IWAKI APN-S041-D3 User manual

2016 IWAKI CO., LTD.
Instruction manual
Thank you for choosing our product.
Please read through this instruction manual before use.
Iwaki Air Pump
APN-S041-D3/-D4 (built-in type)
T982-1 '17/11
Contents
Order confirmation..........................................................................1
Safety instructions ..........................................................................1
WARNING .............................................................................1
CAUTION...............................................................................2
Precautions for use.........................................................................3
Overview.........................................................................................3
Part names ............................................................................3
Identification codes ...............................................................4
Installation.......................................................................................4
Pump mounting......................................................................4
Pipework................................................................................5
Wiring.....................................................................................5
Before wiring..................................................................5
Operation ........................................................................................6
Before a long period of stoppage (1 week or more)......7
Maintenance....................................................................................7
Troubleshooting.....................................................................7
Inspection ..............................................................................8
Daily inspection.............................................................8
Wear part replacement..........................................................8
Wear part list .................................................................8
Before service ...............................................................8
Diaphragm replacement................................................9
Valve replacement.......................................................10
Specification/Outer dimension .....................................................12
Specification........................................................................12
Outer dimension..................................................................12
Performance curves............................................................13
Parts names & Structure.....................................................13

- 1 -
Order confirmation
a. Check if the delivery is correct.
Check the nameplate to see if the information such as model codes,
discharge capacity and discharge pressure are as ordered.
b. Check if the delivery is damaged or deformed.
Check for transit damage and loose bolts.
Safety instructions
Read through this section before use. This section describes
important information for you to prevent personal injury or property
damage.
Ŷ6\PEROV
Warning Indicates mishandling could lead to a fatal or
serious accident.
Caution Indicates mishandling could lead to personal
injury or property damage.
Export Restrictions
Technical information contained in this instruction manual might be
treated as controlled technology in your countries, due to agree-
ments 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.
WARNING
Turn off power before service
Risk of electrical shock. Be sure to turn off power to stop
the pump and related devices before service is performed.
Stop operation
If you notice any abnormal or dangerous conditions, sus-
pend 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
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SURGXFWLQVSHFL¿HGFRQGLWLRQVRQO\
Do not modify the pump
Alterations to the pump carries a high degree of risk. It is
not the manufacturer's responsibility for any failure or injury
resulting from alterations to the pump.
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pump is properly grounded.
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Always wear protective clothing such as an eye protection,
chemical resistant gloves, a mask and a face shield during
disassembly, assembly or maintenance work. The specif-
ic solution will dictate the degree of protection. Refer to
MSDS precautions from the solution supplier.
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Do not pull, knot, or crush the power cable. Damage to the pow-
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- 2 -
CAUTION
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sonnel 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.
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be kept dry.
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Fumes or vapours can be hazardous with certain solutions.
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ment.
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of plumbing or pump damage (secondary containment).
Preventative maintenance
Follow instructions in this manual for replacement of wear
parts. Do not disassemble the pump beyond the extent of
the instructions.
Do not use a damaged pump
Use of a damaged pump could lead to an electric shock or
death.
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Dispose of any used or damaged pump in accordance with
local rules and regulations. If necessary, consult a licensed
industrial waste disposal company.
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This product is not protected against an electromagnetic
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Do not touch the pump or pipe with bare hands
Risk of burning. The surface temperature of the motor rises
high in or right after operation.
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pump.
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Solution in the discharge line may be under pressure.
Release the pressure from the discharge line before dis-
connecting plumbing or disassembly of the pump to avoid
solution spray.
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WLRQRQO\
The bottom of the pump (case) is opened and the eccentric
cam in the case is not entirely protected. Always mount the
pump on the opened bottom, or cover the open surface, so
make sure nothing will interfere with the cam motion.

- 3 -
Overview
The APN-S041-D3/-D4 is a built-in type small diaphragm air
pump.
The rotary motion of the motor is converted through a con-
necting rod to the reciprocation of the diaphragm in the pump
chamber, where gas is transferred from the inlet to outlet.
Part names
Precautions for use
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erwise, personal injury or property damage may result.
Do not install the pump in a place where the pump can get wet.
Avoid using wet gas, or internal condensation will build up and con-
sequently result in the reduction of pump performance or the short
lives of the valve and diaphragm.
Do not use the pump in a dusty place. Be sure to provide the inlet
with a filter to prevent foreign matters from getting into the pump.
Otherwise, the pump performance may reduce or the lives of the
valve and diaphragm remarkably shorten.
Do not install the pump in a corrosive or flammable gas atmos-
phere. Keep good ventilation in a working area. Ambient and gas
temperature should not fall below 0°C or exceed 40°C.
If the compressed air (higher pressure than atmospheric pressure)
is transferred to the pump, sharp deterioration to the lives of the
valve, diaphragm and bearing may result. Always keep atmospheric
or lower pressure in the suction line.
Do not tube pump heads in series. It may prevent the motor from
starting, causing burning out or may damage the diaphragm or
piping.
Do not tube two or more pumps in series. It may prevent the motor
from starting and lead to a burn out.
An air injection point below the liquid level must be lower than the
pump position. Or siphon action or back flow may result.
Use care handling the pump. Do not drop. An impact may affect
pump performance. Do not use a pump that has been damaged to
avoid the risk of electrical damage or shock.
Do not apply power other than that specified on the nameplate.
Otherwise, failure or fire may result.
The pump can not start with full discharge/suction pressure.
Remove pressure before operation. After a long period of stoppage,
pump performance at the beginning of operation becomes occa-
sionally unstable. In this case, warm the pump up for 10 minutes
with no discharge/suction line pressure.
Always use a suction valve to adjust an air flow.
Do not clean the pump or nameplate with a solvent such as ben-
zine, thinner or kerosene. This may discolour the pump or erase
printing. Use a dry or damp cloth or a neutral detergent.
Motor
Anchor point
Always fix with M3
screws at the bottom.
Pump head
Not capable of liquid
transfer. Air transfer
purpose only.
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in drive unit)
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Use the pump accord-
ing to the specifica-
tions on the label.

- 4 -
Identification codes
The model code represents the following information.
APNS 041 M E D401
a b c d e f g h
a. Series name
Air pump
b. Pump head
S: Dual-head with in-line tubing
c. Pump size
d. Type
M: Vacuum
e. Diaphragm/valve materials
((3'0
f. Pump connection
No code: ø4.5 tube connection
g. Power voltage
D3: 24VDC BLDC motor (without speed control)
D4: 24VDC BLDC motor (with variable speed control)
h. Special specification
,QVWDOODWLRQ
This section describes the installation of the pump, tubing and
wiring. Read through this section before work.
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- Do not operate the pump in a flammable atmosphere.
Pump mounting
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See the Precautions for use section before installation.
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Use M3 screws.
127(
Install the pump on a level location, free from vibration

- 5 -
Wiring
Wiring for power source, earthing and external signal.
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Confirm to local electric codes.
- Do not perform wiring work while power is on. Otherwise, an
electrical shock or short circuit may result, and consequently
the pump may fail. Be sure to turn off power before service is
performed.
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- Check that the main power is turned off.
- Apply the specified power voltage. See the spec label.
- When an external fuse is used and it has blown, always solve the
root cause of blowout. Be sure to unplug the power cable before
investigation. If the fuse blows frequently, the starting current may
be a root cause.
- For the APN-S041-D3, red(+) and black(-) leads are for power
voltage.
- For the APN-S041-D4, red(+) and black(-) leads are for power volt-
age. Yellow(+) and black(-) leads are for 1-5VDC external variable
signal. The black(-) lead is common for both the power and the
signal.
Pipework
Connect tubes to the pump.
- Cut tube ends flat.
- The short tubing with the minimum bends is optimal to reduce
resistance.
- Use tubes resistant to the pumping
pressure. A proper tube size should
be used according to the O.D. of the
pump inlet/outlet for the prevention of
gas ingress/leak or other failure.
127(
Do not have tubing bent or pressed. Otherwise, the inlet and outlet of
the pump may break.
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DQGRXWOHWDVIDUDVWKH\ZLOOJR
*If suction line connection is imperfect,
the pump entrains air and will not run
correctly.
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Install a valve in the suction line
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Outlet
Inlet

- 6 -
127(
Observe polarity, otherwise failure or malfunction may result. Note
that rotational direction of the motor does not change by reversing
polarity.
D3 Type
Red: 24VDC (+)
Black: GND (-)
D4 Type
Red: 24VDC (+)
Black: GND (-)
Yellow: 1-5VDC external variable signal (+)
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- In order to make the ON-OFF operation, install the switch between
the DC power supply and the pump. Installing it between the DC
power supply and the AC power supply, the pump may not run.
- After wiring work, check that the system is free from the inductive
noise at start-up.
- Noise accompanies the high-speed switching of the drive circuit.
Check it does not affect peripheral devices.
- If a power source is shared with the inductive load such as solenoid
and relay, take protective measures against surge.
Operation
The pump becomes ready after tubing and wiring is completed.
%HIRUHRSHUDWLRQ
- Check that the pump is firmly fixed on a mounting position.
- Check that a suction tube is connected to the inlet and a dis-
charge tube is connected to the outlet.
*If a suction line and a discharge line are connected the other way
around, pumping process is inverted.
- Check that every tube connection is secured.
- Check that electrical wiring is properly done without the possi-
bility of short-circuit and protected by an fuse.
- Check that power voltage that is specified on the nameplate is
applied to the pump.
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*Operation may occasionally be upset when starting temperature is low.
Warm up the pump under no load operation (a few minutes).
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IXOOVFDOHRSHUDWLRQ
- Always adjust an air flow by a suction valve.
- In case electric power has failed while the pump is running,
switch off main power. Otherwise, the motor may not restart or
may burn out depending on a line pressure at the time of power
recovery.
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VHHLIWKHVSHFLILHGDLUIORZLVREWDLQHG
AC powerAC power DC power DC power PumpPump

- 7 -
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Depressurize the system and stop air/gas supply. Do not install/store
the pump:
- In a flammable/corrosive atmosphere.
- In a dusty/humid environment.
- In direct sunlight or wind & rain.
- Under vibration.
- Where ambient temperature can exceed 0-40°C.
Maintenance
This section describes troubleshooting, inspection, wear part
replacement, exploded views and specifications.
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- Follow instructions in this manual for replacement of wear
parts. Do not disassemble the pump beyond the extent of the
instructions.
7URXEOHVKRRWLQJ
If you notice any abnormal or hazardous conditions, suspend opera-
tion immediately and check the following points. If the following meas-
ures do not help remove problems, contact your nearest distributor.
States Possible causes Solutions
The pump
does not
run.
The pump is not powered. Check the pump is powered.
Power voltage is too low or too
high. Observe the rated voltage of 24VDC.
Wrong tubing or poor connec-
tion &KHFNDQG¿[WXELQJFRQQHF- tions.
'LDSKUDJP¿[LQJVFUHZLV
loose. Tighten the screw.
(FFHQWULFVKDIWKDVEURNHQ Replace the connecting rod
unit. Contact us.
The pump
does not
run.
Connecting rod bearing has
worn. Replace the connecting rod unit. Contact us.
Motor trouble Replace the motor. Contact
us.
Suction line pressure is higher
than atmospheric pressure. Keep it lower than atmospher- ic pressure.
Pump
operation
uninten-
tionally
stops.
Power voltage is too low or too
high. Observe the rated voltage of 24VDC.
Connecting rod bearing has
worn. Replace the connecting rod unit. Contact us.
Motor trouble Replace the motor. Contact
us.
Suction line pressure is higher
than atmospheric pressure. Keep it lower than atmospher- ic pressure.
Discharge line pressure is high-
er than atmospheric pressure. Keep it lower than 0MPa.
$QDLUÀRZ
rate and a
discharge
pressure
are too
low.
Wrong tubing or poor connec-
tion &KHFNDQG¿[WXELQJFRQQHF- tions
Pump head mounting screws
are loose. Tighten the screws.
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loose. Tighten the screw.
Diaphragm is broken. Replace the diaphragm.
Filter is clogged. &OHDQWKH¿OWHU
Valve has worn. Replace the valve.
6LJQL¿FDQW
noise Pump head mounting screws are loose. Tighten the screws.
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loose. Tighten the screw.
Diaphragm is broken. Replace the diaphragm.
(FFHQWULFVKDIWKDVEURNHQ Replace the connecting rod
unit. Contact us.
Connecting rod bearing has
broken. Replace the connecting rod unit. Contact us.
Motor trouble Replace the motor. Contact
us.

- 8 -
Inspection
Perform daily and periodic inspections to keep pump performance
and safety.
Ŷ'DLO\LQVSHFWLRQ
Check the following points every day. If you notice any abnormal or
hazardous conditions, suspend operation immediately and remove
problems according to the "Troubleshooting" section.
When wear parts come to the life limit, replace them by new ones.
Contact us or your distributor for detail.
No. States Points to be checked
1 Pumping ,IWKHVSHFL¿HGSRZHUYROWDJH
starting current are observed.
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2 Noise and vibration ,IDEQRUPDOQRLVHRUYLEUDWLRQ
occurs. They are signs of abnormal
operation.
3 Gas ingress/leak from
pump head joints and a
suction line.
&KHFNOLQHVIRUDOHDNDQGUHWLJKWHQ
as necessary.
:HDUSDUWUHSODFHPHQW
To run the pump for a long period, wear parts need to be replaced
periodically. It is recommended that the following parts are always
stocked for immediate replacement. Contact your nearest distributor
for detail.
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If pump performance has remarkably reduced, replace diaphragms,
valves, and sheet with new ones.
Application (VWLPDWHGOLIH
Valve Diaphragm Sheet
All APN-S041 models 8000hr 8000hr 8000hr
*Wear part duration varies with the pressure, temperature and characteristics
of gas.
*The estimated life above is calculated based on continuous operation at the
room temperature of 20°C.
*The estimated life above is not guaranteed.
Ŷ%HIRUHVHUYLFH
Depressurize the pump system before service is performed.
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WKHSXPSIURPWXELQJV\VWHP

- 9 -
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Remove the screws, pump
head, valve, and valve seat.
*Do not remove the valve from the
valve seat.
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HUVKHHWDQGGLDSKUDJP
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*The diagram has a mounting direc-
tion as shown.
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Use the Loctite®222 to the flat
screws and tighten them by
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WKHORZHVWSRVLWLRQ
Replace the valve and the valve
seat to original positions.
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Diaphragm
Case
Valve/
Valve seat
Pump head
Screw
Diaphragm
Case
Valve/
Valve seat
Pump head
Screw
Diaphragm
Case
Sheet
Retainer
Flat screw
Slider

- 10 -
)LWWKHWXEHWRWKHLQOHWDQGRXWOHW
One end of the tube to the inlet
and the other to the outlet.
127(
The pump may fail if the tube is
connected improperly.
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Remove the screws, pump head,
valve, and valve seat.
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YDOYHVHDW
Outlet
Inlet
Diaphragm
Case
Valve/
Valve seat
Pump head
Screw
Valve seat
Hole
Valve
Pin

- 11 -
3XVKGRZQWKHGLDSKUDJPWR
WKHORZHVWSRVLWLRQ
Replace the valve and the valve
seat to original positions.
)DVWHQWKHSXPSKHDGE\
1P
)LWWKHWXEHWRWKHLQOHWDQG
RXWOHW
One end of the tube to the inlet
and the other to the outlet.
127(
The pump may fail if the tube is
connected improperly.
127(
- When the pump is taken apart for diaphragm/valve replacement,
do not remove or loosen any other screws which hold the pump or
motor.
- Contact us or your distributor when the slider, the eccentric shaft, or
the motor is to be replaced.
Diaphragm
Case
Valve/
Valve seat
Pump head
Screw
Outlet
Inlet

- 12 -
6SHFLILFDWLRQ2XWHUGLPHQVLRQ
Information in this section is subject to change without notice.
Specification
Model
Code Max air
ÀRZ
L/min Max
vacuum
Motor Connec-
tion Weight Lowest
Starting
Temp
Power
cons. Rated current Tube
APN-S041 0.8 L/min 9.33 kPa 6W 0.25A ø4.5 0.4kg &
*This data is based on operation at 24VDC power voltage and 5VDC control
voltage.
*Observe the maximum allowable discharge pressure of 0.0MPa.
$OORZDEOHJDVWHPSHUDWXUHUDQJHLV&
$OORZDEOHDPELHQWWHPSHUDWXUHUDQJHLV&
*Maximum operating noise is 41dB at 1m (A scale).
Names Materials
Pump head GFRPPS
Diaphragm (3'0
Valve
Valve seat GFRPPS
Retainer
Sheet 37)(
Tube CR
GFRPPS: Glass fiber reinforced polypropylene sulfide
(3'0(WK\OHQHSURS\OHQHGLHQHPRQRPHU
37)(3RO\WHWUDIOXRURHWK\OHQH
CR: Polychloroprene
Outer dimension
IN OUT
(107)
60
32
(74)
(37)
ij3.2
ij4.5 8
(80)
300 +30
0 (5)
65
46 11.5
44
32
4×M3 Depth7 Preparation hole depth10

- 13 -
62
1
2
3
94
33
61
5
130
4
95
40
Performance curves Parts names & Structure
No. Part names Q'ty No. Part names Q'ty
1 Pump head 2 40 Motor 1
2 Valve 2 61 Flat screw 2
3Valveseat 2 62Screw 4
4Diaphragm 2 94Slider 1
5Retainer 2 95Hose 1
33 Case 1 130 Sheet 2
L/min (Air flow)
Vacuum
pressure
(kPa) [abs]
Discharge
pressure
(MPa)
101.32
74.66
47.99
21.33
7.99
0.05
0.10
0.15
00.5 1.0 1.5

- 14 -

T982-1 '17/11
http://www.iwakipumps.jp
IWAKI CO.,LTD. 6-6 Kanda-Sudacho 2-chome Chiyoda-ku Tokyo 101-8558 Japan
7(/)$;
European office ,:$.,(XURSH*PE+
7(/)$;
Norway / IWAKI Norge AS
7(/)$;
$XVWUDOLD / IWAKI Pumps Australia Pty Ltd.
7(/)$;
Germany ,:$.,(XURSH*PE+
7(/)$;
Sweden / IWAKI Sverige AB
7(/)$;
China (Hong Kong) / IWAKI Pumps Co., Ltd.
7(/)$;
+ROODQG ,:$.,(XURSH*PE+1HWKHUODQGV%UDQFK
7(/)$;
8. / IWAKI Pumps (U.K.) LTD.
7(/)$;
China*XDQJ]KRX*)7=,:$.,(QJLQHHULQJ7UDGLQJ&R/WG
7(/)$;
,WDO\ ,:$.,(XURSH*PE+,WDO\%UDQFK
7(/)$;
86$ / IWAKI America Inc.
7(/)$;
China / IWAKI Pumps (Shanghai) Co., Ltd.
7(/)$;
Spain ,:$.,(XURSH*PE+6SDLQ%UDQFK
7(/)$;
Argentina / IWAKI America Inc. (Argentina Branch)
7(/
Korea / IWAKI Korea Co., Ltd.
7(/)$;
%HOJLXP / IWAKI Belgium N.V.
7(/)$;)$;
Singapore / IWAKI Singapore Pte Ltd.
7(/)$;
Taiwan / IWAKI Pumps Taiwan Co., Ltd.
7(/)$;
Denmark / IWAKI Nordic A/S
7(/)$;
Indonesia / IWAKI Singapore (Indonesia Branch)
7(/)$;
7KDLODQG / IWAKI (Thailand) Co., Ltd.
7(/)$;
)LQODQG / IWAKI Suomi Oy
7(/)$;
0DOD\VLD / IWAKIm SDN. BHD.
7(/)$;
Vietnam / IWAKI Pumps Vietnam Co., Ltd.
7(/)$;
)UDQFH / IWAKI France S.A.
7(/)$;