IWAKI APN-P60-W User manual

Read this manual before use of product
IWAKI
Gas-Liquid Transfer Pump
APN-P60-W (built-in type)
Instruction Manual

Thank you for selecting an IWAKI APN-P60-W gas-liquid trans-
fer pump (BLDC motor). This instruction manual deals with
"Safety Instructions", "Outline", "Installation", "Operation"
and "Maintenance" sections.
Please read through this instruction manual to ensure the opti-
mum performance, safety and service of your pump.
This instruction manual should be kept on hand by the end user
for quick reference.
Contact us or your nearest dealer if you have any questions.
Important Instruction
WARNING
Nonobservance or misapplication of the
contents of “Warning” section could lead to
a serious accident which may result in death.
CAUTION
Nonobservance or misapplication of the
contents of “Caution” section could lead to
personal injury or property damage.
Types of Symbols
Indicates a prohibited action or procedure. Inside or near this cir-
cle, a concrete and practical image of the activity to be avoided is
depicted.
Indicates an important action or procedure which must be per-
formed or carried out without fail. Failure to follow the instruc-
tions herein can lead to malfunction or damage to the pump.
For the Safe and
Correct Handling of the Pump
●"Safety Instruction" section deals with important details about
handling of the product. Before use, read this section carefully for
the prevention of personnel injury or property damage.
●Observe the instructions accompanied with "WARNING" or
"CAUTION" in this manual. These instructions are very impor-
tant for protecting pump users from dangerous situations.
●The symbols on this instruction manual have the following meanings:
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.
Contents
Safety Instructions ······················································· 1
Outline 1. Unpacking & Inspection····························· 3
2. Operating principle ·································· 3
3. Identification code···································· 4
4. Specifications ········································· 4
5. Outer dimension ······································ 5
6. Performance curve ··································· 6
7. Overview & Label···································· 6
8. Part names & Structure······························ 7
Installation 1. Before installation ···································· 8
2. Installation/Tubing/Electrical wiring ············ 10
Operation 1. Before operation ····································· 13
2. Pump operation ······································ 14
Maintenance 1. Troubleshooting······································ 15
2. Maintenance & Inspection ························· 15
3. Wear part replacement······························ 16

- 1 -
Safety Instructions
● 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.
● 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 specified may result in
failure or injury. Use this product in specified
conditions only.
● Do not modify the pump
Alternations to the pump carries a high
degree of risk. It is not the manufacturer'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 resistant gloves, a
mask and a face shield during disassembly,
assembly or maintenance work.
Electrical shock
Prohibited
Prohibited
No remodeling
Wear protectors
WARNING
Electrical shock
WARNING
● Use specified power only
Do not apply power other than that speci-
fied on the nameplate. Otherwise failure or
fire may result. Ensure the pump is properly
grounded.
● Do not damage the power cable
Do not pull, knot, or crush the power cable.
Damage to the power cable could lead to a
fire or electrical shock if cut or broken.
● Do not operate the pump in a flammable
atmosphere
Do not place explosive or flammable mate-
rial near the pump.
CAUTION
● Qualified personnel only
The pump should be handled or operated
by a qualified personnel with a full under-
standing of the pump.
● Ventilation
Fumes or vapours can be hazardous with
certain solutions. Ensure proper ventilation
at the operation site.

- 2 -
Safety Instructions
● Do not install or store the pump:
1. Where ambient temperature falls below
0°C or exceeds 40°C.
2. Under a flammable/corrosive atmosphere.
● Spill precautions
Ensure protection and containment of
solution in the event of plumbing or pump
damage (secondary containment).
● Keep electric parts and wiring dry
Risk of fire or electric shock. Install the
pump where it can be kept dry.
● Do not use a damaged pump
Use of a damaged pump could lead to an
electric shock or death.
● Stop operation
If you notice any abnormal or dangerous
conditions, suspend operation immediately
and inspect/solve problems.
● 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.
CAUTION
Prohibited
Prohibited
Caution
Prohibited
Prohibited
Electrical shock
Prohibited
CAUTION
● Do not touch the pump or pipe with bare hands
Risk of burning. The surface temperature of
the pump or pipe rises high along with liquid
temperature in or right after operation.
● Electromagnetic precautions
This product is not protected against an
electromagnetic field. Take appropriate
measures as necessary.
● Damaged power cable
Do not use any damaged power cable for
the prevention of a fire or electrical shock.
The cable is not replaceable, so that the
whole pump unit needs to be replaced
when the cable is damaged.
● 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.

2. Operating principle
The APN-P60-W is a gas-liquid transfer pump with a small
size diaphragm.
The rotary motion of the motor is converted via a con-
necting rod to the reciprocation of the diaphragm in the
pump chamber, where the mixture of gas and liquid is
transferred from the inlet to outlet.
- 3 -
Before use, check the specification, limitation and hazardous
nature of the pump.
1. Unpacking & Inspection
On unpacking the product, check the following points. If
you find any problems, contact your nearest distributor.
1. Check the information on the nameplate to see that the
product is delivered as per order.
2. Check for transit damage, deformation, and loose bolts.
Outline
Valve
Gasket
Diaphragm
Connecting rod

- 4 -- 4 -
Outline
3. Identification code
APN- P 60 G D4 - W 02
a b c d e f
a. Pump head
P : Dual-head with in-line tubing
b. Series name
60 : APN-60
c. Bracket type
No code : without base
G : with base
d. Rated voltage
D4 : 24V BLDC (with variable speed control)
e. Gas-liquid transfer type
f. Special specification
No code : Standard
01-99 : Special design
4. Specifications
■ Pump
Gas transfer Liquid transfer Motor Connec-
tion
Weight
(g)
Max. air
ow
(ml/min)
Max.
discharge
pressure
(MPa)
Max.
vacuum
(kPa)
Max.
liquid ow
(ml/min)
Max.
discharge
pressure
(MPa)
Rated
voltage
(V)
Rated
current
(A)
Tube ID
2400
(1200×2) 0.08 47. 9 9 1000
(500×2) 0.05 24DC 0.86 ø5.5 240
NOTE1. Observe the maximum discharge pressure.
NOTE2. The max liquid flow is based on the operation with clean
water at 20ºC and may change with liquid temperature, vis-
cosity and specific gravity.
NOTE3. Allowable gas temperature range is 5-40°C.
Allowable liquid temperature range is 10-40°C.
NOTE4. Allowable ambient temperature range is 5-40°C.
NOTE5. Maximum noise level is 65dB at 1m (A scale) in operation
with clean water at 20°C.
■ Wet end material
Parts Materials
Pump head GFRPP
Diaphragm PTFE/EPDM
Valve FKM
Valve seat GFRPP
Gasket FKM
GFRPP: Glass fiber reinforced polypropylene
PTFE: Polytetrafluoroethylene
EPDM: Ethylene propylene diene monomer
FKM: Fluorine-contained rubber (Viton®)

- 5 -
5. Outer dimensions
■ APN-P60D4-W
Dimension in mm
- 5 -
Outline
(31)
12
ø3.2
ø5.5
11
(95)
(6)
(300)
(52)
(55)
19
13
(51.3)
13
8×M3 Effective depth is 6mm.
(42)
(ø32)
(52.5)
IN
OUT
IN
OUT
■ APN-P60GD4-W
Dimension in mm
(6)
(300)
(31)
12
ø3.2
ø5.5
11
(41)
37
(64.5) 15
(95)
(52)
(55)
3.5
R1.75
(47)
(52.5)
IN
OUT
IN
OUT

- 6 -- 6 -
6. Performance curve
Outline
7. Overview & Label
0
400 800 1200 1400
0.02
0.04
0.06
0.08
1000600200
101.32
61.32
87.99
74.66
0
800 1600 2400
0.02
0.04
0.06
0.08
47.99
20001200400
34.66
Gas transfer (with ambient air at 20ºC)
2800
Pressure
(MPa)
Air Flow
(ml/min)
Vacuum
(kPa[abs.])
Pressure
(MPa)
Liquid transfer (with clean water at 20ºC)
Liquid Flow
(ml/min)
Pump head Name plate
Model and MFG. No.
(Production number) are
described.
Driven unit
This pump is not drip-
proof. An installation
location should be free
from liquid spillage.
Base part
Anchor the pump via
the base. For the pumps
with no base, use the M3
screw holes beneath the
driven units.
Outlet Inlet

- 7 -
8. Part names & Structure
No. Part names Q'ty No. Part names Q'ty
1Pump head A 220 Bracket 2
2Valve 435 Bearing 2
3 Valve seat A 2 40 Motor 1
4Diaphragm 260 Set screw (M3×8) 4
8Eccentric cam 262 Screw washer (M3×16) 8
11 Bracket cover 263 Screw (2×6) 4
13 Bearing 266 Screw (M3×6) 4
19 Connecting rod 2103 Gasket 2
Outline
62
1
2
3
4
19
8
35
1166 13 60 20
63
40
103

- 8 -
● Do not install the pump in a
place where the pump can
get wet.
● For gas transfer, 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 may remarkably
shorten.
● Do not install the pump in a
corrosive or flammable gas
atmosphere. Keep good
ventilation in a working area.
The allowable ambient and
air temperature is between
5 and 40°C. Liquid tempera-
ture should be between 10
and 40°C.
1. Before Installation
Read through this instruction manual before use. Carry
out installation work with a full understanding.
Installation
● Observe the rated voltage
specified on the name plate.
Applying any voltage than
the rated one may result in
failure.
● Surface temperature may
rise high in operation but it
dose not mean failure.
Do not touch the pump body
directly or place the objects
which may be deformed by
heat close to the pump.
● Solution in the discharge
line may be under pressure.
Release the pressure
from the discharge line
before disconnecting plumb-
ing or disassembly of the
pump to avoid solution spray.
？V

- 9 -
● Do not tube two or more
pumps in series. It may pre-
vent the motor from starting,
causing burning out or may
damage the diaphragm or
piping.
● Do not tube pump heads in
series. It may prevent the
motor from starting, causing
burning out or may damage
the diaphragm or piping.
Installation

- 10 -
2. Installation/ Tubing/ Electrical wiring
2.1 Installation
1. Installation location
This pump is designed to be built into
equipment under proper protection.
• Do not install the pump in direct
sunlight, wind & rain or mechanical
vibration.
• Select a level location, free from
vibration, that won't hold liquid.
• Keep good ventilation. The pump
should always be free from liquid
spillage.
• Observe the allowable ambient
temperature of 0-40°C and max
ambient humidity of 90%RH.
• Allow sufficient space around the
pump for easy access and mainte-
nance.
2. Pump fixation
Use M3 bolts to anchor the pump.
CAUTION
Do not install the pump on a unsta-
ble place.
2.2 Tubing
1. Before tubing
The short tubing with the minimum
bends is optimal to reduce resistance.
CAUTION
Do not have tubing bent or pressed.
Otherwise, the tube end may break.
2. Tube preparation
• Cut the tube ends flat beforehand.
• Use chemically-resistant tubes or
temperature-/pressure-resistant
braided tubes as necessary.
• For liquid transfer, a suction and dis-
charge line I.D. should be ø4mm or
less. Otherwise, the motor is locked
by overfeeding.
Installation
If you notice any abnormal or dangerous conditions, suspend
operation immediately and inspect/solve problems.
WARNING

- 11 -
3. Tube connection
Push the tubes into the inlet and outlet as far as they will go.
Use tube bands to make sure tubes are fastened as neces-
sary.
NOTE: If suction line connection is imperfect, the pump sucks
air and it prevents the pump from bringing out full per-
formance.
4. Connection checkout
Check that a suction line is connected to the inlet and a dis-
charge line is connected to the outlet.
CAUTION
If a suction line and a discharge line are connected the
other way around, pumping process is inverted.
5. Valve mounting
For adjustment of an air flow and a vacuum (not for liquid flow
adjustment), install a control valve on a suction line.
2.3 Electrical wiring
Electrical wiring must be performed by a qualified electrician.
We are not responsible for personal injury or property dam-
age due to nonobservance of this warning. Contact us or your
nearest distributor for wiring as necessary.
■Before wiring
1. Confirm that power is disconnected before work.
2. Wiring work should be done in accordance with local elec-
tric codes. Use the recommended wiring accessories.
3. Observe the rated voltage specified on the name plate.
4. After wiring work, check that the system is free from the
inductive noise at start-up. The maximum length of power
and signal leads is 3m. Take appropriate measures when
extending the leads over the maximum length.
5. The drive circuit generates noise because of its high-speed
switching. Check if peripheral devices are not affected by
the noise.
6. When an earth leakage breaker is used and has tripped,
always investigate and solve root causes. Be sure to unplug
the pump before investigation is performed.
7. This pump can be controlled by 1-5VDC control signal and
make feedback control when used with a flow sensor.
8. Always use the 1-5VDC control signal for ON-OFF control.
9. Always stop the 1-5VDC control signal before turning ON or
OFF the pump power.
Installation

- 12 -
Installation
■ Wiring
1. Power lead polarity
The red power lead leading from the pump is positive polarity
and must be connected to a positive contact of a DC power
supply, and the black power/signal lead leading from the pump
is negative polarity and must be connected to a negative con-
tact of the power supply.
2. 1-5V control signal polarity
The white signal lead leading from the pump is positive polarity
and must be connected to a positive contact of a 1-5VDC sig-
nal generator, and the black power/signal lead leading from the
pump is negative polarity and must be connected to a negative
contact of the signal generator.
NOTE: The black power and signal leads are leading from the
common negative terminal of the pump.
3. Pump speed signal polarity
The green signal lead leading from the pump is positive polar-
ity and must be connected to a positive polarity of the counter.
4. Wiring diagram
Optimal diagram changes depending on if the 1-5VDC control
signal is used or not.
5. External fuse
Install an external fuse in the power line for overcurrent protec-
tion.
24VDC power supply
1-5VDC signal generator
Counter, etc.
+
+
+
−
−
−
Red power line (+)
Black power line (−)
White control
signal input line
Green speed signal
output line
Operation with 1-5VDC control signal
Pump
+
+
−
−
Operation with no control signal
Pump
24VDC power supply
Red power line (+)
Black power line (−)
White control
signal input line
Green speed signal
output line
Counter, etc.

- 13 -
● Use care handling the pump.
Do not drop. An impact may
affect pump performance.
● The pump can not start
with full discharge/suction
pressure or liquid. Remove
pressure or liquid before
operation.
● After a long period of stop-
page, pump performance at
the beginning of operation
becomes occasionally unsta-
ble. In this case, warm the
pump up by running pump
dry for about ten minutes.
● Do not use solvents such as
benzine, alcohol, thinner for
maintenance or cleaning,
otherwise a coat discolours
or comes off.
● Always use a suction valve
to adjust an air flow.
● If the compressed air or
liquid (higher pressure than
atmospheric pressure) is
transferred to the pump,
the lives of the valves, dia-
phragm and bearing may
be sharply reduced. Always
keep atmospheric or lower
pressure in the suction line.
● Do not close discharge line
during operation. The pump
and piping may be damaged.
Always observe the maxi-
mum discharge pressure.
1. Before operation
Operation
Prohibited
Prohibited

- 14 -
2. Pump operation
■ Operation
Operate the pump according to the following steps.
No. Procedure Points to be checked
1Check tubing, wir-
ing and voltage.
● Check installation, tubing and wiring
are properly done and wiring system
is fused.
● Check the spec label to see if power
supply voltage is correct.
2Open valves. ●
Fully open both discharge and suction lines.
3Supply power to the
pump.
● Smooth starting may not be obtained
when ambient temperature is 10ºC or
below. In this case, run the pump with
no discharge line pressure for a few
minutes to warm it up.
● Smooth starting may not be obtained
when the pump chamber is lled with
liquid. Get rid off liquid before operation.
4Adjust air ow.
● Provide a running-in period (about 10
minutes) before full scale operation.
● Always adjust an air ow by a suction
valve.
5
Points to be
checked during
operation
● After starting, check a pressure gauge
to see if suction and discharge line
pressure are correct and an air ow
meter to see if the specied air ow is
obtained.
● Keep a suction line pressure at or
below atmospheric pressure.
● In case electric power has failed while
the pump is running, switch off main
power. Otherwise, the motor may not re-
start or may burn out depending on a line
pressure at the time of power recovery.
Operation
■ Stop and Storage
● Before a long period of stoppage (1 week or more):
Depressurize/empty the pump. Some liquids may harden
or crystallize when they are left for a long time. In this case
clean wet ends before resuming operation.
● Do not store the pump:
• In a flammable/corrosive atmosphere.
• In a dusty/humid environment.
• Where ambient temperature can exceed 0-40°C.
• Under mechanical vibration or wind & rain.

- 15 -
Maintenance
1. Troubleshooting
Turn off power on sensing danger and check the follow-
ing. In case trouble can not be solved, contact us or your
nearest distributor.
Phenomenon
Causes
Pump does not run. Pump stops running. Poor air ow or discharge pressure Pump makes noise.
Measures
No power distribution Check wiring.
Motor trouble (disconnection) Replace the pump.
Wrong tubing or poor connection Check and x tubing.
Pump head mounting screws are loose. Tighten the screws.
Diaphragm insertion is loose. Tighten diaphragm.
Diaphragm is damaged. Replace diaphragm.*
Filter is clogged. Remove foreign matters.
Valves are worn. Replace valves.*
Front cover xing screws are loose. Secure them.
Eccentric shaft has worn. Replace the pump.
Connecting rod bearing has worn. Replace the pump.
Motor bearing has worn. Replace the pump.
Voltage reduction Increase voltage to the rated level.
Higher suction pressure than atmospheric Reduce suction pressure.
Contact us for the measures marked with *.
2. Maintenance & Inspection
Handling of the pump, maintenance and inspection
should be carried out within the descriptions of this
instruction manual.
We are not responsible for personal injury or property
damage due to nonobservance of this warning. Contact
us or your nearest distributor as necessary.
■ Daily inspection
Pay attention to the following items during operation. Stop
operation on sensing danger and solve problems on the
Troubleshooting section. If pump performance has remarkably
reduced, replace wear parts.
No. Check that... Measure
1 pump operation is normal.
• Apply correct voltage and
amperage.
• Adjust discharge/suction
pressure.
2there is no noise or vibra-
tion problem.
• Unusual noise/vibration
may occur when pump
operation is not normal.
3
there is no air leak or air
ingress from pump parts
and tubing connections.
• Retighten connections.

- 16 -
Maintenance
3. Wear part replacement
CAUTION
● 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.
● Do not touch the pump or pipe with bare hands
Risk of burning. The surface temperature of the
pump or pipe gets high in or right after operation.
● Wear protective clothing
Always wear protective clothing such as an eye protec-
tion, chemical resistant gloves, a mask and a face shield
during disassembly, assembly or maintenance work.
■ Pump replacement
Replace the pump at the end of life span or when performance
has remarkably reduced.
Conditions Part names Diaphragm Valve Gasket
<gas transfer>
0.08MPa or below (pressurization)
or 47.99KPa (abs.) or below (vacuum)
4000hr 4000hr 4000hr
<gas transfer>
0MPa 4000hr 4000hr 4000hr
<liquid transfer>
0.05MPa or below (pressurization) 2000hr 2000hr 2000hr
*Part lives vary with the pressure, temperature and character of gas/
liquid. Values on the above table are collected in continuous opera-
tion with 20°C gas or liquid at rated voltage.
■ Diaphragm replacement
1. Unscrew the screws and
take out the pump head A,
valves, gasket and valve
seat A.
2. Turn the diaphragm anti-
clockwise so as to detach it
from the connecting rod.
3. Mount a new diaphragm into
the rod and fasten as far as
it will rotate.
NOTE: Hold the midmost of the
diaphragm then fasten
it. Damage or deforma-
tion of diaphragm will
reduce the pump per-
formance.
4. Push down the diaphragm
until it bottoms out and then
rebuild the pump head.
Fasten the fixing screws by
0.58N•m.
Pump head A
Screw/Washer
Valve
Valve seat A
Gasket
Diaphragm
Valve
Con' rod

- 17 -
■ Valve & Gasket replacement
1. Unscrew the pump head fixing
screws and take out the pump
head A, valves, gasket and
valve seat A.
2. Replace old valves and gas-
kets with new ones.
3. Push down the diaphragm until
it bottoms out and then rebuild
the pump head. Fasten the fix-
ing screws by 0.58N•m.
NOTE1. Finish either pump head first and then start with the
other.
NOTE2. Do not loosen the motor-bracket fixing screws during
maintenance work.
Pump head A
Gasket
Valve
Valve seat A
Valve
Maintenance

T847-1 '13/07
( )Country codes
IWA KI 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]
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TEL : [phone] FAX : [phone]
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TEL : [phone] FAX : 1367 2030
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TEL : [phone] FAX : [phone]
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TEL : [phone] FAX : [phone]
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TEL : [phone] FAX : [phone]
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TEL : [phone] FAX : [phone]
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TEL : [phone] FAX : [phone]
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TEL : [phone] FAX : [phone]
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TEL : [phone] FAX : [phone]
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TEL : [phone] FAX : [phone]
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