Microsoft Word - JOWA BIO STP 2 manual revB

Date: 2008-04-09

JOWA

Rev: B.080409

BIO - STP

Sign: jim

K:\1-NYA K\1.3-JOWA PROJEKT\Sewage unit\JOWA BIO STP\Manual\JOWA BIO STP 2
manual revB.doc

Table of Contents

1.1

ENERAL

SYSTEM DESCRIPTION

SPECIFICATIONS

INSTALLATION INSTRUCTIONS

3.1 D

ELIVERY

3.2 JOWA

BIO

STP

LOCATION

3.3 E

XTERNAL PIPE CONNECTIONS

3.4 E

LECTRIC CONNECTIONS

3.5 E

ALARM CONNECTION

3.6 E

XTERNAL VALVES INSTALLED BY YARD

OT INCLUDED

)

3.7 V

ACUUM SYSTEM

OPERATIONS

4.1 S

TART UP

4.2 N

ORMAL OPERATION

4.3 N

ORMAL OPERATION WITH STERILISATION OF THE DISCHARGE WATER

4.4 D

ISCHARGE OF BIOREACTOR AND SETTLING TANK

4.5 M

AINTENANCE

TROUBLESHOOTING

P&I DIAGRAM

MECHANICAL GA DRAWINGS

ELECTRICAL WIRING DIAGRAMS

DISCHARGE PUMP

MACERATING PUMP

METERING PUMP (OPTIONAL)

AIR BLOWER

JOWA UV (OPTIONAL)

LEVEL SWITCHES

SPARE PART LIST

CERTIFICATES

VACUUM SYSTEM (OPTIONAL)

Date: 2008-04-09

JOWA

Rev: B.080409

BIO - STP

Sign: jim

K:\1-NYA K\1.3-JOWA PROJEKT\Sewage unit\JOWA BIO STP\Manual\JOWA BIO STP 2
manual revB.doc

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

Date: 2008-04-09

JOWA

Rev: B.080409

BIO - STP

Sign: jim

K:\1-NYA K\1.3-JOWA PROJEKT\Sewage unit\JOWA BIO STP\Manual\JOWA BIO STP 2
manual revB.doc

1 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 pre-treatment chamber and the macerating pump,
removing the requirement for the handling of septic solids and their costly disposal. In

Date: 2008-04-09

JOWA

Rev: B.080409

BIO - STP

Sign: jim

K:\1-NYA K\1.3-JOWA PROJEKT\Sewage unit\JOWA BIO STP\Manual\JOWA BIO STP 2
manual revB.doc

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 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.

Date: 080409
Rev:
Sign: Jim

JOWA BIO - STP

K:\1-NYA K\1.3-JOWA PROJEKT\Sewage unit\JOWA BIO STP\Manual\manual
delar\tech spec stp.doc

Specification all sizes

TYPE:

STP 1

STP 2

STP 3

STP 4

STP 5

STP 6

Capacity:
(At black water
gravity system)

10 P.E

25 P.E

35 P.E

50 P.E

75 P.E

200 P.E

Certified
hydraulic load:
(m3/d)

0,7 1,75

2,45

3,5 5,25

Certified
organic load:
(BOD

5/day)

0,51kg 1,29kg 1,8kg 2,57kg 3,86kg

10,29kg

Sterilization
Method:

Chlorine. (Std)

UV light. (option)

Ambient
temperature:

5-45

°C

Operation
pressure:

Atmospheric pressure

Dry COG:

X:381,06
Y:490,63
Z:577,59

X:398,29
Y:725,78
Z:828,11

X:395
Y:1043
Z:819

X:470,77
Y:1081
Z:935,860

X:407
Y:1441
Z:817

X:788
Y:2346
Z:933

Weight
(empty / full
kg)

510/
1050

792/
2172

965/
2965

1126/
3976

1435/
5672

2450/
13203

Power supply:

3 X 380 - 480 VAC / 50 / 60 Hz (Std. power supply)

Other as option.

Power
consumption:

4,1 kW

Protection
class:

IP54

Air supply:

4-6 Bar (instrument air)

Alarm:

Relay output, normally open/closed

Tank material:

Mild steel (stainless steel is option)

Painting: Acc.

Internationals paint spec.

Dimension:

Refer to chapter 8. MECHANICAL GA DRAWINGS

External pipe
connection:

Refer to P&I Diagram Chapter 7 and MECHANICAL GA
DRAWINGS chapter 8.

Date: 080409
Rev:
Sign: Jim

JOWA BIO - STP

K:\1-NYA K\1.3-JOWA PROJEKT\Sewage unit\JOWA BIO STP\Manual\manual
delar\tech spec stp.doc

BLOWER:

STP 1 STP 2 STP 3 STP 4 STP 5 STP 6

Type: Becker

DT 4.10

Becker
DT 4.10

Becker
DT 4.25

Becker
DT 4.40

Inlet capacity:

10-12
m3/h

25-30
m3/h

40-48
m3/h

Pressure: 1000

mbar.

Voltage: 175-520

VAC

175-520
VAC

190-500
VAC

Frequency:

50 / 60 Hz 3 phase

Power
Consumption:

0,37-
0,45 kW

1,1-1,3
kW

1,9-2,2
kW

Current: 1,33-

2,35 A

1,33-
2,35 A

2,8-6,2
A

4,5-10
A

R.P.M 1420-

1700

1420-
1700

1420-
1690

Protection

class: IP54 IP54 IP55 IP55 IP55 IP55

Macerating
pump:

Type:

Zenit. GRS 100/2/G40H AOCT

H: 18M

Q: 1L/S

Voltage: 460

VAC

Frequency:

60 Hz 3 phase

Power
Consumption:

0,9kW

Current: 1,99

R.P.M 3480

Protection class:

IP68

Date: 2008-04-09

JOWA

Rev: B.080409

BIO - STP

Sign: jim

K:\1-NYA K\1.3-JOWA PROJEKT\Sewage unit\JOWA BIO STP\Manual\JOWA BIO STP 2
manual revB.doc

3 Installation instructions

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

3.2  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.

3.3  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.

3.3.1 Black, grey and galley water inlet
Location

Bioreactor,

Pipe dimension

DN100

Standard

DIN

PN16

Nos. of inlets

1 off

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

Outlet

chamber

Pipe dimension

DN50

Standard

DIN

PN16

Nos. of inlets

1 off

3.3.3 Ventilation (to be connected to funnel)
Location

Bioreactor and settling chamber

Pipe dimension

DN65

Standard

DIN

PN16

Nos. of inlets

1 off

3.3.4 Discharge
Location

After the UV or 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.

3.3.5 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

DN50

Date: 2008-04-09

JOWA

Rev: B.080409

BIO - STP

Sign: jim

K:\1-NYA K\1.3-JOWA PROJEKT\Sewage unit\JOWA BIO STP\Manual\JOWA BIO STP 2
manual revB.doc

4 Operations

For easy understanding please see

chapter 7, P&I Diagram and valve designation list

and

chapter 9, Electrical-wiring diagram

4.1 Start up

• Close valves V02 (Settling tank), V03 (Bioreactor), V50 (Bioreactor drain cock) and

V51 (Discharge chamber drain cock).

•  Open valve V01 (Discharge) and V05 (UV bypass).
•  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 S3 to start the macerating pump and check that the motor has the

correct rotation.

• Turn the switch S4 and start the Air blower and check that the motor has the correct

rotation.

• Turn the switch S1 in position “AUTO”.

4.2 Normal operation

• The valves V02 (Settling tank), V03 (Bioreactor), V50 (Bioreactor drain cock) and

V51 (Discharge chamber drain cock) should be closed.

•  The valves V01 (Discharge) and V05 (UV bypass) 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, when the valves opens it will start
the solids airlift from the settling tank back to bioreactor.

4.3 Normal operation with sterilisation of the discharge water
Follow the points above in chapter 5.2 and turn the switch S6 to “Chemical dosing” or “UV
sterilisation”

4.3.1 Start up of sterilisation with chemical dosing (optional)
The producer prior to the delivery adjusts the metering pump do not change the adjustments.

• Fill the plastic chemical container with the sterilisation chemical.
• Turn the switch S6 to the position “Chemical dosing”

The metering pump starts after every discharge when the level switch LS01 (low level) is
indicated. The metering pump adds sufficient amount of chemicals for sterilisation of a full
discharge chamber.

Date: 2008-04-09

JOWA

Rev: B.080409

BIO - STP

Sign: jim

K:\1-NYA K\1.3-JOWA PROJEKT\Sewage unit\JOWA BIO STP\Manual\JOWA BIO STP 2
manual revB.doc

4.3.2 Start up of sterilisation with UV light (optional)
For detailed information regarding the operation of the UV please read the JOWA UV
manual, chapter 14. Note that this UV is not supplied with a solenoid valve.

•  Open valves V04 UV inlet.
•  Close valve V10 (UV bypass).
•  Fill up the chamber via manually running of the discharge pump. De-air the UV via

the valve V07.

• Turn on the main power on the UV control cabinet.
• Turn the switch S6 on the main control cabinet to the position “UV sterilisation”.

Note! Never run the UV without water in the UV chamber, this can destroy the UV lamps.
4.4 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 V01 and if the unit is supplied with a UV close also VO4.
•  Open valve V02 (settling tank), V03 (bioreactor tank) and V05.
•  Turn the switch S4 to start the Discharge pump.
•  Make the reverse of the points above before the start of filling up the plant.

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.

4.5 Maintenance
4.5.1 Daily inspections

• Check that there are no alarm indications.

4.5.2 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.

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.

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.

Date: 2008-04-09

JOWA

Rev: B.080409

BIO - STP

Sign: jim

K:\1-NYA K\1.3-JOWA PROJEKT\Sewage unit\JOWA BIO STP\Manual\JOWA BIO STP 2
manual revB.doc

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.

4.5.3 Monthly inspection

• When a UV steriliser is installed the chamber needs to be cleaned. Follow the steps in

the

UV Manual (chapter 5.1), chapter 14.

• Check the sludge content in the bioreactor.

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

cock V50.

Leave the Imhof conical glass still for 30 minutes to let the sludge to settle.

After 30 minutes check the level of sludge content.

If the reading is below 500 ml the system is OK.

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.

4.5.4 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.
Follow the steps in chapter 5.4.

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

Control the inner paint system.

Control the diffusers, unscrew them and check if the membrane is all right.

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

4.5.5 Sewage treatment plant accessories maintenance

All the STP accessories needs different maintenance, read about their requirements in the
enclosed manuals.

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

#2 080206 ES

26-0002-01-

2003-02-10

JOWA BIO STP 2

1475

850

124

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

#2 080206 ES

26-0002-01-

2003-02-10

ISO

JOWA BIO STP 2

SINGLE DISCHARGE & AIR BLOWER

26001-00006

1.721 kg

PVC

DOSAGE PUMP

26-0002-01-09

1.500 kg

SETTLING LAMELLAS STP 2

26-0002-01-10

5.000 kg

BIOREACTOR MATRIX STP 2

26001-00004

36.500 kg

AIR BLOWER DT 4.25

20054-25252

0.5 kg

CONTAINER 25L

26001-00007

0.2 kg

BRASS

DRAIN COCK

26001-00008

5.530 kg

Ball Valve DN50

26000-00201

15.0 kg

CONTROL CABINET

26001-00001

49 kg

GG-25

DISCHARGE PUMP

26001-00002

21.120 kg

GG-25

MACERATING PUMP

26-0002-01-27

1.057 kg

DIFUSOR

26000-20120

665.012 kg

S235

JOWA BIO TANK STP2

ID NUMBER

MASS

MTRL

DESCRIPTION

ITE

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

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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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
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30 KEY
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37 STRAINER
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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

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

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

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

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

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