IWAKI PUMPS FLP-75W User manual

©2014 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
FLP-75W
Iwaki
Pneumatic Drive Bellows Pump
Safety instructions Overview Installation Operation Maintenance Specication
( )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)
T911 '15/02
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 IWAKIPumps (Guangdong) Co., Ltd.
TEL:[phone] FAX:[phone]
Singapore IWAKI Singapore Pte. Ltd.
TEL:[phone] FAX:[phone]
China GFTZIWAKIEngineering&Trading(Guangzhou)
TEL:[phone] FAX:[phone]
Spain IWAKI Europe GmbH, Spain Branch
TEL:[phone] FAX:[phone]
China GFTZIWAKIEngineering&Trading(Beijing)
TEL:[phone] FAX:[phone]
Sweden IWAKI Sverige AB
TEL:[phone] FAX: [phone]
Denmark IWAKI Nordic A/S
TEL:[phone] FAX:[phone]
Switzerland IP Service SA
TEL:[phone] FAX:[phone]
Finland IWAKI Suomi Oy
TEL:[phone] FAX:[phone]
Taiwan IWAKI Pumps Taiwan Co., Ltd.
TEL:[phone] FAX:[phone]
France IWAKI France S.A.
TEL:[phone] FAX:[phone]
Taiwan IWAKIPumpsTaiwan(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]
HongKong IWAKI Pumps Co., Ltd.
TEL:[phone] FAX:[phone]
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 distributor.
a. Check if the delivery is correct.
Check the nameplate to see if the information such as model codes are as ordered.
b. Check if the required number of accessories is provided.
<Attached accessories>
• Four straight ttings (displacement sensor cooling air inlets/outlets) with plugs.
• Two silencers
*Necessary electrical wiring male connectors are attached to the LPC-1 controller package.
c. 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.................................................................... 7
Warning..........................................................................................................................................................8
Caution...........................................................................................................................................................9
Precautions for use ....................................................................................................................................11
Overview...................................................................................12
Introduction .................................................................................................................................................12
Pump structure & Operating principle......................................................................................................12
Features...................................................................................................................................................13
Operation mode .......................................................................................................................................13
Safety functions........................................................................................................................................13
Part names...................................................................................................................................................14
Pump........................................................................................................................................................14
LPC-1 .......................................................................................................................................................15
Control panel.......................................................................................................................................15
LEDs ...................................................................................................................................................16
Operating conditions..................................................................................................................................17
Pump stroke .............................................................................................................................................17
Supply air pressure range........................................................................................................................17
Liquid temperature range.........................................................................................................................17
Liquid characteristics ...............................................................................................................................17
Do not run the pump with the following liquid: ....................................................................................17
Use care handling the following liquid:................................................................................................17
Operation and Stoppage..........................................................................................................................18
During operation .................................................................................................................................18
When stopping the pump....................................................................................................................18
During stoppage..................................................................................................................................18
Air exhaust port........................................................................................................................................18
Leak sensor..............................................................................................................................................18
Ambient temperature................................................................................................................................18
Pump surface temperature.......................................................................................................................18
Noise from pump......................................................................................................................................18
Identication codes....................................................................................................................................19

4Contents
Installation .............................................................................. 20
Pump mounting...........................................................................................................................................20
Liquid line piping ........................................................................................................................................22
Suction line...............................................................................................................................................23
Flooded suction...................................................................................................................................23
Filtration (suction line end)..................................................................................................................23
When installing a valve on the suction line:........................................................................................23
Discharge line ..........................................................................................................................................23
When installing a valve on the discharge line:....................................................................................23
Filtration (circulation)...........................................................................................................................23
Filtration (discharge line end)..............................................................................................................23
Depressurization at pump stop...........................................................................................................23
Degassing................................................................................................................................................24
Air line piping ..............................................................................................................................................25
Before air piping.......................................................................................................................................25
Solenoid valve (SV).............................................................................................................................25
Regulator.............................................................................................................................................25
Air line piping layout (FLP-75W)..........................................................................................................25
Supply air port I.D...............................................................................................................................26
Effective cross-sectional area..................................................................................................................27
Effective cross-sectional area required for decompression process..................................................27
Composite effective cross-sectional area required for compression process....................................27
Air supply capacity of pneumatic devices...........................................................................................28
Preventive measures against condensation .......................................................................................28
Recommended pneumatic devices.....................................................................................................28
Air line piping diagram..............................................................................................................................29
Electric wiring .............................................................................................................................................31
Installation................................................................................................................................................31
Lead wires...........................................................................................................................................31
Extension of leak sensor wires ...........................................................................................................31
Installation of proximity switch wires...................................................................................................31
Extension of proximity switch wires ....................................................................................................31
Preventative measures against noise.................................................................................................31
Wiring diagram (LPC-1)............................................................................................................................32
Wiring diagram (normal operation with a single solenoid valve)..............................................................33
Wiring diagram (feedback control with a single solenoid valve)...............................................................34
End terminals ...........................................................................................................................................35
Power line............................................................................................................................................35
Single solenoid valve ..........................................................................................................................35
Double solenoid valve.........................................................................................................................36

5
Contents
User PLC.............................................................................................................................................36
Proximity switch/Displacement sensor/Leak sensor...........................................................................38
Electropneumatic regulator or Pressure sensor..................................................................................39
Operation................................................................................. 40
Before operation .........................................................................................................................................40
Programming menu ....................................................................................................................................42
Basic key operation..................................................................................................................................43
Main menu ..........................................................................................................................................43
Pump operation...........................................................................................................................................44
Pump model selection..............................................................................................................................44
Teaching...................................................................................................................................................45
Manual operation .....................................................................................................................................46
Operation start....................................................................................................................................46
Operation stop.....................................................................................................................................48
AUTO operation .......................................................................................................................................49
Display information...................................................................................................................................50
Operation display................................................................................................................................50
Total count display ..............................................................................................................................50
Speed compensation (AUTO mode)........................................................................................................50
External input for speed compensation operation..............................................................................50
Operation programming.............................................................................................................................51
Feedback control (4. SETTING: 1. QUANT. CONST. CTRL)...................................................................52
Target ow setting ...............................................................................................................................52
Electropneumatic regulator (EPREG) setting......................................................................................53
Liquid volume per shot setting ............................................................................................................54
Alarm output (4. SETTING: 2. ALARM)...................................................................................................55
Time up alarm setting (Default: 20sec)..............................................................................................55
Fast alarm setting (Default: 140spm)..................................................................................................55
Life alarm setting (Default: 99,999,999 counts).................................................................................55
Setting conrmation (4. SETTING: 3. SET VALUE CONFIRMATION)....................................................56
Stroke length conrmation ..................................................................................................................56
Pump model........................................................................................................................................56
MANU or AUTO ..................................................................................................................................56
Drive mode..........................................................................................................................................56
Default setting (4. SETTING: 4. RESET ALL DATA)................................................................................57
Keypad lock (5. KEY PROTECT).............................................................................................................58
Keypad lock activation ........................................................................................................................58
Keypad lock deactivation ....................................................................................................................58
Total number of pump shots conrmation/cancellation (6. TOTAL COUNT) ...........................................59

6Contents
Conrmation........................................................................................................................................59
Cancellation ........................................................................................................................................59
Regulator set pressure conrmation (8. PRESSURE SENSOR).............................................................60
Alarm output cancellation (9. ALARM RESET) .......................................................................................61
Maintenance............................................................................ 62
Troubleshooting..........................................................................................................................................62
Inspection ....................................................................................................................................................65
Daily inspection........................................................................................................................................65
Periodic inspection...................................................................................................................................65
Wear part list............................................................................................................................................66
Specication/Outer dimension..................................................................................................................67
Specication.............................................................................................................................................67
Pump...................................................................................................................................................67
LPC-1 controller..................................................................................................................................67
Proximity switch ..................................................................................................................................68
Displacement sensor ..........................................................................................................................68
Leak sensor.........................................................................................................................................68
Outer dimension.......................................................................................................................................69
FLP-75W .............................................................................................................................................69
LPC-1 controller..................................................................................................................................69
Part names...............................................................................................................................................70
FLP-75W .............................................................................................................................................70

7
Safety instructions
Safety instructions
WARNING
CAUTION
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 follow-
ing symbols. Please pay attention to the information associated with the symbols.
Indicates mishandling could lead to a fatal or serious acci-
dent.
Indicates mishandling could lead to personal injury or prop-
erty damage.
A symbol accompanies each precaution, suggesting the use of "Caution", "Prohibited actions"
or specic "Requirement".
Export Restrictions
Technical information contained in this instruction manual might be treated as controlled tech-
nology 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.
Caution marks Prohibited marks Requirement marks
Prohibited
Electrical
shock
Caution Do not rework
or alter Requirement Wear
protection
Fire ban

8
WARNING
WARNING
Turn off power before work
Risk of electrical shock. Be sure to turn off power to stop the pump and
related devices before service is performed. Let other people know about
the situation by displaying a notice such as "POWER OFF (Maintenance)"
near the power switch.
Conrm safety in your working area
Keep away from the pump when turning on power. The pump doesn't have
an ON-OFF switch. The pump starts as a power cable is plugged in.
Stop operation
If you notice any abnormal or dangerous conditions, suspend operation
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 specied conditions only.
Do not modify the pump
Alterations to the pump carries a high degree of risk. It is not the manufac-
turer'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 re-
sistant gloves, a mask and a face shield during disassembly, assembly or
maintenance work. The specic solution will dictate the degree of protec-
tion. Refer to MSDS precautions from the solution supplier.
Spill precautions
Ensure protection and containment of solution in the event of plumbing or
pump damage (secondary containment).
Do not touch the pump or pipe with bare bands
Risk of burning. The surface temperature of the pump or pipe rises high
along with liquid temperature in or right after operation.
Do not remove covers
Do not remove the right-and-left cylinder head covers or the top-and-bot-
tom covers during operation. Or personal injury may result.
Depressurize piping before disassembly
Release a pressure from both liquid and air lines before dismantling the
pump or removing piping.
Requirement
Do not remodel
Wear
protectors
Requirement
Requirement
Requirement
Caution
Requirement
Prohibited
Prohibited

9
Safety instructions
CAUTION
Do not lift the pump by gripping the right-and-left cylinder head cov-
ers or the top-and-bottom covers
The pump can drop unintentionally as one of those parts breaks. Hold the
pump by the handgrips to lift it up.
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.
Use specied power only
Do not apply any power other than that specied on the nameplate. Other-
wise, failure or re may result. Ensure the pump is properly grounded.
Ventilation
Fumes or vapours can be hazardous with certain solutions. Ensure proper
ventilation at the operation site.
Do not install or store the pump:
• In a ammable atmosphere.
• In a dusty/humid environment.
• In a corrosive atmosphere.
Do not stand on the pump
Do not use the pump as a platform. Injury or damage may result when the
pump turns over.
Flushing before operation
Flush the inside of the pump and piping with pure water or the liquid to be
delivered before the start of operation.
Do not run the pump with the following liquid:
• Liquid that easily crystallizes
• Slurry
• Low conductivity hydrocarbon liquid
Use care handling the following liquid:
• Stripper
• Solvent
• Hydrazine
• Fuming sulfuric acid
CAUTION
Requirement
Requirement
Requirement
Requirement
Requirement
Prohibited
Prohibited
Prohibited
Requirement

10
CAUTION
Static electricity
When low electric conductivity liquids such as ultra-pure water and fluor
inactive liquid (e.g. FluorinertTM) are handled, the static electricity may be
generated in the pump and may cause static discharge. Take counter-
measures to remove the static electricity.
Wear part replacement
Follow instructions in this manual for wear part replacement. Do not dis-
mantle the pump beyond the extent of the instructions.
Before returning product
Be sure to drain chemicals and clean the inside of the pump before return
so that a harmful chemical does not spill out in transit.
Observe the maximum stroke rate
Operation above the maximum stroke rate may reduce the life of bellows.
See "Specification" on page 67 for detail. Set a fast alarm speed to the
LPC-1 controller to avoid over-speed operation.
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
Requirement
Requirement
Requirement
CAUTION