IWAKI PUMPS APN-110 Series User manual

Iwaki Air Pump
APN-110
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.
Safety instructions
Overview Installation Operation Maintenance Specication
© 2010 IWAKI CO.,LTD.
T814-2 '15/03
( )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:13672030
Malaysia IWAKIm Sdn. Bhd.
TEL :[phone] FAX:[phone]
China IWAKIPumps (Shanghai)Co.,Ltd.
TEL :[phone] FAX: [phone]
Norway IWAKI Norge AS
TEL :[phone] FAX:[phone]
China IWAKI Pumps(Guangdong) Co., Ltd.
TEL :[phone] FAX:[phone]
Singapore IWAKI Singapore Pte. Ltd.
TEL :[phone] FAX: [phone]
China GFTZIWAKIEngineering&Trading(Guangzhou)
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TEL :[phone] FAX : [phone]
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Taiwan IWAKI Pumps Taiwan Co., Ltd.
TEL :[phone] FAX :[phone]
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Taiwan IWAKI PumpsTaiwan (Hsin-chu)Co.,Ltd. TEL :[phone]
FAX :[phone]
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Thailand IWAKI (Thailand) Co.,Ltd.
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TEL :[phone] FAX: [phone]
U.K. IWAKI Pumps (UK) LTD.
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HongKong IWAKI Pumps Co., Ltd.
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U.S.A. IWAKI AMERICA Inc
TEL :[phone] FAX:[phone]
Indonesia IWAKISingapore(IndonesiaBranch)
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 voltage/Earthing ...............................................................................17
Operation.....................................................................................18
Pump operation ..............................................................................................18
Operation.....................................................................................................18
Before a long period of stoppage (1 week or more) ....................................19

4Contents
Maintenance................................................................................20
Troubleshooting............................................................................................. 20
Inspection....................................................................................................... 22
Daily inspection .......................................................................................... 22
Wear part replacement.................................................................................. 23
Wear part list............................................................................................... 23
Before service............................................................................................. 23
Diaphragm replacement ..............................................................................24
Valve replacement ...................................................................................... 25
Specication/Outer dimension .................................................................... 26
Specication ............................................................................................... 26
Pump ..................................................................................................... 26
Motor ..................................................................................................... 26
Outer dimension ......................................................................................... 27
APN-110 ................................................................................................ 27
APN-P110.............................................................................................. 28
APN-S110.............................................................................................. 28
Performance curves ................................................................................... 29
APN-110 ................................................................................................ 29
APN-P110.............................................................................................. 29
APN-S110.............................................................................................. 29
Part names & Structure .............................................................................. 30
APN-110 ................................................................................................ 30
APN-P110...............................................................................................31
APN-S110.............................................................................................. 32

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 Prohibition 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.
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.
Grounding
Risk of electrical shock! Always properly ground the pump. Con-
form to local electric codes.
CAUTION
Requirement
Requirement
Caution
Prohibited
Prohibited
Prohibited
Grounding

8CAUTION
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.
Install a GFCI (earth leakage breaker)
An electrical failure of the pump may adversely affect other de-
vices on the same line. Purchase and install a GFCI (earth leakage
breaker) separately.
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
Electrical
shock
Prohibited
Electrical
shock

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.
• 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.
Caution

11
Safety instructions
• 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.
• The APN-S110 is designed for vacuum application
only. Do not pressurize the discharge line of the
pump.
• 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.
• When an earth leakage breaker is used and it has
blown, always solve the root cause of blowout. Be
sure to unplug the power cable before investiga-
tion.
Precautions for use
Benzine
Thinner
Suction valve
Caution

12
Pump characteristics, features and part names are described
in this section.
Introduction
Pump structure & Operating principle
The APN-110 is a diaphragm type air pump with a AC 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 - S 110 K V X - 1 - 02
a b c d e f g
a. Pump head
No code : Single head
S : Dual-head with series tubing
P : Dual-head with parallel tubing
b. Pump size
c. Inlet/outlet
K : Parallel type
L : In-line type
d. Diaphragm/Valve materials
V : FKM
E : EPDM
e. Pump connection
No code : ø8 tube connection
X : Rc1/4 female thread connection
X1 : G1/4 female thread connection
f. Power voltage
1 : 100VAC
2 : 200VAC
3 : 115VAC
4 : 220/240VAC
E4 : 220/240VAC (3-core cabtyre cable)
g. Special specication

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 an unstable place.

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
entrains 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 and earthing.
Observe the following points
• Electrical work should be performed by a qualied electrician. Conform
to local electric codes.
• Do not apply power other than that specified on the nameplate. Other-
wise, failure or fire may result.
• 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.
• Be careful for electric power not to be turned on during work.
Power voltage/Earthing
Check that the main power is turned off.
Connect power cable via crimp contacts.
Earth the pump.
Be sure to earth the pump.
Wiring
1
2

18 Pump operation
The pump becomes ready after pipework and wiring is completed.
Pump operation
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
1
2

19
Operation
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)
Release pressure from the pump/tubing and turn off the main power. Keep the
inside of the pump head free from residual gas.
Do not 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

20 Troubleshooting
This section describes troubleshooting, inspection, wear part
replacement, exploded views and specications.
Observe the following points
• Follow instructions in this manual for replacement of wear parts. Do not
disassemble the pump beyond the extent of the instructions.
• Always wear protective clothing such as an eye protection, chemical
resistant gloves, a mask and a face shield during disassembly, assembly
or maintenance work.
• Risk of electrical shock. Be sure to turn off power to stop the pump and
related devices before service is performed.
Troubleshooting
If you notice any abnormal or dangerous conditions, suspend operation im-
mediately and check the following points. If the following measures do not help
remove problems, contact your nearest distributor.
States Possible causes Solutions
The pump
does not
run.
Power voltage is too low. • Observe the allowable voltage
range.
The pump is not powered. • Check the pump is switched on if
any.
• Correct wiring.
• Replace a breaking wire to new one.
Wrong tubing or poor connection • Check and x tubing.
Diaphragm xing screw is loose. • Tighten the screw.
Eccentric shaft has worn. • Replace the connecting rod unit.
Contact us.
Connecting rod bearing has worn. • Replace the connecting rod unit.
Contact us.
Motor trouble (a breaking wire, ca-
pacitor failure or bearing damage)
• Replace the motor. Contact us.
Suction line pressure is com-
pressed and is higher than atmos-
pheric pressure.
• Keep it lower than atmospheric
pressure.
Maintenance