IWAKI PUMPS APN-110-D4 User manual

Safety instructions
Overview Installation Operation Maintenance Specication
© 2010 IWAKI CO.,LTD.
Iwaki Air Pump
APN-110-D4
Instruction manual
Thank you for choosing our product.
Please read through this instruction manual before use.
This instruction manual describes important precautions and
instructions for the product. Always keep it on hand for quick
reference.
T762-3 '14/01
( )Country codes
IWAKI CO.,LTD. 6-6 Kanda-Sudacho 2-chome Chiyoda-ku Tokyo 101-8558 Japan
TEL:[phone] FAX:[phone](http://www.iwakipumps.jp)
Australia IWAKI Pumps Australia Pty. Ltd.
TEL : [phone] FAX : [phone]
Italy IWAKI Europe GmbH, Italy Branch TEL : [phone] FAX : [phone]
Austria IWAKI EUROPE GmbH
TEL : [phone] FAX : [phone]
Korea IWAKI Korea Co.,Ltd.
TEL : [phone] FAX : [phone]
Belgium IWAKI Belgium n.v.
TEL : [phone] FAX : 1367 2030
Malaysia IWAKIm Sdn. Bhd.
TEL : [phone] FAX : [phone]
China IWAKI Pumps (Shanghai) Co., Ltd.
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Norway IWAKI Norge AS
TEL : [phone] FAX : [phone]
China IWAKI Pumps (Guangdong) Co., Ltd.
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Singapore IWAKI Singapore Pte. Ltd.
TEL : [phone] FAX : [phone]
China GFTZ IWAKI Engineering & Trading (Guangzhou)
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Denmark IWAKI Nordic A/S
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Switzerland IP Service SA
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Finland IWAKI Suomi Oy
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Taiwan IWAKI Pumps Taiwan Co., Ltd.
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France IWAKI France S.A.
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Taiwan IWAKI Pumps Taiwan (Hsin-chu) Co., Ltd. TEL : [phone]
FAX : [phone]
Germany IWAKI EUROPE GmbH
TEL : [phone] FAX : [phone]
Thailand IWAKI (Thailand) Co.,Ltd.
TEL : [phone] FAX : [phone]
Holland IWAKI Europe GmbH, Netherlands Branch TEL : [phone] FAX : [phone] U.K. IWAKI Pumps (UK) LTD.
TEL : [phone] FAX : [phone]
Hong Kong IWAKI Pumps Co., Ltd.
TEL : [phone] FAX : [phone]
U.S.A. IWAKI AMERICA Inc
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Indonesia IWAKI Singapore (Indonesia Branch)
TEL : [phone] FAX : [phone]
Vietnam IWAKI Pumps Vietnam Co.,Ltd.
TEL : [phone] FAX : [phone]

2
Order conrmation
Open the package and check that the product conforms to your order. If
any problem or inconsistency is found, immediately contact your distribu-
tor.
a. Check if the delivery is correct.
Check the nameplate to see if the
information such as model codes,
discharge capacity and discharge
pressure are as ordered.
b. Check if the delivery is damaged or deformed.
Check for transit damage and loose bolts.
Order conrmation

3
Contents
Contents
Order conrmation ............................................................................................. 2
Safety instructions ....................................................................... 5
WARNING.......................................................................................................... 6
CAUTION ........................................................................................................... 7
Precautions for use ......................................................................................... 9
Overview...................................................................................... 12
Introduction.....................................................................................................12
Pump structure & Operating principle .........................................................12
Part names.......................................................................................................13
Identication codes........................................................................................14
Installation .................................................................................. 15
Pump mounting...............................................................................................15
Pipework ..........................................................................................................16
Tube connection ..........................................................................................16
Wiring...............................................................................................................17
Power & External signal cables...................................................................17
Before work ............................................................................................17
Rated current & Starting current ............................................................18
Operation..................................................................................... 19
Pump operation ..............................................................................................19
Start-up........................................................................................................19
Operation.....................................................................................................19
Before a long period of stoppage (1 week or more) ................................... 20

4Contents
Maintenance................................................................................ 21
Troubleshooting..............................................................................................21
Inspection....................................................................................................... 23
Daily inspection .......................................................................................... 23
Wear part replacement.................................................................................. 24
Wear part list................................................................................................24
Before service..............................................................................................24
Diaphragm replacement ............................................................................. 25
Valve replacement ...................................................................................... 26
Specication/Outer dimension .................................................................... 27
Specication ............................................................................................... 27
Outer dimension ......................................................................................... 28
Performance curves ................................................................................... 28
Part names & Structure .............................................................................. 29

5
Safety instructions
Read through this section before use. This section describes
important information for you to prevent personal injury or
property damage.
■ Symbols
In this instruction manual, the degree of risk caused by incorrect use is noted
with the following symbols. Please pay attention to the information associated
with the symbols.
Indicates mishandling could lead to a fatal or
serious accident.
WARNING
A symbol accompanies each precaution, suggesting the use of "Caution", "Pro-
hibited actions" or specic "Requirements".
Indicates mishandling could lead to personal
injury or property damage.
CAUTION
Caution marks Prohibited marks Requirement marks
Electrical
shock
Caution
Safety instructions
Requirement
Wear
protection
Grounding
Prohibited Do not rework
or alter
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.

6WARNING
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.
Stop operation
If you notice any abnormal or dangerous conditions, suspend op-
eration immediately and inspect/solve problems.
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
specied may result in failure or injury. Use this product in a speci-
ed conditions only.
Do not modify the pump
Alterations to the pump carries a high degree of risk. It is not the
manufacturer's responsibility for any failure or injury resulting from
alternations to the pump.
Use specied power only
Do not apply power other than that specied on the nameplate.
Otherwise, failure or re may result. Ensure the pump is properly
grounded.
Wear protective clothing
Always wear protective clothing such as an eye protection, chemi-
cal resistant gloves, a mask and a face shield during disassembly,
assembly or maintenance work. The specic solution will dictate the
degree of protection. Refer to MSDS precautions from the solution
supplier.
Do not damage a power cable
Do not pull, knot or crush the power cable. Damage to the power
cable could lead to a re or electrical shock if cut or broken.
WARNING
Do not remodel
Wear
protectors
Requirement
Electrical
shock
Prohibited
Prohibited
Requirement

7
Safety instructions
CAUTION
Qualied personnel only
The pump should be handled or operated by qualied personnel
with a full understanding of the pump. Any person not familiar with
the product should not take part in the operation or maintenance of
the pump.
Keep electric parts and wiring dry
Risk of re or electric shock. Install the pump where it can be kept
dry.
Ventilation
Fumes or vapours can be hazardous with certain solutions. Ensure
proper ventilation at the operation site.
Do not install/store the pump:
• In a ammable atmosphere.
• In a dusty/humid environment.
• Where operating (or storage) temperature can fall below 5ºC (or
0ºC) or exceed 40ºC.
• In direct sunlight or wind & rain.
Spill precautions
Ensure protection and containment of solution in the event of
plumbing or pump damage (secondary containment).
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.
Do no use a damaged power cable
Risk of fire or electric shock. The cable is not replaceable. The
whole pump unit needs to be replaced when the cable is damaged.
CAUTION
Requirement
Requirement
Caution
Prohibited
Prohibited
Prohibited
Electrical
shock

8CAUTION
Preventative maintenance
Follow instructions in this manual for replacement of wear parts. Do
not disassemble the pump beyond the extent of the instructions.
Do not use a damaged pump
Use of a damaged pump could lead to an electric shock or death.
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. Requirement
Requirement
Prohibited

9
Safety instructions
• Electrical work should be performed by a qualied
electrician. Otherwise, personal injury or property
damage may result.
• Do not install the pump in a place where the pump
can get wet. Avoid using wet gas, or internal con-
densation will build up and consequently result in
the short lives of the valve and diaphragm.
• 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 performance may reduce or the lives of the
valve and diaphragm remarkably shorten.
• Do not install the pump in a corrosive or flamma-
ble gas atmosphere. Keep good ventilation in a
working area. Ambient temperature should not fall
below 5°C or exceed 40°C. Observe the allowable
gas temperature range of 0 and 40°C.
• If the compressed air (higher pressure than atmos-
pheric pressure) is transferred to the pump, sharp
deterioration to the lives of the valve, diaphragm
and bearing may result. Always keep atmospheric
or lower pressure in the suction line.
Precautions for use
Precautions for use
Caution
Do not increase suc-
tion line pressure

10 Precautions for use
• Do not tube two or more pumps in series. It may
prevent the motor from starting and lead to a burn
out.
• Injection point must be below the pump position.
Or siphon action or back flow may result.
• Use care handling the pump. Do not drop. An
impact may affect pump performance. Do not use
a pump that has been damaged to avoid the risk of
electrical damage or shock.
• Do not apply power other than that specified on
the nameplate. Otherwise, failure or fire may
result.
?V

11
Safety instructions
• The pump can not start with full discharge/suc-
tion pressure. Remove pressure before operation.
After a long period of stoppage, pump perform-
ance at the beginning of operation becomes occa-
sionally unstable. In this case, warm the pump up
for 10 minutes with no discharge line pressure.
• Risk of burning. A pump and a pipe surface tem-
perature rises high along with liquid temperature.
Do not touch the pump or pipe surface directly
during operation or right after operation.
• Always use a suction valve to adjust an air flow.
• Do not clean the pump or nameplate with a solvent
such as benzine, thinner or kerosene. This may
discolour the pump or erase printing. Use a dry or
damp cloth or a neutral detergent.
Precautions for use
Suction pressure
Suction valve
Keep a discharge
valve full open.
Benzine
Thinner

12
Pump characteristics, features and part names are described
in this section.
Introduction
Pump structure & Operating principle
The APN-110-D4 is a diaphragm type air pump with a brushless DC motor.
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.
Overview
Suction process
Outlet Inlet
Connecting rod
Diaphragm
Discharge process
Outlet Inlet
: Diaphragm reciprocation
: Gas flow
Introduction

13
Overview
Part names
Part names
Outlet
Base
Always fix with screws.
Specification label
Use the pump accord-
ing to the specifica-
tions on the label.
Pump head
Not capable of liquid transfer. Air
transfer purpose only.
Inlet
Pump body (with a
built-in drive unit)

14 Identication codes
Identication codes
The model code represents the following information.
APN - 110 K V X - D4 - 02
a b c d e f
a. Pump size
b. Tubing direction
K : Parallel type
L : In-line type
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 specication
No code : Standard
01-99 : Special design

15
Installation
Pump mounting
1
2
Installation
This section describes the installation of the pump, tubing and
wiring. Read through this section before work.
Observe the following points
• Risk of electrical shock. Be sure to turn off power to stop the pump and
related devices before service is performed.
• If you notice any abnormal or dangerous conditions, suspend operation
immediately and inspect/solve problems.
• Do not operate the pump in a ammable atmosphere.
Pump mounting
Select a suitable place.
See the Precautions for use section before installation.
Anchor the pump.
Use suitable bolts or screws.
NOTE
Do not install the pump on a wobbly pedestal.

16 Pipework
1
2
Pipework
Connect tubes to the pump.
Before operation
• Cut the tube ends at.
Tube connection
a. The short tubing with the minimum bends is optimal to reduce resist-
ance.
b. Use vinyl tubes resistant to the pumping pressure.
Tube I.D. should be equal to the O.D. of the pump
inlet/outlet for the prevention of gas ingress/leak or
other failure.
* Do not have tubing bent or pressed. Otherwise, the tube
end may break.
Connect tubes into the inlet and outlet.
Push the tubes into the inlet and outlet as far
as they will go.
*If suction line connection is imperfect, the pump
sucks air and it prevents the pump from bringing
out full performance.
Valve mounting
Install a valve in the suction line for adjusting an air ow.
Tube end (Side view)
Inlet
Outlet

17
Installation
Wiring
Wiring for power source, earthing and external signal.
Observe the following points
• Electrical work should be performed by a qualied electrician. Conform
to local electric codes.
• Do not perform wiring work while power is on. Otherwise, an electrical
shock or short circuit may result, and consequently the pump may fail. Be
sure to turn off power before service is performed.
Power & External signal cables
■Before work
• Check that the main power is turned off.
• Apply the specified power voltage. See the spec label.
• When an external fuse is used and it has blown, always solve the root cause
of blowout. Be sure to unplug the power cable before investigation. If the fuse
blows frequently, the starting current may be a root cause.
• Red(+) and black(-) leads are for power voltage. Yellow(+) and black(-) leads
are for 1-5V external variable signal. The black(-) lead is common for both the
power and the signal. Observe the maximum signal voltage of 5.5VDC.
NOTE
• 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)
Wiring

18 Wiring
Wiring example
• In order to make the ON-OFF operation, install the switch between the DC
power supply and the pump. Installing it between the DC power supply and
the AC power supply, the pump may not run.
• After wiring work, check that the system is free from the inductive noise at
start-up.
• Noise accompanies the high-speed switching of the drive circuit. Check it
does not affect peripheral devices.
• If a power source is shared with the inductive load such as solenoid and
relay, take protective measures against surge.
■ Rated current & Starting current
Model Rated current Starting current
A PN -110 - D 4 1.4A 4A or below
AC power Pump
No good
DC power
supply
AC power Pump
DC power
supply
Good

19
Operation
The pump becomes ready after pipework and wiring is completed.
Pump operation
Start-up
Before operation
a. Check that the pump is firmly fixed on a mounting position.
b. Check that a suction tube is connected to the inlet and a discharge tube
is connected to the outlet.
* If a suction line and a discharge line are connected the other way around,
pumping process is inverted.
c. Check that every tube connection is secured.
d. Check that electrical wiring is properly done without the possibility of
short-circuit and protected by an fuse.
e. Check that power voltage that is specified on the nameplate is applied
to the pump.
Operation
Open the suction and discharge lines.
Turn on power.
Operation may occasionally be upset when starting temperature is low.
Warm up the pump under no load operation (a few minutes).
Operation
Pump operation
1
2

20 Pump operation
After the pump has reached a specied stroke rate, initiate full
scale operation.
•Always adjust an air ow by a suction valve.
• 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.
After starting, check a pressure gauge to see if suction and dis-
charge line pressure are correct and an air ow meter to see if the
specied air ow is obtained.
Before a long period of stoppage (1 week or more)
Depressurize the system and stop air/gas supply. Do not install/store the pump:
• In a flammable/corrosive atmosphere.
• In a dusty/humid environment.
• In direct sunlight or wind & rain.
• Under vibration.
• Where ambient temperature can exceed 0-40°C.
3
4