0601
TEL : (86)10 6442 7713 FAX : 10 6442 7712
TEL : (86)21 6272 7502 FAX : 21 6272 6929
TEL : (63)2 888 0245

FAX : 2 843 3096

TEL : (82)2 3474 0523 FAX : 2 3474 0221

Thank you for choosing an Iwaki s ES Series pump. This instruction manual deals with the correct
installation, operation, maintenance, and troubleshooting procedures for the ES model pump. Please
read through it carefully to ensure the optimum performance, safety and service of your pump.

TABLE OF CONTENTS

IMPORTANT INSTRUCTION

------------------------------------------1

Safety Section

------------------------------------------1

1.0 INTRODUCTION ------------------------------------------5
1.1

Welcome

------------------------------------------5

1.2

Safety and Caution Notes

------------------------------------------5

1.3

Principle

Operation

------------------------------------------5

1.4

Specifications

------------------------------------------6

2.0 INSTALLTION

------------------------------------------7

2.1

Unpacking

------------------------------------------7

2.2

Location

------------------------------------------7

2.3

Supply

Tubing

------------------------------------------8

2.4

Discharge

Tubing

------------------------------------------8

2.5

Electrical

------------------------------------------8

0 OPERATION

------------------------------------------9

3.1 Priming

------------------------------------------9

3.2 Adjustment

------------------------------------------9

3.3

Calibration

----------------------------------------10

0 MAINTENANCE

----------------------------------------11

4.1 Diaphragm

Replacement

----------------------------------------11

4.2 Valve

Replacement

----------------------------------------11

4.4 Consumable

parts

----------------------------------------11

0 Troubleshooting

----------------------------------------12

0 Model Code & Exploded View ----------------------------------------13

6.1 Model

Code

----------------------------------------13

6.2 Dimensions

----------------------------------------14

6.3 Exploded

View

----------------------------------------15

4.3 Tubing

----------------------------------------11

Important Instruction

Read the "Safety Instructions" sections carefully to prevent accidents involving you 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.

The symbols relate to the following meanings described below.

Warning.

Nonobservance or misapplication of the contents of the "Warning"
section could lead to a serious accident, including death or injury.

Caution.

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.

For the Safe and Correct Handling of the Pump

Safety Section

Warning.

Turn off the power supply
Working without disconnecting the power supply 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.

Electrical

Shock

Terminate operation
When you detect or become aware of a dangerous sign or abnormal condition
during operation, terminate the operation immediately and start from the
beginning again.

For specified application only
The use of a pump in any application other than those clearly specified may
result in injury or damage to the pump. Use the pump strictly in accordance with
the pump specifications and application range.

Prohibited

No remodeling
Never remodel a pump. Otherwise, a serious accident may result. IWAKI will not
be responsible for any accident or damage of any kind which is caused by the
user remodeling the pump without first obtaining permission or instructions from
IWAKI .

No Remodeling

Wear protectors
If you touch or come in contact with any type of hazardous chemical liquid,
including but not limited to chemicals, you may experience a serious injury.
Wear protective gear (protective mask, gloves, etc.) during the pump
operation.

Wear

protective gear

Operating site must be free of water and humidity
The pump is not designed to be complete water-proof or dust – proof. The use
of the pump in places where water splashes or humidity is high may result in an

Prohibited

electrical shock or short circuit.

Safety Section

Caution.

Qualified operators only
The pump operator and pump operation supervisor must not allow any operators
who have little or no knowledge of the pump to run operate the pump. Pump
operators must have a sound knowledge of the pump and its operation.

Prohibited

Specified power only.
Do not operate the pump on voltage which is not specified on the nameplate.
Failure to do so may result in damage or fire. Only the specified power level is to
be applied

Prohibited

Do not run the pump dry.
Do not run the pump dry (without liquid inside the pump). Heat generated as a
result of abrasion between elements inside the pump during operation without
liquid may damage the inside of the pump.

Prohibited

Do not wet or dampen
If an electric part or wiring gets wet with the liquid spilled over accidentally, a fire
or electrical shock may be caused. install the system in a place free from liquid

Do not wet or

dampen

Ventilate
Poisoning may result during an operation, which involves toxic or odorous liquid.
Ventilate the operating site sufficiently.

Caution

Spill-out accident
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

Damaged pump
Never operate a damaged pump. A damaged pump may cause leakage or
electrical shock.

Prohibited

Do not damage or change power cable
Do not scratch, damage, process, or pull the power cable forcibly. An extra lode
onto the cable, such as heating the cable or placing something heavy on the

cable, may damage the cable and finally cause a fire or an electrical shock.

Caution

spillage or leakage.

Safety Section

Caution.

Install an earth leakage breaker (option)
The operation of a pump without using an earth leakage breaker may cause an
electrical shock. Please purchase an optional leakage breaker and install in the
system.

Electrical

Shock

Handling of power cable
Use of a defective or damaged power cable may result in a fire or electrical
shock. Handle the power cable carefully.

Electrical

Shock

Follow the instruction manual
Replace the consumable part by following the descriptions in the instruction
manual. Do not disassemble any part of the pump if the disassembling procedure
for the part in question is not included in the instruction manual.

Limited operating site and storage
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 (40

C or higher) or

extremely low (0

C or lower).

Prohibited

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

disposing company.)

1.0 Introduction

1.1 Welcome

Thank you for choosing an IWAKI ES Series metering pump. This instruction manual
deals with the correct installation, operation, maintenance and troubleshooting
procedures for the ES model metering pumps. Please read through it carefully to
ensure the optimum performance, safety and service of your pump.

1.2 Safety

and

Caution

Notes

Avoid areas where ambient temperature exceeds 40

C or falls below 0

C, or where

the pump or tubing would be exposed to direct sunlight.

Disconnect the pump from electrical power source before performing any
maintenance.

When working on or around a metering pump, always wear proper protective
clothing and equipment as recommended by the supplier of the liquid being pumped.

Depressurize the discharge tubing before disconnecting the tubing or performing any
maintenance on the pump.

1.3 Principle

Operation

The ES series electronic metering pump consists of a pump unit, a drive unit, and a
control unit. The drive unit is an electromagnetic solenoid. When the solenoid coil
is energized by the control unit the armature shaft moves forward due to the
magnetic force of the solenoid. The shaft is attached to a PTFE faced diaphragm
which is part of the pump unit. The diaphragm is forced into the pump head cavity
decreasing volume and increasing pressure which forces liquid in the pump head out
through the discharge check valves. When the solenoid coil is de-energized, a
spring returns the armature to its starting position. This action pulls the diaphragm
out of the head cavity increasing volume and decreasing pressure. Atmospheric
pressure then pushes liquid from the supply tank through the suction check valves to
refill the pump head.

1.0 Introduction

1.4 Specifications

Capacity/Pressure Rating

Size

Maximum Output

Capacity

(L/hr) (ml/min)

Output Per

Stroke (ml)

Connection

Size

Tubing (mm)

B10 2.28 38

0.11

1.0

4 x 6

B15 3.9 65

0.18

0.7

4 x 6

B20 5.7 95

0.26

0.4

4 x 6

B30 12.0 200

0.56

0.2

9 x 12

Adjustment Range
Recommended frequency adjustment range

0 to 360 strokes per minute

Materials of Construction

Liquid End

Code

Pump Head

& Fitting

Diaphragm

Valve

Ball

Valve

Seat

O-Ring Gasket

VC PVC

PTFE

(bonded to EPDM)

CE FKM FKM PTFE

CE Ceramic

EPDM

: Alumina
: Polytetrafluoroethylene
: Polyvinylchloride

Ethylene propylene diene monomer

PTFE FKM

Fluoroelastmer

PVC (translucent)

Electrical

ESB-N3 230

VAC

10% 0.3 Amp max. 16 watt avg.

50 Hz, single phase

Operating Conditions

Ambient temperature

C to 40

Relative humidity

35% to 90% non-condensing

Maximum

Pressure

MPa

2.0 Installation

2.1 Unpacking

Open the shipping carton and inspect contents for damage. If any items are
missing or damaged contact your local distributor to arrange for replacement.

2.2 Location

Choose a location for the pump which is clean, dry, close to an electrical outlet, and
allows convenient access to frequency control and tubing connections. Avoid areas
where ambient temperature exceeds 40

C or falls below 0

C, or where the pump or

tubing would be exposed to direct sunlight. Flooded suction (mounting the pump
below the level of liquid in the supply tank) is strongly recommended, especially
when pumping liquids that readily generate gas bubbles. Sodium hypochlorite and
hydrogen peroxide are common examples of such liquids. (See Figure 1.)

If flooded suction mounting is not possible, a shelf adjacent to (but not directly
above) the supply tank often works well. (See Figure 2.)
The supply tank or cover can also be used if it has provisions for mounting a pump.
(See Figure 3.) In any case, the total suction lift should not exceed (1.0 m).

Figure 1

Figure 2

Figure 3

Flooded Suction

Shelf Mount

Tank Mount

2.0 Installation

2.3 Supply

tubing

The supply tubing run should be as short as possible. For flooded suction mounting,
install a shut-off valve with an appropriate tubing connector at the tank outlet. Cut a
length of tubing from the coil supplied and install between the shut-off valve and the
pump inlet fitting. For suction lift applications, install a foot valve on one end of
suction tubing and cut the tubing to a length such that the foot valve hangs vertically
about 25mm above the bottom of the tank. Avoid any loops in the tubing run that
could form a vapor trap. Running the tubing through a length of PVC pipe will help to
keep tubing straight.

2.4 Discharge

tubing

The discharge tubing run is less critical and can be any length required to reach the
application point. Avoid sharp bends or kinks in the tubing and protect the tubing
from sharp edges that could chafe or cut it. Install a check valve (optionally available)
at the injection point and connect the discharge tubing to the check valve.

Caution.

Any check valve using Hastelloy or other metal springs in liquid end is not
usable for chemicals (such as HCL) which corrode the Hastelloy or other
metal springs. Ask IWAKI for a special check valve for this application.

2.5 Electrical

Connect the pump power cord to a GROUNDED outlet supplying proper voltage.
Avoid branch circuits that also supply power to heavy machinery or other equipment
that could generate electrical interference.

3.0 Operation

Caution.

Do not operate the pump with a completely closed discharge-side
valve.
Operating the pump with the discharge-side valve fully closed may
lead to liquid leakage or pipe rupture. Make sure not to operate the
pump with the discharge-side valve closed.

Do not run the pump dry.
A pump, which has been run dry, may experience liquid leakage during
its liquid feeding operation. Make it a rule to run the pump after
supplying liquid inside the pump.
* Dry operation of the pump over a long time (longer than 30 minutes)
causes the pump to overheat and the pump unit (pump head, valve
guide etc.) to become deformed or the pump head attachment to
become loose, which may result in liquid leakage trouble.

Keep the pump head firmly assembled.
If the installation bolts on the pump head are loosened, liquid leakage
may result.
* Fasten the 4 hex. socket bolts tightly before starting the initial pump
operation. (The bolts may be loosened during storage or
transportation of the pump, depending upon the condition of each.)
* Fastening torque: 2.16 N• m
Tighten all the bolts fully by applying an equal amount of torque in a
diagonal order among the bolts.

3.1 Priming

Install the pump as described above. With the pump turned on, set frequency at
100%. If the pump is equipped with an air vent valve, open the knob 1/2 turn.
Liquid should move through the suction tubing and into the pump head. When
liquid starts running through the vent tubing, close the air vent knob and continue
with output adjustment described below. If the pump has no air vent valve,
disconnect the discharge tubing from the injection valve. When liquid enters the
discharge tubing at the pump head, set frequency to 0% to stop the pump and
reconnect the discharge tubing to the injection valve.

3.2 Adjustment

If less than full output is required, set the frequency to the approximate percentage
of maximum desired.

3.3 Calibration

If exact output calibration is required, first prime and adjust the pump as above.

Then connect a calibration column to the suction side of the pump. Turn the pump
on for one minute and read the amount of liquid pumped from the column. Adjust
the frequency up or down as necessary and check the output again. When the

desired output is reached, disconnect the calibration column and reconnect the
suction tubing. (See Figure 4.)

Figure 4

Calibration

4.0 Maintenance

Caution: Before working on the pump, disconnect the power
cord, depressurize the discharge tubing and drain or flush any
residual liquid for the pump head and valves.

4.1 Diaphragm

Replacement

Remove the power cord from the electrical outlet and disconnect the suction tubing,
discharge tubing, and air vent tubing. Remove the four head bolts with a 4mm or
5mm hex wrench. Unscrew the diaphragm and remove its retainer (small disk
behind the diaphragm). Install the new retainer and diaphragm on the shaft. Turn
the diaphragm clockwise until it bottoms on the shaft. Replace the pump head and
tighten the head bolts to a torque of 2.16 N-m.

4.2 Valve

Replacement

Remove the suction and discharge tubing. Remove the suction fitting, the valve
ass y (consists of 2 x valve ball, 2 x valve seat, 2 x valve guide, 1 x gasket & 1 x
o-ring). Install the new valve ass y. Be sure both valve seats are in the same
orientation. Refer to Figure 5, below. Tighten the suction fitting. Similarly remove
and replace the discharge valve ass y.

Figure 5

Valve Ass y Orientation

4.3 Tubing

Check ends of tubing for splits, cracks or thin spots. Examine the full length of
tubing for damage due to chafing, abrasion, stress cracks, excessive temperature or
exposure to ultraviolet light (direct sunlight or mercury vapor lamps). If any signs of
deterioration exist, replace the entire length of tubing. It is a good idea to replace

FLOW

Valve Guide

Ball

Valve Seat

Gasket

discharge tubing on a regular preventive maintenance schedule every 12 months.

Part

Qty.

Replacement

Timing

Valve set

Diaphragm

2 sets

Approx.

8,000 hrs.

4.4 Consumable

parts

The durability of expendable parts depends on the pressure, temperature, and
properties of the liquid handled. The value in the above table is obtained from a
continuous run of the pump using clean water at ambient temperature. Take the value
as a guideline for replacement.

5.0 Troubleshooting

Caution: Before Working on the pump disconnect the power cord,
depressurize the discharge tubing and drain or flush any residual
liquid from the pump head and valves.

Problem

Possible Cause

Corrective Action

- Faulty wiring

- Correct wiring

- Improper voltage

- Connect to proper voltage source

Pump does not
start

- Electronic control unit is
damaged

- Replace control unit

- Air in suction tubing

- Reroute suction tubing to
eliminate air trap

- Valve gasket is not installed

- Install valve gasket

- Valve ass’y direction is wrong.

- Reassemble valve ass’y

- Pump is air locked

- Open air vent valve

- Suction or discharge valve is
clogged with foreign matter

- Disassemble, inspect, clean

Pump does not
prime

- Adhesion of valve onto valve
seat

- Disassemble, inspect, clean

- Suction or discharge valve is
clogged with foreign matter

- Disassemble, inspect, clean

- Air is trapped in pump

- Open air vent valve

- Overfeeding

- Install injection valve or back
pressure valve

Output fluctuates

- Diaphragm is damaged

- Replace diaphragm

- Fitting or coupling nut is loose

- Tighten

- Pump head is loose

- Tighten pump head bolts
- Torque: 2.16 N-m

- Diaphragm is damaged

- Replace diaphragm

Liquid leaks

- O-ring or valve gasket missing

- Install o-ring or valve gasket

6.0 Model Code, Dimensions & Exploded View

6.1 Model

Code

ES – B15 VC N – 3

e r

: Pump

Series

ES :

Electronic metering pump with manual speed control
(adjustable to 360 strokes per minute)

: Capacity/Pressure Rating

Size

Maximum Output

Capacity

(L/hr) (ml/min)

Output

Per Stroke (ml)

Connection

Size

Tubing (mm)

B10 2.28 38

0.11

1.0

4 x

B15 3.9 65

0.18

0.7

4 x

B20 5.7 95

0.26

0.4

4 x

B30 12 200

0.56

0.2

9 x

: Liquid End

Liquid End

Code

Pump Head

& Fitting

Diaphragm

Valve

Ball

Valve

Seat

O-Ring Gasket

VC PVC

PTFE

(bonded to EPDM)

CE FKM FKM PTFE

: Control Module

For all ES-B models with plug, Fixed stroke length only.

: Voltage

230 VAC, 50 Hz

Maximum

Pressure

MPa

6.0 Model Code, Dimensions & Exploded View

6.2 Dimensions

mm]

[

Model

A B C D E F G H J L

P&Q

Tubing

ES-B10VC N-3

ES-B15VC N-3

ES-B20VC N-3

81.5

22 2 90 37 5 150

184

175

4 x

100

ES-B30VC

N-3

81.5

26 2 90 16 5 - 172

8 158

9 x

100

Mounting Dimensions

ES all variations

6.2

6.0 Model Code, Dimensions & Exploded View

6.3Exploded View (for B-10/15/20)

Models with thermoplastic liquid end materials and air vent valve

ES-B30

A : Air Vent Ass y

B : Valve Ass y

D : Control Unit

C : Drive Unit

Q’ty per Item

Item Description Material

B10

B15

B20 B30

1 Head,

PVC

1 Head,

PVC

1 Head,

PVC

1 Head,

PVC

Fitting,

4 x

PVC 1

Fitting nut,

4 x

PVC 3

Fitting,

9 x

PVC

Fitting nut,

9 x

PVC

Air vent body B

PVC

6 Lock

nut

PVC

7 Diaphragm,

10 PTFE+EPDM

7 Diaphragm,

15 PTFE+EPDM

7 Diaphragm,

20 PTFE+EPDM

7 Diaphragm,

30 PTFE+EPDM

9 Retainer,

PPS

9 Retainer,

PPS

9 Retainer,

PPS

9 Retainer,

PPS

Air vent body A

PVC

11 Valve

guide

PVC

Valve seat, .

FKM-A

Valve ball, .

14 Gasket,

PTFE

17 O-ring,

S14

FKM

18 Spacer:0.2,0.3,0.5,0.7mm

Brass

Bolt, M4X34

SUS304 equivalent

Bolt, M4X36

SUS304 equivalent

23 Adjusting

Screw

PVC

25 O-ring,

FKM-A

26 O-ring,

P10A

FKM-A

27 O-ring,

FKM-A

38 Gasket

EPDM

39 Cord Gasket E

6mm

NBR 1

41 Cord

Nut

POM

42 Case

Gasket

NBR

Control unit case

PPE

Control unit cover

PPE

45 SF

Gasket

EPDM

46 SF

Knob

Screw 4x25

SUS304 equivalent

48 Terminal

Gasket

NBR

53 Pump

body

PPG

52 Plug

55 Cap

Gasket

EPDM

56 Screw,

M3x35 SUS304

equivalent

Read this manual before use of product

IWAKI

Electromagnetic Metering Pump

ES Type

Instruction Manual

T324-2 02/06

( )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)

Germany

: IWAKI EUROPE GmbH

Italy

: IWAKI Italia S.R.L.

Denmark

: IWAKI Pumper A/S

Sweden

: IWAKI Sverige AB

Finland

: IWAKI Suomi Oy

Norway

: IWAKI Norge AS

France

: IWAKI France S.A.

U.K.

: IWAKI PUMPS (UK) LTD

Switzerland : IWAKI (Schweiz) AG
Austria

: IWAKI (Austria) GmbH

Holland

: IWAKI Holland B.V.

Spain

: IWAKI Iberica Pumps,S.A.

Belgium

: IWAKI Belgium n.v.

TEL : (49)2154 9254 0 FAX : 2154 1028
TEL : (39)02 990 3931 FAX : 02 990 42888
TEL : (45)48 24 2345

FAX : 48 24 2346

TEL : (46)8 511 72900 FAX : 8 511 72922
TEL : (358)9 2742714

FAX : 9 2742715

TEL : (47)66 81 16 60

FAX : 66 81 16 61

TEL : (33)1 69 63 33 70 FAX : 1 64 49 92 73
TEL : (44)1743 231363 FAX : 1743 366507
TEL : (41)32 3235024

FAX : 32 3226084

TEL : (43)2236 33469

FAX : 2236 33469

TEL : (31)297 241121

FAX : 297 273902

TEL : (34)943 630030

FAX : 943 628799

TEL : (32)1430 7007

FAX : 1430 7008

U.S.A.

: IWAKI WALCHEM Corporation

Australia

: IWAKI Pumps Australia Pty. Ltd.

Singapore : IWAKI Singapore Pte. Ltd.
Indonesia : IWAKI Singapore (Indonesia Branch)
Malaysia

: IWAKIm Sdn. Bhd.

Taiwan

: IWAKI Pumps Taiwan Co., Ltd.

Thailand

: IWAKI (Thailand) Co.,Ltd.

Hong Kong : IWAKI Pumps Co., Ltd.
China

: IWAKI Pumps Co., Ltd. (Guangzhou office)

China

: IWAKI Pumps Co., Ltd. (Beijing office)

China

: IWAKI Pumps (Shanghai) Co., Ltd.

Philippines : IWAKI Chemical Pumps Philippines, Inc.
Korea

: IWAKI Korea Co.,Ltd.

TEL : (1)508 429 1440 FAX : 508 429 1386
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
TEL : (86)20 8130 0605 FAX : 20 8130 0601
TEL : (86)10 6442 7713 FAX : 10 6442 7712
TEL : (86)21 6272 7502 FAX : 21 6272 6929
TEL : (63)2 888 0245

FAX : 2 843 3096

TEL : (82)2 3474 0523 FAX : 2 3474 0221

Date: 2003-04-02

JOWA

Rev: A

BIO – STP 2

Sign: PB

13 Air blower

K:\1-NYA K\1-JOWA PROJEKT\Sewage unit\JOWA BIO STP\Manual\JOWA Bioreactor
STP manual STP 2.doc

www.becker-international.com

Ersatzteilliste
Spare parts list
Liste de pièces de rechange
Listino pezzi di ricambio
Lista de piezas de recambio
Lista de peças sobresselentes
Reserveonderdelenlijst
Reservedelsliste
Reservdelslista

Reservedelsliste
Varaosaluettelo
Wykaz czêœci zamiennych
Seznam náhradních dílù
Tartalékalkatrész lista

Wartung

Maintenance
Entretien
Manutenzione
Mantenimiento

Menge *
Quantity *
Quantité *
Quantità *
Cantidad *

Bestell-Nr.
Ident No.
No. Identification
No. Identificazione
No. de pedido

Bezeichnung
Description
Designation
Designazione
Descripcion

Pos.

Gebr. Becker GmbH & Co.KG
Hölker Feld 29-31

D-42279 Wuppertal

* erforderlich / necessary / nécessaire / necessaria / necesaria

SERVICE

XXXX

XXXX
XXXX

Index
Option

Tel:
Fax:
E-Mail:

Service:

+49 (0)202 697-171
+49 (0)202 64 44 74
info@becker-international.com

www.becker-international.com

28010200000 08/2004

DT 4.25K
DT 4.40K

XXXXXXX

DT 4.25K

-XX

Index A

901349 00000

909505 00000

901352 00000

909505 00000

Schieber, Rotor Vane, Palette, Silenciador

Filterpatrone, Filter cartridge, Cartouche
Filtrante, Cartuccia filtro, Cartucho de filtro

Schieber, Rotor Vane, Palette, Silenciador

Filterpatrone, Filter cartridge, Cartouche
Filtrante, Cartuccia filtro, Cartucho de filtro

DT 4.25K

DT 4.40K

www.becker-international.com

Index

DT 4.25K

DT 4.40K

15
16
17
18
19
21
22
23
24
25
28
29
30
33
34
35
46
48
49
50
61
67
72
76
77
78
83
84
85
88
89
90
91
92
94
95
96
97
98
101
102
103
104
125
126
130

020000 16400
016800 16500
911012 00000
949203 00000
945320 00000
000100 27500
951806 00000
945320 00000
901349 00000
952009 00000
000701 27600
945373 00000
008900 16500
560200 27500
005700 27600
945325 00000
502300 16400
947713 00000
949454 00000
901804 00000
004803 27600
009000 16300
909505 00000
945373 00000
948021 00000
913161 00000
006800 27500
742609 01000
951920 00000
006803 27600
741365 00000
945318 00000
951922 00000
964108 00000
015100 27600
951921 00000
068000 27600
945328 00000
949451 00000
833903 99597
951906 00000
068002 16500
548800 16300
728003 99611
943132 00000
951225 00000

DT 4.40K

DT 4.40K/0-06

(1~)

(3~)

15
16
17
18
19
21
23
24
25
28
29
30
33
34
35
46
48
49
50
61
67
72
76
77
78
83
84
85
88
89
90
91
92
94
95
96
97
98
101
102
103
104
125
126
130

020000 16500
016800 16500
911008 00000
949203 00000
945320 00000
000100 27600
945322 00000
901352 00000
952009 00000
000701 27600
945374 00000
008900 16500
560200 27600
005700 27600
945325 00000
902300 27600
947713 00000
949454 00000
901804 00000
004803 27600
009000 16300
909505 00000
945373 00000
948021 00000
913161 00000
006800 27600
742609 01000
951920 00000
006803 27600
741365 00000
945318 00000
951922 00000
964108 00000
015100 27600
951921 00000
068000 27600
945328 00000
949451 00000
833903 99597
951906 00000
068002 16500
548800 16300
728003 99611
943133 00000
951225 00000

DT 4.25K

DT 4.25K/0-06

(1~)

(3~)

Description

Pos.

Ident No.

OPTIONAL

Items different from standard appliance see appendix (back of drawing)

ROTOR
CLAMPING DISC
STAR-TOLERANCE-RING
TOOTHED SPRING WASHER
SOCKET HEAD SCREW
PUMP BODY
LOCATING PEG
SOCKET HEAD SCREW
CARBON VANES

(7x)

LOCATING PEG
LID
SOCKET HEAD SCREW
GASKET
COOLER
GASKET
SOCKET HEAD SCREW
FAN
KEY
WASHER
SHAFT END BOLD
FILTER COVER
LEAF SPRING
FILTER CARTRIDGE C 75/2

(1x)

SOCKET HEAD SCREW
SEALING RING
O-RING
PROTECTING HOOD
TUBE FLEXIBLE
RUBBER ELEMENT
PROTECTING HOOD
RUBBER BUFFER
SOCKET HEAD SCREW
RUBBER ELEMENT
EDGE PROTECTION
FOOT
RUBBER ELEMENT
SPACING COLLAR
SOCKET HEAD SCREW
WASHER
VALVE DISC
RUBBER BUSHING
SPACER TUBE
RING SCREW
PRESSURE REGUL. VALVE
NOZZLE
LOCKING SCREW

Design - single-phase AC

Design - without filter / three phase AC

necessary order quantity / maintenance

Description

OPTIONAL

Items different from standard appliance see appendix (back of drawing)

Pos.

Ident No.

necessary order quantity / maintenance

Design -

single-phase AC

Design - without filter / three phase AC

ROTOR
CLAMPING DISC
STAR-TOLERANCE-RING
TOOTHED SPRING WASHER
SOCKET HEAD SCREW
PUMP BODY
SOCKET HEAD SCREW
CARBON VANES

(7x)

LOCATING PEG
LID
SOCKET HEAD SCREW
GASKET
COOLER
GASKET
SOCKET HEAD SCREW
FAN
KEY
WASHER
SHAFT END BOLD
FILTER COVER
LEAF SPRING
FILTER CARTRIDGE C 75/2

(1x)

www.becker-international.com

standard

optional
en option
optionale
opcional

SER

VICE

øa

ød

C = ? µF

U = ? V

91 78 61

125

50 49

34 33 35

97 98

96 95

104 101 102 103

16 18

126

130

DT 4.25K (3~)

DT 4.40K (3~)

Index -

www.becker-international.com

standard

optional
en option
optionale
opcional

Variante(n)
Modifications
Variantes

Pos

Beschreibung / Description / Designation / Designazione / Desripcion

Bestell Nr. / Ident No. / No. Identification /
No. Identificazione / No. De pedido

12
13
83
83
94

25
28
30
61
67
72
76

77
78
88

125

126
130

WINKEL / BRACKET / COUDES / GOMITO / ÁNGULO
BLINDNIET / BLIND RIVET / RIVET AVEUGLIE / RIVETTO CIECO / REMACHE CIEGO
KABEL / CABLE / CABLE / CAVO / CABLE
DT 4.25K HAUBE / PROTECTING HOOD / CARTER PROTECTEUR / CARTER DI PROTEZIONE / CAPERUZA
DT 4.40K HAUBE / PROTECTING HOOD / CARTER PROTECTEUR / CARTER DI PROTEZIONE / CAPERUZA
FUSS / FOOT / PIED / PIEDE / PIE

SPANNHÜLSE / LOCATING PEG / DOVILLE DE ETRAGE / SPINE DI RISCONTRO / CASQUILLO TENSOR

SEITENDECKEL / LID / COUVERCLE / COPERCHIO / TAPA LATERAL

DICHTUNG / GASKET / JOINT / GUARNIZIONE / JUNTA
FILTERDECKEL / FILTER COVER / COUVERCLE DU FILTRE / COPERCHIO FILTRO / TAPA DE FILTRO
ANPRESSFEDER / LEAF SPRING / RESSORT-JAME / MOLLA / MUELLE DE PRESIÓN
FILTERPATRONE / FILTER CARTRIDGE / CARTOUCHE FILTRANTE / CARTUCCIA FILTRO / CARTUCHO DE FILTRO
INNENSECHSKANTSCHRAUBE / SOCKET HEAD SCREW / VIS HEXAGONALE INTERNE / VITE ESAGONALE INTERNA /
TORNILLO HEXAGONAL INTERIOR
DICHTRING / SEALING RING / JOINT / ANELLO GUARNIZIONE / ANILLO DE JUNTA
O-RING / O-RING / ANNEAU-O / ANELLO-O / JUNTA TÓRICA

FRONTHAUBE / PROTECTING HOOD / CARTER PROTECTEUR AVANT / CARTER DI PROTEZIONE /
CAPERUZA FRONTAL
GUMMI-PUFFER / RUBBER BUFFER / AMORTISSEUR EN CAOUTCHOUC / AMMORTIZZATORE IN GOMMA /
AMORTIGUADOR DE GOMA
INNENSECHSKANTSCHRAUBE / SOCKET HEAD SCREW / VIS HEXAGONALE INTERNE / VITE ESAGONALE INTERNA /
TORNILLO HEXAGONAL INTERIOR

GUMMIFORMTEIL / RUBBER ELEMENT / ELEMENT EN CAOUTCHOUC / ELEMENTO IN GOMMA / PIEZA DE ORMA DE GOMA
DRUCKREGULIERVENTIL / PRESSURE REGUL. VALVE / SOUPAPE REGLAGE PRESSION / VALVOLA REGULAZIONE
PRESS. / VÁLVULA REGULADORA DE PRESIÓN
DÜSE / NOZZLE / GICLEUR / UGELLO / TOBERA
VERSCHLUSS-SCHRAUBE / LOCKING SCREW / BOUCHON / VITE DI CHIUSURA / TORNILLO DE CIERRE

DT 4.25K

(1~)

DT 4.40K

(1~)

DT 4.25K/0-06

(3~)

DT 4.40K/0-06

(3~)

DT 4.25K (1~)
DT 4.25K/0-06 (3~)

DT 4.40K (1~)
DT 4.40K/0-06 (3~)

Index -

964233 00000
948766 00000
742002 30000
006802 27500
006804 27600
015101 27600

000702 27600

006810 27500

741310 90000

945377 00000

006800 27500
006800 27600
015100 27600

952009 00000
000701 27600
008900 16500
004803 27600
009000 16300
909505 00000
945373 00000

948021 00000
913161 00000
006803 27600

741365 00000

945318 00000

951922 00000
728003 99611

943132 00000
951225 00000

variantenabhängige Bauteile / variant-dependent components / composants variante-dependantes / componenti variante-dispendenti / componentes variante-dependientes

Date: 2003-04-02

JOWA

Rev: A

BIO – STP 2

Sign: PB

14 Level switches

K:\1-NYA K\1-JOWA PROJEKT\Sewage unit\JOWA BIO STP\Manual\JOWA Bioreactor
STP manual STP 2.doc

Date: 2003-04-02

JOWA

Rev: A

BIO – STP 2

Sign: PB

15 PLC Manual

K:\1-NYA K\1-JOWA PROJEKT\Sewage unit\JOWA BIO STP\Manual\JOWA Bioreactor
STP manual STP 2.doc

LOGO! Manual

A5E00119092-01

152

5.1 Switching To Parameter Assignment

Mode

In RUN mode, you can switch to parameter assignment
mode by pressing the ESC key:

06.21.01

Mo 09:30

ESC

...and press

LOGO! switches to parameter assignment mode and dis-
plays Parameter assignment menu:

>Stop
Set Param
Set Clock
Prg Name

Description of the four menu options in the parameter assign-
ment menu

Stop

You are going to use this menu item to stop your program
and, as a result, open the main menu in programming
mode. Proceed as follows:

1. Move the ’>’ character to ’Stop’:

per or

2. Confirm the ’Stop’:

Stop Prg
>No
Yes

3. Move the ’>’ character to ’Yes’:

per or

4. Confirm ’Yes’:

Configuring LOGO!

153

LOGO! Manual
A5E00119092-01

LOGO! returns to the main menu:

>Program..
PC/Card..
Clock..
Start

Set Param

The diverse parameters are described in the following
Chapters 5.1.1 to 5.1.3.

Set Clock

The menu item ’Set Clock’ is only executed in a LOGO!
equipped with a clock (LOGO!..C). In ’Set Clock’ you can
set the internal clock of the LOGO!. Closer detail in sec-
tion 5.2.

Prg Name

Under this menu item you can only read your program
name. In parameter assignment mode it is not possible to
change the program name.

5.1.1 Parameter

Parameters are:

The delay times of a timer relay.

The switching times (cams) of a timer switch.

The threshold value of a counter

The monitoring time for an operating hours counter

The switching thresholds of a threshold switch.

Each one of the parameters is identified by its block num-
ber and mnemonics. Examples:

B01:T

Block number

Mnemonic

T: ...is a configurable time.

Cam 1: ...is the first cam of a timer switch.

Par: ...denotes multiple counter parameters that can be
monitored.

Configuring LOGO!

LOGO! Manual

A5E00119092-01

154

5.1.2 Selecting the Parameters

Select a parameter:

1. In the parameter assignment menu via ’Set Param’ op-

tion
or

STOP
>Set Param
Set Clock
Prg Name

2. Press OK

LOGO! displays the first parameter. If parameters can-
not be set, you can use ESC to return to the parameter
assignment menu.

B01:T

= 00:00m

T = 12:00m

Parameter

Value set for the parameter

the current time in the LOGO!

Press ESC

No Param

Parameters cannot be changed:
ESC returns you to the parameter
assignment menu

3. Now, Select the desired parameter:

Use the or
LOGO! displays one parameter respectively in separate
windows.

4. If you want to edit a parameter, select it and press OK.

Configuring LOGO!

155

LOGO! Manual
A5E00119092-01

5.1.3 Changing the Parameters

To change a parameter, you first have to select it (see ”Se-
lecting a parameter).

You change the value of the parameter in the same way as
you entered it in programming mode:

1. Move the cursor to the point at which you want to make

the
change: per

2. Change the value:

per or

3. Confirm the value:

B01:T

= 00:00m

Move:

Change the value:

Done: OK

T =

1:00m

Note

In parameter assignment mode, you cannot change the
unit of the delay time or the parameter protection for the
parameter T. This is only possible in programming mode.

Current value of a time T

If you view a time T in parameter assignment mode, it look
like this:

B01:T

= 00:00m

T = 12:00m

Set time T

Current time T

You can change the set time T (see ”Changing a parame-
ter).

Configuring LOGO!

LOGO! Manual

A5E00119092-01

156

Current value of the timer switch

If you view a cam of a timer switch in parameter assign-
ment mode, it looks like this, for example:

The timer switch is off (sta-
tus ’0’ at the output)

The timer switch is on
(status ’1’ at the output)

B02:Cam 1

Off=10:00

Day = Su

The circuit state of the timer switch
is displayed:

On =09:00

LOGO! displays the circuit state of the timer switch rather
than the circuit state of a cam. The circuit state of the timer
switch depends on all three cams (Cam 1, Cam 2 and
Cam 3).

Current value of a counter

If you view the parameter of a counter in parameter assign-
ment mode, it looks like this:

Cnt=000028

Lim=000300

B03:Par

Switching threshold

Current count value

Current value of an operating hours counter

If you view the parameter of an operating hours counter in
parameter assignment mode, it looks like this:

B05:Par
MI = 0100h
MN = 0017h
OT =00083h

time–to–go

Operating hours elapsed

Monitoring time

Configuring LOGO!

157

LOGO! Manual
A5E00119092-01

Current value of a threshold switch

If you view the parameter of a threshold switch in parame-
ter assignment mode, it looks like this:

B06:Par

Off threshold

Measured value

On threshold

=0050

=0048

=0012

Configuring LOGO!

LOGO! Manual

A5E00119092-01

158

5.2 Setting the Time–of–day and the Date

(LOGO! ... C)

You can set the TOD and the date

In parameter assignment mode

In programming mode.

How to set the TOD and the date in parameter assignment
mode:

1. Open the parameter assignment mode (refer to Chap-

ter 5.1)

2. Select ’Set Clock’ ( or ) and press OK.

Set Clock
_Th 15:30
MM.DD.YY
06.21.01

The cursor position
precedes the day of
the week.

3. Select the day of the week:

per or

4. Move the cursor to the next position:

per or

5. Change the value: per or

6. Set the correct TOD. Repeat steps 4 and 5.

7. Set the correct date. Repeat steps 4 and 5

8. Close your entries:

How to set the TOD and the date in programming mode:

1. Switch to programming mode: In RUN, execute the

menu item ’Stop’. (see page 45)

2. Select ’Clock..’ ( or ) and press OK.

3. Select ’Set Clock’ ( or ) and press OK

Now you can set the day of the week and the time, as de-
scribed above (as of step 3.).

Configuring LOGO!

Date: 2003-04-02

JOWA

Rev: A

BIO – STP 2

Sign: PB

16 Spare part list

Description

Part

Number

Designation

Diffuser membrane

26001-00009

Pneumatic Valve, normally closed DN15 93003-15006

V30

Level switch JOLA SSP-3K

27050-00001

LS01, 02, 03

* Fuse

20600-00100 FU1

For the Discharge pump

Ball bearing - 27

60000-60019

P02

Ball bearing - 28

60000-60020

P02

Mechanical

Seal

60000-60018 P02

For the Air Blower

Filter Cartridge - 72

P03

Filter Cartridge - 73

P03

Filter Cartridge - 74

P03

Carbon Vanes - 24

P03

For the Macerating Pump

Ball bearing - Lower

P01

Ball bearing - Upper

P01

Mechanical

Seal

P01

For the Metering Pump
Injection

nozzle

22500-02011 P04

Membrane

EH0562

P04

Double valve EH0070

P04

Recommended spare parts for 2 years of operation are items with an *.
Items with an ** are consumables, and is recommended to be Included for 2 years of
operation.

K:\1-NYA K\1-JOWA PROJEKT\Sewage unit\JOWA BIO STP\Manual\JOWA Bioreactor
STP manual STP 2.doc