IWAKI PUMPS HRP-54V User manual

© 2008 IWAKI CO.,LTD.
Iwaki Hi-Resolution Pump
HRP (Standard)
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.
T674-2 '10/01
( )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 Italia S.R.L. TEL : [phone] FAX : [phone]
Austria IWAKI (Austria) 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. TEL : [phone] FAX : [phone] Norway IWAKI Norge AS TEL : [phone] FAX : [phone]
China IWAKI Pumps (Guandong) Co., Ltd. TEL : [phone] FAX : [phone] Singapore IWAKI Singapore Pte. Ltd. TEL : [phone] FAX : [phone]
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2
Order conrmation
HRP
Instruction manual
Instruction manual
HRP with a special power cable
Order conrmation
After unpacking, check the following points. Contact us or your nearest
dealer if the delivery is imperfect.
a. Check if the delivery is as per order.
Check the nameplate to see if the dis-
charge capacity, discharge pressure
and voltage are as per order.
b. Check for transit damage.
c. Check for loose screws.
Delivery should include...

3
Contents
Contents
Order conrmation ............................................................................................. 2
Safety instructions ....................................................................... 5
WARNING.......................................................................................................... 6
CAUTION........................................................................................................... 7
Precautions for use ......................................................................................... 9
Outline ......................................................................................... 11
Introduction.....................................................................................................11
Pump structure & Operating principle .........................................................11
Features.......................................................................................................12
Operational function ....................................................................................12
Part names.......................................................................................................13
Identication codes........................................................................................14
Installation .................................................................................. 15
Pump mounting...............................................................................................15
Pipework ..........................................................................................................16
Tube connection ..........................................................................................16
Check valve mounting .................................................................................17
AVC check valve with an air vent (Option)...................................................19
Wiring.............................................................................................................. 20
Power & External signal cables.................................................................. 20
Operation..................................................................................... 24
Before operation ............................................................................................ 24
Points to be checked ...................................................................................24
Retightening of pump head unit xing screws .............................................24
Degassing................................................................................................... 25
Operation.................................................................................................... 27

4
Contents
Operation of the Pulse control type....................................................... 27
Operation of the 4-20mA control type................................................... 27
Operation of the 1-5V control type........................................................ 28
Operation of the STOP control type...................................................... 28
Flow rate adjustment .................................................................................. 29
Relation between the ow rate & stroke rate ........................................ 29
Maintenance................................................................................ 30
Troubleshooting............................................................................................. 30
Inspection........................................................................................................31
Daily inspection ...........................................................................................31
Periodic inspection ..................................................................................... 32
Before a long period of stoppage ............................................................... 32
Wear part replacement.................................................................................. 33
Wear part list............................................................................................... 33
Before replacement .................................................................................... 34
Pump head/Diaphragm replacement.......................................................... 34
Maintenance (AVC check valve)....................................................................37
Exploded view (AVC check valve) ...............................................................37
Wear parts list (AVC check valve) .............................................................. 38
Wear parts replacement (AVC check valve)............................................... 38
Exploded view................................................................................................ 42
Pump head, Drive unit & Control unit ..........................................................42
Specication/Outer dimension .................................................................... 43
Specication ............................................................................................... 43
Pump & Drive units................................................................................ 43
Control unit ............................................................................................ 43
Power cable........................................................................................... 43
Option ......................................................................................................... 44
Check valve with an air vent.................................................................. 44
Check valve........................................................................................... 44
Outer dimension ......................................................................................... 45
HRP-54V ............................................................................................... 45
HRP-54H............................................................................................... 45

5
Safety instructions
Read through this section before use. This section describes
important information for you to prevent personal injury or
property damage.
■ Pictorial indication
In this instruction manual, the estimated risk of degree caused by incorrect use
is ranked with the following pictorial indications. First, fully understand informa-
tion on the pictorial indications.
Indicates mishandling could lead to a fatal or
serious injury accident.
WARNING
Pictorial indication accompanies each precaution, suggesting "Caution", "Pro-
hibition" and "Requirement".
Indicates mishandling could lead to personal or
property damage.
CAUTION
Caution marks Prohibition mark Requirement mark
Prohibition
Electrical
shock
Caution
Do not remodel
Requirement
Wear
protectors
Earthing
Safety instructions
For exportation
Technology related to the use of goods in this instruction manual falls in the
category of technology contained in the Foreign Exchange Order Attachment,
which includes complementary export control of technology. Please be remind-
ed that export license, which is issued by the Ministry of Economy, Trade, and
Industry could be required, when this is exported or provided to someone even
in Japan.

6WARNING
Turn off power before work
Risk of electrical shock. Be sure to turn off power to stop the pump
and related devices before work.
Stop the operation
On sensing any abnormality or dangerous sign, suspend operation
immediately and inspect/solve problems.
Do not use the pump in anything other than a specied purpose
The use of the pump in any purpose other than those clearly speci-
ed may result in failure or injury. Use this product in a specied
condition.
Do not modify the pump
Remodelling the pump carries a high degree of risk. We are not
responsible for any failure or injury results from remodelling.
Wear protective clothing
Always wear protective clothing such as an eye protection, chemi-
cal resistant gloves, a mask and a work cap during dismantlement,
assembly or maintenance work.
Do not damage the power cable
Do not pull or knot the power cable or place a heavy stuff on it.
Damage to the power cable could lead to a re or electrical shock.
Do not use the pump in a ammable atmosphere
Do not place dangerous or ammable goods near the pump for your
safety.
WARNING
Prohibition
Requirement
Do not remodel
Wear
protectors
Electrical
shock
Prohibition
Prohibition

7
CAUTION
A qualied operator only
The pump must be handled or operated by a qualied person with a
full understanding of the pump. Any person who is not familiar with
this product should not take part in operation or management.
Use a specied power only
Do not apply any power other than the one specied on the nameplate.
Otherwise, failure or re may result.
Do not run pump dry
Do not run pump dry for more than 30 minutes (even when the
pump runs for degassing). Otherwise, the pump head unit xing
screws may loosen, or the pump head unit and valve case may
deform by friction heat, and consequently leakage results. Optimise
your system in order for the pump not to run dry.
Do not wet electric parts or wiring
Risk of re or electrical shock. Install the pump free from liquid spill.
Ventilation
Poisoning may result when handling a toxic or odorous liquid. Keep
good ventilation in your operating site.
Do not install or store the pump in the following places where...
• Under a ammable atmosphere or in a dusty/humid place.
• Ambient temperature is beyond 0-40 degrees Celsius.
• Under direct sunlight or wind & rain.
Countermeasure against efux
Take a protective measurement against an accidental chemical
overow results from pump or piping breakage.
CAUTION
Prohibition
Requirement
Prohibition
Prohibition
Caution
Caution
Requirement

8
CAUTION
Observe the correct polarity
Otherwise the pump may fail.
Do not use the pump in a water place
The pump is not totally waterproof. The use of the pump in water or
high humidity could lead to electrical shock or short circuit.
Wear part replacement
Follow instructions in this manual for wear part replacement. Do not
dismantle the pump beyond the extent of the instructions.
Do no use a damaged pump
Using a damaged pump could lead to an electric leak or shock.
Disposal of the used pump
Dispose of any used or damaged pump in accordance with relevant
regulations. Consult a licensed industrial waste products disposing
company.
Keep the pump head unit securely xed
Liquid may leak if pump head unit xing screws are loose. Tighten
the screws diagonally and evenly before initial operation. Also, peri-
odically tighten the screws for the prevention of leakage.
Tightening torque: 0.7 N•m
Prohibition
Requirement
Requirement
Caution
Prohibition
Caution

9
Precautions for use
• Electrical work should be performed by a qualied opera-
tor. Otherwise, personal or property damage accident may
result.
• Do not install the pump in the following places where...
–Under a ammable atmosphere or in a dusty/humid place.
–Under direct sunlight or wind & rain.
–Ambient temperature is beyond 0-40 degrees Celsius.
Protect the pump with a cover when installing it out of
doors.
• Select a level location where is free from vibration and
liquid can't stay. Fix the pump with M4 screws so as not to
vibrate. If the pump is installed at a tilt, the ow may reduce.
• When two or more pumps are installed, the pump opera-
tion interacts each other and vibration becomes signicant,
resulting in poor performance or failure of internal electri-
cal devices. Select an installation location where tolerates
vibration to enough degree.
• Keep a wide maintenance space around the pump.
• Install the pump as close to a supply tank.
• Install the pump in a cool and dark place when handling
liquids that readily generate gas bubbles such as sodium
hypochlorite or hydrazine solution. Flooded suction mount-
ing is strongly recommended when using the pump with a
supply tank.
Precautions for use
Caution
Caution
Caution
Caution
Requirement

10
Precautions for use
• Be careful not to drop the pump onto the oor. A strong
impact may reduce pump performance. Do not use a pump
which has once damaged. Otherwise an electrical leak or
shock may result.
• The pump is a light water-/dust-proof structure of IP65, but
is not totally waterproof. Do not have the pump wet with the
liquid handled or rainwater.
• Never wet the pump head, control unit and drive unit. Oth-
erwise, Failure or an accident may result. Immediately wipe
off liquid if the pump has got wet.
• Do not close the discharge line during operation. Other-
wise, liquid may leak or tubing may break.
• Do not remove the control unit. Otherwise, an electrical
circuit or the drive unit may fail.
• Release the pressure from the discharge line before disman-
tling the pump or removing tubing. Otherwise, chemical liquid
gushes out.
• Be careful not to come in contact with residual liquid.
• Do not clean the pump or nameplate with a solvent such
as benzene and thinner. This may discolour the pump or
erase printing. Use a dry cloth or a wet cloth with water or
neutral detergent.
Caution
Caution
Caution
Caution
Caution
Requirement
Benzine
Thinner

11
Introduction
The information such as characteristics, features and part
names are described in this section.
Introduction
Pump structure & Operating principle
The HRP series is a diaphragm metering pump which consists of a pump
head, drive unit and control unit. A diaphragm is directly driven by electromag-
netic force.
Principle of operation
The pulse signal controls the electromagnetic force in order to make recip-
rocating motion that is assisted by spring force. The reciprocating motion is
transferred to a diaphragm through a plunger and then volumetric change oc-
curs in the pump head. This action transfers liquid along with pump head valve
action.
Pump head
Drive unit
Spring
Pump head valve
(Discharge side)
Pump head valve
(Suction side)
Plunger
Diaphragm
Control unit
Outline
IN
OUT

12
Introduction
Features
12/24VDC power voltage
The HRP series powered by 12VDC or 24VDC offers the best t to the built-in
application.
High resolution
Digitally-controlled spm range is 0-720spm. The minimum ow of 0.055ml per
shot offers a constant imperceptible injection.
*The operation speed of the stop control type is always xed to 720spm and is not vari-
able.
Waterproof and dustproof structure
The sealed drive unit and control unit assure the water-/dust-proof of IP65.
*This pump is not completely water resistant. Do not expose it to wind and rain.
Operational function
The HRP pump is controlled by the external signal and falls into the following
types.
Pulse control type (see page 27)
The input of the pulse signal controls the pump operation (stroke rate).
The pump makes one shot per pulse synchronously.
*The signal input is required to make operation after power activation for this type.
*The pump can not run over 720spm even if the external signal is entered to run the
pump beyond the maximum spm.
4-20mA control type (see page 27)
The input of 4-20mA proportionally controls the pump operation (stroke rate).
*The signal input is required to make operation after power activation for this type.
1-5V control type (see page 28)
The input of 1-5V proportionally controls the pump operation (stroke rate).
*The signal input is required to make operation after power activation for this type.
Stop control type (see page 28)
The input of the stop signal suspends the pump operation.
*This type of pump starts to run at 720spm upon power activation.

13
Part names
Part names
Pump head unit
(Pump head)
Nameplate
Describes the pump
specification.
Inlet
Outlet
Power cable terminal
Control unit
Base
Always fix with screws.
Drive unit
V type
H type

14
Identication codes
Identication codes
The model code represents the following information.
HRP - 5 4 V - 1 P 1 -
a b c d e f g H
a. Series name
HRP: High resolution pulse pump
b. Drive unit (Average power consumption)
5: 5.6W
c. Discharge capacity
4: 38ml/min
d. Pump head
V: Vertically oriented H: Horizontally oriented
e. Power voltage
1: 12VDC
2: 24VDC
f. Control method
P: Pulse control A: 4-20mA control V: 1-5V control S: Stop control
g. Connection bore
No. Tube connection bore
1ø3×ø6mm
2ø4×ø6mm
3ø1/8"×ø1/4"
H. Special version
Wet end materials
Pump head Valve O ring Valve seat Valve spring Gasket Diaphragm
PVDF Alumina
ceramic FKM FKM PEEK
(H type only)
PTFE PTFE+
EPDM (non wet end)
*Valve springs are equipped to the H type only.
Material code
PVDF : Polyvinylidene diuoride FKM: Fluorine-contained rubber
PTFE : Polytetrauoroethylene PEEK: Polyetheretherketone

15
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 when installing the pump.
• Be sure to turn off power to stop the pump and related devices before work.
• Upon sensing abnormal condition or a dangerous sign, stop the work im-
mediately. Remove problems before resuming work.
• Do not place dangerous or ammable goods near the pump for your safety.
• Risk of an electrical leak or shock. Do not use a damaged pump.
Pump mounting
Select an installation location and mount the pump.
Necessary tools
• Two M4 screws (pump xing) • Phillips screwdriver
• Two plate washers (pump xing)
*Use chemical resistant tools as necessary.
Select a suitable place.
Always x the pump on a at oor where is free of vibration and liquid
can't stay. See page 9 for detail.
Position the pump lower than the supply tank to assure ooded suction.
Fix the pump by M4 screws.
Be sure to x the pump at two points.
NOTE
Install the pump horizontally. If the pump is installed at a
tilt, the ow may reduces.

16
Pipework
Pipework
Connect tubes to the pump and install a check valve.
Before operation
• Select proper chemical resistant tubes.
• The tubes should resist liquid temperature and pressure.
• Cut the tube ends at.
Tube connection
Pass a tube into the tting nut and slide down
the tube onto the tting. Then hand tighten
the tting nut until it bottoms out.
*The tting nut is made by plastics and may be
broken if it is tightened too much.
Connect tubes into the inlet and outlet.
*Be careful not to bend a tube completely.
Tube end (Side view)
Tube
Fitting nut
Fitting
(Both inlet
& outlet)
Slide it down
1
Tube
Tube
Outlet
Inlet
Tubes
Inlet
Outlet

17
NOTE
Air vent valve mounting
• Install valves on both suction and discharge
lines for the convenience of maintenance.
• Install a three-way joint on the discharge line
close to the pump to lay on an air vent line.
• Keep a distance between the suction tube
end and the tank bottom.
• In the suction lift application, install a foot
valve for the prevention of a back ow at
pump stop. A ltering foot valve is also avail-
able to prevent deposits and foreign matters
from entering.
Check valve mounting
The use of a check valve prevents a back ow, siphon and overfeeding.
In the following cases install a check valve to assure back pressure and a con-
stant ow rate.
• A n injection point is below the suction side
liquid level at atmospheric pressure. In this
state siphon happens.
• The discharge side liquid level is higher
than the suction side one but the elevation
difference between two liquid levels is ve
meters or below. In this state the differential
pressure between two liquid levels is too
low and overfeeding happens.
Pipework
Pump
Maintenance
valve
Check valve
Discharge line
Three way joint
Air vent
valve
Suction line
Foot valve
(Suction lift)
Suction side
Suction side
Discharge side
Discharge side
5m or
below

18
Pipework
• Suction line pressure is higher than discharge line
pressure. In this state siphon or overfeeding happens.
Mount the optional check valve at the discharge tube end.
*The CA check valve has R1/2 and R3/8 thread connections as well as tube
connection. Cut off and adjust the connection length to t the check valve into
tubing.
CA check valve CB check valve
*Tubes can be connected to both ends of the CB check valve. Contact us or
your nearest dealer for detail.
NOTE
Periodically clean or replace the check valve with new one because it may be clogged
when handling sodium hypochlorite or other crystallizing liquids.
Tubing layout
Flooded suction application Suction lift application
*Flooded suction is recommended when handling a gaseous liquid such as sodium hypochlorite.
Outer dia Ф9R1/2
R3/8
1
Pump
Maintenance (shutoff) valve Foot (Backflow prevention) valve
Pressure (monitoring) gauge
Air vent valve
Air vent valve
Pump
Check (Siphon prevention) valve
Maintenance (shutoff) valve
Check (Siphon prevention) valve
Pressure (monitoring) gauge
Maintenance (shutoff) valve

19
AVC check valve with an air vent (Option)
AVC check valve is designed for being used with the HRP and works for both
back-ow check and bleeding.
■ Specication
Model Set pressure Tube connection bore
AVC-FC1
0.1MPa
ø3×ø6mm
AVC-FC2 ø4×ø6mm
AVC-FC3 1/8"×1/4"
■ Back-ow check/Bleeding changeover
Select either function by rotating the changeover knob.
*The knob can rotate up to 270 degrees. A stopper is provided to determine the rota-
tion limit of the knob.
NOTE
Do not apply much stress to the stopper screw, or it may break.
OUT
IN
38
30
(85)
15
(57)
(42)
26 30
3.5
AIR
AVC air vent check valve
Changeover knob
OUT
IN
AIROUT
OUT
IN
AIROUT
IN
Stopper
Changeover
knob
Back-flow check Bleeding
270°270°
Pipework

20
Wiring
Wiring for the power source, earthing and external signal.
Observe the following points during wiring work.
• Electrical work should be performed by a qualied operator. Always ob-
serve applicable codes or regulations.
• Observe the rated voltage. Otherwise the electrical circuit on the control
unit may break.
• Do not perform wiring work while the power is on. Otherwise, an electri-
cal shock and short circuit may result, and consequently the pump may
fail. Be sure to turn off power before wiring work.
• Be careful for the power not to be turned on during work.
• Observe the correct polarity.
• Always use the attached triplex cable.
• Do not extend cable length more than 10m.
• Do not lay on the cable out of doors.
Power & External signal cables
Before work
• Check that the main power is turned off.
• Wait for one minute to start wiring work. The internal pump is still electri-
cally charged right after power is turned off.
Applicable power cable
Use the attached triplex cable.
Triplex cable: UL3265 AWG22
Pink: +12VDC/+24VDC
Black: GND
White: EXT
* The attached triplex cable is designed for the HRP. Do not use another cable.
Wiring