IWAKI PUMPS APN-085-D4 Series User manual

Read this manual before use of product
IWAKI Air Pump
APN-085-D4
Instruction Manual

Thank you for selecting an IWAKI APN-085-D4 air pump. This
instruction manual deals with "Safety Instructions", "Outline",
"Installation", "Operation" and "Maintenance" sections.
Please read through this instruction manual to ensure the opti-
mum performance, safety and service of your pump.
This instruction manual should be kept on hand by the end user
for quick reference.
Contact us or your nearest distributor if you have any questions.
Contents
Safety Instructions ······················································· 1
Outline 1. Unpacking & Inspection····························· 3
2. Operating principle ·································· 3
3. Identification code···································· 4
4. Specifications ········································· 4
5. Outer dimension ······································ 5
6. Performance curve ··································· 6
7. Overview & Label···································· 6
8. Part names & Structure······························ 7
Installation 1. Before installation ···································· 8
2. Installation/Tubing/Electrical wiring ············ 10
Operation 1. Before operation ····································· 13
2. Pump operation ······································ 14
Maintenance 1. Troubleshooting······································ 16
2. Maintenance & Inspection ························· 16
3. Wear part replacement······························ 18
Important Instruction
WARNING
Nonobservance or misapplication of the
contents of “Warning” section could lead to
a serious accident which may result in death.
CAUTION
Nonobservance or misapplication of the
contents of “Caution” section could lead to
personal injury or property damage.
Types of Symbols
Indicates a prohibited action or procedure. Inside or near this cir-
cle, a concrete and practical image of the activity to be avoided is
depicted.
Indicates an important action or procedure which must be per-
formed or carried out without fail. Failure to follow the instruc-
tions herein can lead to malfunction or damage to the pump.
For the Safe and
Correct Handling of the Pump
●"Safety Instruction" section deals with important details about
handling of the product. Before use, read this section carefully for
the prevention of personnel injury or property damage.
●Observe the instructions accompanied with "WARNING" or
"CAUTION" in this manual. These instructions are very impor-
tant for protecting pump users from dangerous situations.
●The symbols on this instruction manual have the following meanings:
Export Restrictions
Technical information contained in this instruction manual might be
treated as controlled technology in your countries, due to agreements
in international regime for export control.
Please be reminded that export license/permission could be required
when this manual is provided, due to export control regulations of your
country.

● Turn off power before service
Risk of electrical shock. Be sure to turn off
power to stop the pump and related devices
before service is performed.
● Do not use the pump in any condition
other than its intended purpose
The use of the pump in any conditions other
than those clearly specified may result in
failure or injury. Use this product in specified
conditions only.
● Do not modify the pump
Alternations to the pump carries a high
degree of risk. It is not the manufacturer's
responsibility for any failure or injury resulting
from alterations to the pump.
● Wear protective clothing
Always wear protective clothing such as an
eye protection, chemical resistant gloves, a
mask and a face shield during disassembly,
assembly or maintenance work.
● Use specified power only
Do not apply power other than that speci-
fied on the nameplate. Otherwise failure or
fire may result. Ensure the pump is properly
grounded. - 1 -
Electrical shock
Prohibited
Prohibited
No remodeling
Wear protectors
WARNING
● Qualified personnel only
The pump should be handled or operated
by a qualified personnel with a full under-
standing of the pump.
● Ventilation
Fumes or vapours can be hazardous with
certain solutions. Ensure proper ventilation
at the operation site.
● Do not install or store the pump:
1. Where ambient temperature falls below
0°C or exceeds 40°C.
2. Under a flammable/corrosive atmos-
phere.
● Spill precautions
Ensure protection and containment of
solution in the event of plumbing or pump
damage (secondary containment).
● Keep electric parts and wiring dry
Risk of fire or electric shock. Install the
pump where it can be kept dry.
CAUTION
Safety Instructions
Prohibited
Prohibited
Caution
Caution
Prohibited

- 2 -
Prohibited
Electrical shock
Electrical shock
Prohibited
CAUTION CAUTION
Safety Instructions
●Do not use a damaged pump
Use of a damaged pump could lead to an
electric shock or death.
●Stop operation
If you notice any abnormal or dangerous
conditions, suspend operation immediately
and inspect/solve problems.
●Preventative maintenance
Follow instructions in this manual for
replacement of wear parts. Do not disas-
semble the pump beyond the extent of the
instructions.
●Do not damage the power cable
Do not pull, knot, or crush the power cable.
Damage to the power cable could lead to a
fire or electrical shock if cut or broken.
●Do not use the pump in a wet location
The pump is not waterproof. Use of the
pump in wet or extremely humid locations
could lead to electric shock or short circuit.
●Damaged power cable
Do not use any damaged power cable for
the prevention of a fire or electrical shock.
The cable is not replaceable, so that the
whole pump unit needs to be replaced
when the cable is damaged.
●Disposal of a used pump
Dispose of any used or damaged pump in
accordance with local rules and regulations.
If necessary, consult a licensed industrial
waste disposal company.

2. Operating principle
The APN-085-D4 is a diaphragm type air pump and is
designed to be built into various devices such as a gas
analyser and for contamination-free gas compression,
vacuum and delivery.
The rotary motion of the motor is converted through a
connecting rod to the reciprocation of the diaphragm in
the pump chamber, where gas is transferred from the inlet
to outlet.
- 3 -
Outline
Valve
Diaphragm
Connecting rod
IN OUT
Before use, check the specification, limitation and hazardous
nature of the pump.
1. Unpacking & Inspection
Open the package and check that the product conforms
to your order. If any problem or inconsistency is found,
immediately contact your distributor.
1. Check the nameplate to see if the information such as
model codes, discharge capacity and discharge pressure
are as ordered.
2. Check for transit damage, deformation and loose bolts.

- 4 -- 4 -
4. Specifications
■ Pump Performance at 24VDC (power voltage) and 5VDC (control signal)
Type
Max. air
ow
(L/min)
Max. dis-
charge
pressure
(MPa)
Max.
vacuum
(kPa)
Motor Connection
Weight
(kg)
Lowest
starting
temp.
(°C)
Power
con.
(W)
Rated
current
(A)
Tube Thread
APN-085V
60.08
61.3
15 1.2 ø8
Rc1/4
1.3
10
APN-085E
APN-085LV/HV
34.66
Rc1/4
or
G1/4
5
APN-085LE/HE
0
APN-085LN/HN
NOTE1. Observe the maximum discharge pressure of 0.08MPa.
NOTE2. Allowable gas temperature range is 0-40°C.
NOTE3. Allowable ambient temperature range is 0-40°C. Observe the
lowest starting temperature at the start of operation.
NOTE4. Both the inlet and outlet of the pump are Rc1/4 female thread
connections (JIS taper pipe thread) or G1/4 female thread
connections (JIS parallel pipe thread).
■ Wet end material
Parts Model
LN/HN VLV/HV ELE/HE
Pump head GFRPP
Diaphragm NBR FKM EPDM
Valve
Valve seat GFRPP
Retainer plate GFRPPS
-
GFRPPS
-
GFRPPS
Screw SUS304
equiv
SUS304
equiv
SUS304
equiv
Gasket (X1 type) FKM FKM FKM
GFRPP : Glass fiber reinforced polypropylene
NBR : Nitrile Butadiene Rubber
FKM : Fluorine-contained rubber
EPDM : Ethylene propylene diene monomer
GFRPPS : Glass fiber reinforced polypropylene sulfide
SUS304 : Austenite stainless steel
Outline
3. Identification code
APN - 085 L VX - D4 - 02
a b c d e f
a. Pump size
b. Pump head
No code : Corrosive resistant (Molded diaphragm )
L : High vacuum (Horizontally oriented)
H : High vacuum (Vertically oriented)
c. Diaphragm/Valve materials
N : NBR
E : EPDM
V : FKM
d. Pump connection
No code : ø8 tube connection
X : Rc1/4 female thread connection (JIS taper pipe thread)
X1 : G1/4 female thread connection (JIS parallel pipe thread)
e. Motor
D4 : 24V BLDC motor (with 1-5VDC control signal)
f. Special specification
No code : Standard
01-99 : Special design

- 5 -- 5 -
5. Outer dimension
■APN-085
■APN-085H
Outline
■APN-085L
ø8
ø4
2-Rc1/4
(130)
Total length(136)
(125)
5
17
80
ø71
12 12
APN-085-L type
2-Rc1/4 or 2-G1/4
5
ø8
ø4.8
18
(130)
Total length (140)
(122)
ø72
ø72
80
12 12
APN-085-H type
106
23
17
ø72
(130)
5.5
18.5
21.5
ø8
ø4.8
80 66
5
5.5
114
80
111
(121)
ø72
2-Rc1/4 or 2-G1/4
Total length (121)
APN-085-L type

- 6 -- 6 -
6. Performance curve
■APN-085
■APN-085 L/H
Outline
7. Overview & Label
Pump head
Nameplate
Model and MFG. No.
(Production number) are
described.
Pump body
(Driven unit)
An installation location
should be free from liq-
uid spillage.
Base
Anchor the pump with
bolts.
Outlet
Inlet
Motor
0.10
0.08
0.06
0.04
0.02
0
101.3
87. 9 8
74.65
61.32
47.99
34.66
21.33
8.00
Discharge pressure 0MPa
Vacuum 101.3kPa [abs]
Vacuum 87.98kPa [abs]
Vacuum 74.65kPa [abs]
1 2 3 4 5 6
Discharge pressure
(MPa)
AIR FLOW
(L/min)
Vacuum pressure
(kPa) [abs]
1 2 3 4 5 6
0.10
0.08
0.06
0.04
0.02
0
101.3
87.98
74.65
61.32
47.99
34.66
21.33
8.00
Discharge pressure 0MPa
Vacuum 101.3kPa [abs]
Vacuum 87.98kPa [abs]
Vacuum 74.65kPa [abs]
Discharge pressure
(MPa)
AIR FLOW
(L/min)
Vacuum pressure
(kPa) [abs]

- 7 -
8. Part names & Structure
■ APN-085
No. Part names Q'ty No. Part names Q'ty
1Pump head 119 Connecting rod 1 set
2Valve 120 Bracket 1
3Valve seat 140 Motor 1
4Diaphragm 162 Screw 4
Outline
■ APN-085 L/H
No. Part names Q'ty No. Part names Q'ty
1Pump head 119 Connecting rod 1 set
2Valve 120 Bracket 1
3Valve seat 138 Gasket* 2
4Diaphragm 140 Motor 1
5Retainer plate 161 Screw 1
18 Under retainer plate 162 Screw with washer 4
The Gasket is provided to the X1 type (APN-085 with G1/4 female
thread connection) only.
20
2
31 62
4
19
40 40 4561 3 262
20
138
18
19

- 8 -
● Do not install the pump in a
place where the pump can
get wet. Avoid using wet gas,
or internal condensation will
build up and consequently
result in the short lives of the
valve and diaphragm.
● Do not install the pump in a
corrosive or flammable gas
atmosphere. Keep good ven-
tilation in a working area.
● Ambient temperature should
not fall below 0°C or exceed
40°C. Observe the allowable
gas temperature range of 0
and 40°C.
1. Before Installation
Read through this instruction manual before use. Carry
out installation work with a full understanding.
Installation
● Do not operate the pump in a flammable atmos-
phere
Do not place explosive or flammable material near
the pump.
● Do not use a damaged pump
Use of a damaged pump could lead to an electric
shock or death.
CAUTION

- 9 -
● Observe the rated voltage
specified on the name plate.
Applying any voltage than
the rated one may result in
failure.
● Surface temperature may
rise high in operation but it
dose not mean failure.
Do not touch the pump body
directly or place the objects
which may be deformed by
heat close to the pump.
● Do not use the pump in
a dusty place. Be sure to
provide the inlet with a filter
to prevent foreign matters
from getting into the pump.
Otherwise, the pump per-
formance may reduce or the
lives of the valves and dia-
phragm remarkably shorten.
● Do not tube two or more
pumps in series. It may pre-
vent the motor from starting
and lead to a burn out.
Installation
Provide a filter
Risk of burn
?V

- 10 -
2. Installation/ Tubing/ Electrical wiring
2.1 Installation
1. Do not expose the pump to
direct sunlight, vibration and
wind & rain.
2. Keep good ventilation. The
pump should always be free
from the possibility of getting
wet.
3. Ambient temperature should
not fall below 0°C or exceed
40°C. Observe the allowable
maximum ambient humidity
of 90%RH.
4. Install the pump in a clear
and level place.
Select a convenient place
for maintenance and inspec-
tion.
5. Pump fixation
Set the pump baseplate on a
concrete foundation and fasten
anchor bolts tightly to prevent
the pump from vibrating during
operation.
CAUTION
Do not install the pump on a
unstable place.
2.2 Tubing
1. The short tubing with the mini-
mum bends is optimal to reduce
resistance.
2. Use vinyl tubes resistant to the
pumping pressure.
CAUTION
Do not have tubing bent or
pressed. Otherwise, the tube
end may break.
Installation
If you notice any abnormal or dangerous conditions, suspend
operation immediately and inspect/solve problems.
WARNING

- 11 -
2.3 Electrical wiring
Electrical wiring must be performed by a qualified electrician.
We are not responsible for personal injury or property dam-
age due to nonobservance of this warning. Contact us or your
nearest distributor for wiring as necessary.
■Before wiring
1. Confirm that power is disconnected before work.
2. Wiring work should be done in accordance with local elec-
tric codes. Use the recommended wiring accessories.
3. Observe the rated voltage specified on the name plate.
4. When an external fuse is used and has blown out, always
investigate and solve root causes. Replace the fuse before
resuming operation.
Be sure to unplug the pump before investigating the cause
of blowout. If the fuse blows frequently, starting current may
be a root cause. In this case review the system.
Installation
3. Tube size
Select proper tube size, otherwise liquid leaks and failure
may result.
CAUTION
Use of a wrong tube size bears the risk of coming off,
causing an air leak.
4. Valve installation
Install valves on both discharge and suction lines.
• Suction valve:
For adjustment of an air flow and a vacuum.
• Discharge valve:
For maintenance and shutoff.
5. Tube connection
Push the tubes into the inlet and outlet as far as they will go.
NOTE: If suction line connection is imperfect, the pump sucks
air and it prevents the pump from bringing out full per-
formance.

- 12 -
AC power Pump
DC power
supply
Good
AC power Pump
No good
DC power
supply
Wiring example
5. For wire lead colours, red and black are for power volt-
age. Yellow and black leads are for external variable
signal. The black lead is common for both the power and
the signal. Observe the maximum signal voltage of 5.5VDC.
CAUTION
Observe polarity, otherwise failure or malfunction may
result. Note that rotational direction of the motor does not
change by reversing polarity.
Red: 24VDC (+)
Black: GND (-)
Yellow: 1-5VDC external variable signal(+)
Orange: Encoder output (Max output current: 3mA)
6. In order to make ON-OFF operation, install a switch between
the DC power supply and the pump. Installing it between the
DC power supply and the AC power source, the pump may
not run.
7. After wiring work, check that the system is free from the
inductive noise at start-up.
8. Noise accompanies the high-speed switching of the drive
circuit. Check it does not affect peripheral devices.
9. If a power source is shared with inductive loads such as a
solenoid relay, take protective measures against surge.
■ Rated current & Starting current
Model Rated current Starting current
APN-085-D4 1.2A 4A or below
Installation

- 13 -
● Dropping or subjecting the
pump to strong impact, fail-
ure may result.
Handle the pump with care.
● The pump can not start
with full discharge/suction
pressure. Remove pressure
before operation.
● After a long period of stop-
page, pump performance at
the beginning of operation
becomes occasionally unsta-
ble. In this case, warm the
pump up for 10 minutes with
no discharge line pressure.
● Always use a suction valve
to adjust an air flow.
● If the compressed air (higher
pressure than atmospheric
pressure) is transferred to
the pump, the lives of the
valve, diaphragm and bear-
ing may be sharply reduced.
Always keep atmospheric or
lower pressure in the suction
line.
● Injection point must be below
the pump position. Or siphon
action/back flow may result.
1. Before operation
Operation
Suction pressure
Suction valve
No load operation
Keep a discharge
valve full open.
Suction valve
Do not increase suction
line pressure

- 14 -
● Do not use solvents such as
benzine, alcohol, thinner for
maintenance or cleaning,
otherwise a coat discolours
or comes off.
2. Pump operation
■ Start-up
1. Before pump operation, check that each tube connection is
secured.
2. Check that a suction line is connected to the inlet and a dis-
charge line to the outlet.
CAUTION
If a suction line and a discharge line are connected the
other way around, pumping process is inverted.
3. Check that the pump is firmly fixed on a mounting position.
■ Operation
Operate the pump according to the following steps.
No. Procedure Points to be Checked
1 Check tubing, wir-
ing and voltage.
• See "2.2 Tubing" and "2.3
Electrical wiring" sections.
• Check the spec label to see if
power supply voltage is correct.
2Open valves. • Fully open both discharge and
suction lines.
3 Supply power to the
pump.
• Check the item 1 and 2. Then turn
on power and start the pump.
• Smooth starting may not be
obtained when ambient tempera-
ture is 10ºC or below. In this case,
run the pump with no discharge
line pressure for a few minutes to
warm it up.
4Adjust air flow. • Provide a running-in period before
full scale operation.
• Always adjust an air flow by a suc-
tion valve.
Operation

- 15 -
■ Stop and Storage
Before a long period of stoppage (1 week or more):
● Release pressure and turn off main power.
● Make sure both supply air and gas are stopped.
Before resuming operation:
● Warm up the pump under no load operation. Operation
may occasionally be upset in the beginning.
● Follow the "■ Operation" table to resume operation.
Operation
5 Points to be
checked during
operation
• After starting, check a pressure
gauge to see if suction and dis-
charge line pressure are correct
and an air flow meter to see if the
specified air flow is obtained.
• Keep a suction line pressure at or
below atmospheric pressure.
• In case electric power has failed
while the pump is running, switch
off main power. Otherwise, the
motor may not restart or may burn
out depending on a line pressure
at the time of power recovery.

- 16 -
2. Maintenance & Inspection
Handling of the pump, maintenance and inspection should
be carried out within the descriptions of this instruction
manual.
We are not responsible for personal injury or property dam-
age due to nonobservance of this warning. Contact us or
your nearest distributor as necessary.
■ Daily inspection
Pay attention to the following items during operation. Stop
operation on sensing danger and solve problems on the
Troubleshooting section. If pump performance has remarkably
reduced, replace wear parts.
No. Check that... Measure
1 pump operation is normal.
• Apply correct voltage and
amperage.
• Adjust discharge/suction
pressure.
2there is no noise or vibra-
tion problem.
• Unusual noise/vibration
may occur when pump
operation is not normal.
3
there is no air leak or air
ingress from pump parts
and tubing connections.
• Retighten connections.
Maintenance
1. Troubleshooting
Turn off power on sensing danger and check the follow-
ing. In case trouble can not be solved, contact us or your
nearest distributor.
Phenomenon
Causes
Pump does not run. Pump stops running. Poor air ow or discharge pressure Pump makes noise.
Measures
No power distribution Check wiring.
Motor trouble (disconnection or capacitor failure) Replace the motor.*
Wrong tubing or poor connection Check and x tubing.
Pump head mounting screws are loose. Tighten the screws.
Diaphragm insertion is loose. Tighten diaphragm.
Diaphragm is damaged. Replace diaphragm.
Filter is clogged. Remove foreign matters.
Valve is worn. Replace the valve.
Higher suction pressure than atmospheric Reduce suction pressure.
Eccentric shaft has worn. Replace the connecting rod unit.*
Connecting rod bearing has worn. Replace the connecting rod unit.*
Motor bearing has worn. Replace the motor.*
Voltage reduction Increase voltage to the rated level.
Bracket tightening screws are loose. Secure them.
Condensation in the pump head. Dry up the pump.
Contact us for the measures marked with *.

- 17 -
Maintenance
■ Wear parts
If pump performance has remarkably reduced, replace dia-
phragms and valves with new ones. Wear part duration varies
with the pressure, temperature and characteristics of gas/
liquid.
The estimated life below is calculated based on continuous
operation with clean water at ambient temperature (Room tem-
perature range is 0-40°C.).
Application Load range Estimated life
Valve Diaphragm
Gas transfer All range 8000hr 8000hr
*The above lives are reference values and not warranted.
■ Cleaning
Turn off power and wait until the pump has cooled down. Then
clean off the surface of the pump with a wet cloth. Use a neu-
tral detergent for greasy dirt as necessary and dry it with a dry
cloth.
Check the pump surface has dried up before operation.
CAUTION
Risk of electrical shock. Do not wet electric parts or wir-
ing.
■ Storage
Protect the pump from dust during storage.
Do not store the pump:
• Where ambient temperature falls below 0°C or exceeds 40°C.
• Under a flammable or corrosive atmosphere.
• Under heavy dust or high humidity.
• Under direct sunlight or wind & rain.
• Under vibration.

- 18 -
Maintenance
3. Wear part replacement
For a long period of operation wear parts need to be
replaced periodically.
CAUTION
● Turn off power before service
Risk of electrical shock. Be sure to turn off power to
stop the pump and related devices before service is
performed.
● Do not touch the pump or pipe with bare hands
Risk of burning. The surface temperature of the
pump or pipe gets high in or right after operation.
● Wear protective clothing
Always wear protective clothing such as an eye pro-
tection, chemical resistant gloves, a mask and a face
shield during disassembly, assembly or maintenance
work.
See page 7 "8. Part names & Structure" as necessary.
■ Diaphragm replacement
<APN-085>
1. Unscrew all the pump head
fixing screws and take out
the pump head, valve and
valve seat.
2. Catch the diaphragm nut
with a special spanner and
turn the diaphragm anti-
clockwise so as to detach it
from the con rod (Fig.1).
3. Mount a new diaphragm into
the rod and fasten as far as
it will rotate with the span-
ner.
4. Push down the diaphragm
until it bottoms out and then
mount and secure the valve
seat, valve and pump head
onto the bracket with the
screws by 1.39N•m.
Screw
Diaphragm
Pump
head
Valve
Mating
points
Valve seat
Bracket
Diaphragm
Special
spanner
Bracket
Con rod
Fig.1