IWAKI PUMPS FA Series User manual

Safety instructions Overview Installation Operation Maintenance 6SHFL¿FDWLRQ
Iwaki
Pneumatic Drive Bellows Pump
FA series
©2011 IWAKI CO., LTD.
Thank you for choosing our product.
Please read through this instruction manual before use.
This instruction manual describes important precautions and instruc-
tions for the product. Always keep it on hand for quick reference.
Instruction manual

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Open the package and check that the product conforms to your order. If any problem or
inconsistency is found, immediately contact your distributor.
a. Check if the delivery is correct.
Check the nameplate to see if the information such as model codes are as ordered.
*Electrical wiring changes with the controllers.
b. Check if the required number of accessories is provided.
<Attached accessories>
A FDC-1 controller and two quick exhaust valves
c. Check if the delivery is damaged or deformed.
Check for transit damage and loose bolts.
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Contents
Contents
2UGHUFRQ¿UPDWLRQ ..........................................................................................................................................2
Safety instructions.................................................................... 5
:DUQLQJ..........................................................................................................................................................6
&DXWLRQ...........................................................................................................................................................7
3UHFDXWLRQVIRUXVH ......................................................................................................................................9
Overview...................................................................................10
,QWURGXFWLRQ .................................................................................................................................................10
3XPSVWUXFWXUH2SHUDWLQJSULQFLSOH ......................................................................................................10
3DUWQDPHV...................................................................................................................................................11
3XPS ........................................................................................................................................................11
2SHUDWLQJFRQGLWLRQV..................................................................................................................................12
3XPSVWURNH .............................................................................................................................................12
6XSSO\DLUSUHVVXUHUDQJH ........................................................................................................................12
/LTXLGWHPSHUDWXUHUDQJH .........................................................................................................................12
/LTXLGFKDUDFWHULVWLFV ...............................................................................................................................12
'RQRWUXQWKHSXPSZLWKWKHIROORZLQJOLTXLG .....................................................................................12
8VHFDUHKDQGOLQJWKHIROORZLQJOLTXLGV..............................................................................................12
2SHUDWLRQDQG6WRSSDJH..........................................................................................................................13
'XULQJRSHUDWLRQ .................................................................................................................................13
:KHQVWRSSLQJWKHSXPS ....................................................................................................................13
'XULQJVWRSSDJH..................................................................................................................................13
$LUH[KDXVWSRUW ........................................................................................................................................13
/HDNVHQVRU..............................................................................................................................................13
$PELHQWWHPSHUDWXUH................................................................................................................................13
3XPSVXUIDFHWHPSHUDWXUH.......................................................................................................................13
1RLVHIURPSXPS......................................................................................................................................13
,GHQWL¿FDWLRQFRGHV....................................................................................................................................14
Installation ...............................................................................15
3XPSPRXQWLQJ...........................................................................................................................................15
/LTXLGOLQHSLSLQJ ........................................................................................................................................17
6XFWLRQOLQH...............................................................................................................................................18
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)LOWUDWLRQVXFWLRQOLQHHQG ..................................................................................................................18
:KHQLQVWDOOLQJDYDOYHRQWKHVXFWLRQOLQH ........................................................................................18
Discharge line ..........................................................................................................................................19
3XOVDWLRQUHGXFWLRQ .............................................................................................................................19
:KHQLQVWDOOLQJDYDOYHRQWKHGLVFKDUJHOLQH ....................................................................................19

4Contents
)LOWUDWLRQFLUFXODWLRQ ...........................................................................................................................19
)LOWUDWLRQGLVFKDUJHOLQHHQG..............................................................................................................19
'HSUHVVXUL]DWLRQDWSXPSVWRS ...........................................................................................................19
Degassing ................................................................................................................................................20
$LUOLQHSLSLQJ ..............................................................................................................................................21
6XSSO\DLUSRUW,' ..............................................................................................................................21
$LUOLQHSLSLQJGLDJUDP..............................................................................................................................22
&RPSRVLWHHIIHFWLYHFURVVVHFWLRQDODUHD ................................................................................................24
(IIHFWLYHFURVVVHFWLRQDODUHD.............................................................................................................24
3UHYHQWLYHPHDVXUHVDJDLQVWFRQGHQVDWLRQ .......................................................................................24
(OHFWULFZLULQJ .............................................................................................................................................25
Installation................................................................................................................................................25
Lead wires...........................................................................................................................................25
([WHQVLRQRIOHDNVHQVRUZLUHV ...........................................................................................................25
,QVWDOODWLRQRISUR[LPLW\VZLWFKZLUHV ...................................................................................................25
([WHQVLRQRISUR[LPLW\VZLWFKZLUHV ....................................................................................................25
:LULQJGLDJUDP .........................................................................................................................................26
Operation................................................................................. 27
%HIRUHRSHUDWLRQ .........................................................................................................................................27
3XPSRSHUDWLRQ...........................................................................................................................................28
6WDUWLQJWKHSXPS.....................................................................................................................................28
)ORZUDWHDGMXVWPHQW ................................................................................................................................29
6WRSSDJH..................................................................................................................................................29
Maintenance............................................................................ 30
7URXEOHVKRRWLQJ..........................................................................................................................................30
,QVSHFWLRQ ....................................................................................................................................................33
'DLO\LQVSHFWLRQ ........................................................................................................................................33
3HULRGLFLQVSHFWLRQ ...................................................................................................................................33
:HDUSDUWOLVW ............................................................................................................................................34
6SHFL¿FDWLRQ2XWHUGLPHQVLRQ..................................................................................................................35
6SHFL¿FDWLRQ.............................................................................................................................................35
3XPS...................................................................................................................................................35
2XWHUGLPHQVLRQ.......................................................................................................................................36
FA-2-1..................................................................................................................................................36
FA-2E-1...............................................................................................................................................37
FA-40EW ............................................................................................................................................38
3DUWQDPHV...............................................................................................................................................39
FA-2-1..................................................................................................................................................39
FA-2E-1...............................................................................................................................................40
FA-40EW ............................................................................................................................................ 41
EC DECLARATION OF CONFORMITY..................................................................................................42

5
Safety instructions
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Safety instructions
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Caution
Caution
Caution
Caution
Caution
Caution
Requirement
Requirement
Caution

10
Overview
,QWURGXFWLRQ
Pump characteristics, features and part names are described in this sec-
tion.
,QWURGXFWLRQ
Pump structure & Operating principle
$Q,ZDNL)$VHULHVSQHXPDWLFGULYHEHOORZVSXPSKDVÀXRULFZHWHQGVDQGLVGHVLJQHGIRUVHPLFRQGXFWRU
manufacturing processes.
3ULQFLSOHRIRSHUDWLRQ
7KHSXPSXQLWKDVWZRDLUFKDPEHUVDQGDSDLURIEHOORZV7KHUHFLSURFDWLQJPRWLRQRIWKHEHOORZVLQWKHDLU
FKDPEHUVLQWURGXFHVGHOLYHUVVROXWLRQ
Suction process
(LWKHUEHOORZVWDNHVLQVROXWLRQYLDWKHLQOHWDVLWH[SDQGV
Discharge process
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/LTXLGIORZ
6XSSO\DLU
Air OUT
$LUFKDPEHU
3XPSKHDG
Air IN
%HOORZV OUT
IN
OUT
IN
Air IN Air OUT

11
Overview
3DUWQDPHV
Pump
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)$ 9(:
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3DUWQDPHV
6SHFODEHO
Inlet
2XWOHW
287ODEHO
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,1ODEHO
%DVH
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WKURXJKWKHEDVH
6XSSO\DLUSRUW
6SHFODEHO
Inlet
2XWOHW
3UR[LPLW\VZLWFKDQGHOHF-
WURGHZLUHV&RQQHFWWKHP
to the controller.
287ODEHO
%DVH
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WKURXJKWKHEDVH
6XSSO\DLUSRUW
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6XSSO\DLUSRUW

12 2SHUDWLQJFRQGLWLRQV
2SHUDWLQJFRQGLWLRQV
Pump stroke
Observe the maximum stroke rate of 150spm (FA-2-1/-2E-1) or 80spm (FA-40VEW), or the pump can take in a
large amount of air, resulting dry running.
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Supply air pressure range
Observe the allowable supply air pressure range at each model.
Model 6XSSO\DLUSUHVVXUH
)$( 0.2-0.4MPa
FA-40VEW 0.1-0.4MPa
7U\WRXVHWKHPLQLPXPDOORZDEOHVXSSO\DLUSUHVVXUHWRSURWHFWWKH¿OWHUDQGEHOORZVDQGUHGXFHWKHULVNRIVROXWLRQVSUD\
$ÀRZUDWHFKDQJHVZLWKVXSSO\DLUSUHVVXUH8VHDUHJXODWRUWRNHHSWKHSUHVVXUHFRQVWDQW
Liquid temperature range
Observe the allowable liquid temperature range of 5-100º&1RWHVKDUSWHPSHUDWXUHÀXFWXDWLRQKHDWVKRFN
may reduce the life of the pump. Contact us for detail.
Liquid characteristics
Ŷ'RQRWUXQWKHSXPSZLWKWKHIROORZLQJOLTXLG
•Liquid that easily crystallizes
•Slurry
•Low conductivity hydrocarbon liquid
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'HOLYHU\RIORZFRQGXFWLYLW\K\GURFDUERQOLTXLGFDQFDXVH(6'GDPDJH
Ŷ8VHFDUHKDQGOLQJWKHIROORZLQJOLTXLG
•Stripper
•Solvent
•Hydrazine
•Fuming sulfuric acid
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detail.
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13
Overview
2SHUDWLQJFRQGLWLRQV
Operation and Stoppage
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Ŷ:KHQVWRSSLQJWKHSXPS
•%HIRUHVWRSSLQJWKHSXPSUHOHDVHGLVFKDUJHOLQHSUHVVXUH2WKHUZLVHWKHEHOORZVPD\GHIRUP
•'RQRWFORVHDGLVFKDUJHYDOYHDVVWRSSLQJWKHSXPSRUDQLPSDFWSUHVVXUHPD\GHIRUPWKHEHOORZVRUFRQ-
QHFWLQJSODWH
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$OZD\VFKHFNWKHVSHFL¿FDWLRQRIWKHGRXEOHVROHQRLGYDOYHEHIRUHLQVWDOODWLRQ6RPHW\SHVSUHVVXUHFHQWUH
W\SHVDUHGHVLJQHGWRSUHVVXUL]HERWKWKHULJKWDQGOHIWDLUFKDPEHUVDWWKHVDPHWLPH
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WKHEHOORZVDQGFRUURGHPHWDOSDUWV
Air exhaust port
Do not narrow an air exhaust line (for example by reducing the tube I.D.). Or the residual pressure in the pump
may deform the bellows.
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IURPWKHVROHQRLGYDOYH69RUWKHTXLFNH[KDXVWYDOYH4(92WKHUZLVHLQFUHDVHGSLSHUHVLVWDQFHPD\EUHDNWKHOLPLW
Leak sensors
The sensors occasionally fails to detect leakage depending on operating conditions. Contact us for detail.
Ambient temperature
Observe the allowable operating ambient temperature range of 0-40ºC.
Pump surface temperature
Risk of burning. The surface temperature of the pump or pipe rises high along with liquid temperature in or
right after operation. With the FA-2, for example, a cylinder surface temperature rises up to 75ºC when liquid
temperature is 110ºC and ambient temperature is 17ºC.
Model /LTXLGWHPSHUDWXUH &\OLQGHUVXUIDFH
WHPSHUDWXUH $PELHQWWHPSHUDWXUH
)$( 110ºC 75ºC 17ºC
FA-40VEW 79ºC
Noise from pump
Exhaust noise accompanies pump operation. Provide noise insulation as necessary. With the FA-2, for exam-
ple, a noise level rises up to 67dB (A) at 150spm and 0.39MPa (supply air pressure).
Model 6XSSO\DLUSUHVVXUH 6WURNHUDWH 1RLVHOHYHO
)$( 0.39MPa VSP G%$
FA-40VEW VSP G%$
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14 ,GHQWL¿FDWLRQFRGHV
,GHQWL¿FDWLRQFRGHV
Each code represents the following information.
FA - 40 V E W - 01
a b c d e b f
D6HULHVQDPH
)$0HGLXPOLTXLGWHPSHUDWXUH
E0D[LPXPÀRZUDWH
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H3XPSKHDGEHOORZVFRQQHFWLRQ
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::HOGHG
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15
Installation
Installation
3XPSPRXQWLQJ
Flooded
suction
*
Suction lift
This section describes the installation of the pump, piping and wiring. Read through
this section before work. To operate this pump, a 5-port solenoid valve and FDC-1
controller is needed. Always install QEVs (quick exhaust valves) to secure system
safety. Purchase separately.
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2EVHUYHWKHIROORZLQJSRLQWVZKHQLQVWDOOLQJWKHSXPS
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IRUPHG
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• ,I\RXQRWLFHDQ\DEQRUPDORUGDQJHURXVFRQGLWLRQVVXVSHQGRSHUDWLRQLPPHGLDWHO\DQG
LQVSHFWVROYHSUREOHPV
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3XPSPRXQWLQJ
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,QIORRGHGVXFWLRQDSSOLFDWLRQ
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*)ORRGHGVXFWLRQLVUHFRPPHQGHGIRUKRWOLTXLGWUDQVIHURUIRU
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EHORZ3ODFHWKHSXPSDVFORVHWRWKHVXSSO\WDQNDV
SRVVLEOH
Model 6XFWLRQOLIW
)$( P
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&RQWDFWXVIRUGHWDLOHGLQIRUPDWLRQ

16 3XPSPRXQWLQJ
Select a location
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3URYLGHIRXUKROHVIRUSXPSDQFKRULQJ,'RU0KH[DQFKRULQJEROWVDQGSODWHZDVKHUVE\WKHIRO-
ORZLQJSLWFKDQGGHSWK
8VHVSULQJZDVKHUDVQHFHVVDU\
Model Pitch 'HSWK Hole I.D.
)$( PP PP I.D.8
FA-40VEW PP PP M16
5HWLJKWHQWKHVWXGEROWV
7LJKWHQWKHVWXGEROWVWKDWDUH¿[LQJWKH&RYHU)$(RUWKH&RYHU%)$9(:
Model 7LJKWHQLQJWRUTXH
)$( 1P
FA-40VEW 1P
NOTE
$OHDNUHVXOWVLQRSHUDWLRQLIWKHVWXGEROWVDUHORRVH
2
1
3
Pitch
'HSWK
Pitch 'HSWK

17
Installation
/LTXLGOLQHSLSLQJ
1
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The pump has different sizes of the inlet/outlet PFA tube at each model. See the table below.
8VHDSSOLFDEOHWXEH¿WWLQJVIRUWKHFRQQHFWLRQZLWK\RXUSLSLQJV\VWHP
Model 3)$WXEHVL]HV
)$( 5F
FA-40VEW 5F
*6HOHFWDQDSSURSULDWHWXEHILWWLQJVL]H%RWKGLVFKDUJHDQGVXFWLRQOLQH,'VKRXOGEHODUJHUWKDQWKHSXPSRXWOHWLQOHW2'
*HQHUDOMRLQWVFDQEHXVHGKRZHYHUQROHDNDJHLVDOORZHGXQGHUKRWOLTXLGWUDQVIHURUKHDWF\FOH
8VHPHDVXUHVWRNHHSWKHSXPSFRQQHFWLRQVIUHHIURPVWUHVV
3RLQWVWREHREVHUYHG
$LUEORZRUÀXVKDVXFWLRQDQGDGLVFKDUJHWXEHWRJHWULGRIGHEULVSULRUWRFRQQHFWLQJ
ZLWKWKHSXPS
&RQQHFWDVXFWLRQDQGDGLVFKDUJHWXEHWRWKHSXPSLQOHWDQGRXWOHWYLDWKHWXEH¿WWLQJV
8VHPHDVXUHVWRNHHSWKHSXPSFRQQHFWLRQVIUHHIURPVWUHVVVXFKDVZHLJKWDQGWKHUPDOH[SDQVLRQ
contraction.
NOTE
%HVXUHWRVHFXUHHDFKFRQQHFWLRQWRSUHYHQWOHDNDJHDQGDLULQJUHVV
Tube fitting
5FRU5F3)$WXEH3LSLQJ

18
Suction line
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+DYHWKHVXFWLRQOLQHZLGHDQGVKRUWHVWLQIORRGHGVXFWLRQDSSOLFDWLRQ,QVXFWLRQOLIWDSSOLFDWLRQREVHUYHWKH
PD[LPXPVXFWLRQOLIW
7KHVXFWLRQOLIWGLIIHUVZLWKWKHOLTXLG¶VFKDUDFWHULVWLFVWHPSHUDWXUHDQGVXFWLRQOLQHOHQJWK)RUGHWDLOHGLQIRUPDWLRQFRQ-
WDFWXV
Ŷ)LOWUDWLRQVXFWLRQOLQHHQG
,QVWDOODILOWHURUVWUDLQHUDWWKHVXFWLRQOLQHHQGWRSUHYHQWSDUWLFOHVIURPHQWHULQJWKHEHOORZV7KHILOWHURU
VWUDLQHUVKRXOGQRWLQFUHDVHSLSLQJUHVLVWDQFHWRRPXFKREVHUYHWKHPLQLPXPFRPSRVLWHHIIHFWLYHFURVVVHF-
WLRQDOGLDPHWHU
NOTE
,IZDIHUIUDJPHQWVHQWHUWKHSXPSWKH\PD\JHWVWXFNLQWKHEHOORZVDQGHYHQWXDOO\FDXVHIDLOXUH,IWKH\FORJ
WKHSXPSKHDGYDOYHVWKHGLVFKDUJHYROXPHPD\UHGXFHDQGWKHSXPSLQJRSHUDWLRQPD\EHFRPHXQEDO-
anced.
Ŷ:KHQLQVWDOOLQJDYDOYHRQWKHVXFWLRQOLQH
6HOHFWDYDOYHZLWKDQRULILFHHTXDOWRRUODUJHUWKDQSLSH,'$YDOYHZLWKDVPDOORULILFHPD\LQFUHDVHWKHSLSH
UHVLVWDQFHRUHDVLO\EHFORJJHGZLWKFU\VWDOV$OZD\VRSHQYDOYHVGXULQJRSHUDWLRQ
NOTE
2SHUDWLQJWKHSXPSZLWKDVXFWLRQVLGHYDOYHFORVHQHJDWLYHSUHVVXUHLQFUHDVHVLQWKHEHOORZVDQGGHIRUPV
WKHEHOORZVLQZDUGO\
/LTXLGOLQHSLSLQJ

19
Installation
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Discharge line
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The pipe resistance increases as a discharge line becomes longer or the number of bends increases. In
order to decrease pipe resistance, install a dampener and minimizes pulsation.
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Ŷ:KHQLQVWDOOLQJDYDOYHRQWKHGLVFKDUJHOLQH
Select a valve with an orifice equal to or larger than pipe I.D. A valve with a small orifice may increase the pipe
resistance or easily be clogged with crystals. Always open valves during operation. Do not close the valve until
the discharge pressure reaches "0" after the pump is stopped.
NOTE
'RQRWFORVHDGLVFKDUJHYDOYHULJKWDIWHUVWRSSLQJWKHSXPS,PSDFWSUHVVXUHPD\GHIRUPWKHEHOORZV
Ŷ)LOWUDWLRQFLUFXODWLRQ
&KHFNDILOWHULQJDUHDILOWHULQJSHUIRUPDQFHDQGHIIHFWVRQWKHIORZEHIRUHVHOHFWLQJDF\FOHILOWHU$GHVLUHG
IORZPD\QRWEHREWDLQHGLIVHOHFWLRQLVZURQJ
NOTE
:HWWKHILOWHUEHIRUHXVH$GHVLUHGIORZPD\QRWEHREWDLQHGLIWKHILOWHULVGU\)LOWHUGULHVXSLILWLVXQXVHGIRU
DORQJSHULRG5HDGWKHLQVWUXFWLRQPDQXDORIWKHILOWHUIRUGHWDLOV
Ŷ)LOWUDWLRQGLVFKDUJHOLQHHQG
,QVWDOODILOWHURUVWUDLQHULQDGLVFKDUJHOLQHQRWWRUHOHDVHIRUHLJQPDWWHUVRUZDIHUIUDJPHQWV7KHILOWHURU
VWUDLQHUVKRXOGQRWLQFUHDVHSLSLQJUHVLVWDQFHWRRPXFKREVHUYHWKHPLQLPXPFRPSRVLWHHIIHFWLYHFURVVVHF-
WLRQDOGLDPHWHU
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:KHQVWRSSLQJWKHSXPSEHVXUHWRUHOHDVHGLVFKDUJHSUHVVXUHE\RSHQLQJWKHILOWHUWKHDLUYHQWYDOYHRU
WKURXJKDUHWXUQFLUFXLW
NOTE
6WRSSLQJWKHSXPSZLWKRXWUHOHDVLQJGLVFKDUJHSUHVVXUHPD\GHIRUPWKHEHOORZV

20
Degassing
Gas bubbles are generated when a strong acid is fed into the reaction tank or liquid is transferred through a
narrow tube. If such bubbles enter the bellows, the pump runs dry, increasing stroke rate or disturbing liquid
transfer. Take a proper step for degassing.
3ODQ$,QVWDOODEDIIOHWRUHPRYHJDVEXEEOHV
In flooded suction application
,QVWDOODEDIIOHLQDRYHUIORZWDQNWRVHSDUDWHDLU
IURPWKHOLTXLG
In suction lift application
,QVWDOODEDIIOHWRWKHERWWRPRIWKHUHDFWLRQWDQN
$QGWKHQSODFHWKHHQGRIVXFWLRQOLQHXQGHUWKHEDI-
IOHWRVXFNOLTXLGRQO\
3ODQ%,QVWDOODQDXWRPDWLFYDOYH Periodic degassing
3URJUDPDQDXWRPDWLFYDOYHWRRSHQSHULRGLFDOO\
UHJDUGOHVVRIGU\UXQQLQJ)RUH[DPSOHWKHYDOYH
RSHQVIRUWHQVHFRQGVHYHU\WZRPLQXWHV
6RPHILOWHULQJDUHDPD\EHWRRVPDOOWRUHOHDVHDLU
6HOHFWDVXLWDEOHILOWHUVL]H
3URJUDPDQRSHQWLPHDFFRUGLQJWRWKHV\VWHPSHUIRUP-
ance.
Pinpoint degassing
,QVWDOODQDLUGHWHFWRUDWWKHSXPSLQOHWDQGVHWWKH
DXWRYDOYHWRRSHQWLPHO\
$QRWKHUGHWHFWRUDWWKHSXPSRXWOHWZLOOKHOSGHWHFW
EHOORZVUXSWXUH
Bubbles go up.
Baffle
Overflow
tank
P
Reaction tank
Reaction
tank Bubbles are
sucked.
Baffle
Prevents bubbles.
PP
H 2 O 2 ,O 3 ,H 2 OAir vent line
Auto valve
Filter
Pump
Overflow tank
Heater
Reaction
tank
P
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