IWAKI LK-A/-B TC User manual

Read this manual before use of product
IWAKI Metering pump
LK-A/-B TC
Instruction Manual

Thank you for selecting an Iwaki LK-A/-B TC metering pump. This instruction manual deals
with "Safety instructions", "Outline", "Installation", "Operation" and "Maintenance" sec-
tions. Please read through this manual carefully to ensure the optimum performance, safety
and service of your pump.
Contents
Important instructions ···································································· 1
Safety instructions·········································································· 2
Outline 1. Unpacking & Inspection ..................................................6
2. Product outline .................................................................6
3. Pump mechanism .............................................................7
4. Specification.....................................................................8
5. Model code.......................................................................8
6. Overview..........................................................................9
7. Part names (pump head).................................................10
8. Precautions for use .........................................................11
Installation 1. Before installation ..........................................................13
2. Installation .....................................................................14
3. Pipework.........................................................................15
4. Wiring ............................................................................17
Operation 1. Operational precautions..................................................19
2. Commissioning ..............................................................19
3. Operation........................................................................21
4. Flow rate adjustment ......................................................22
5. Before/After a long period of stoppage ..........................23
Maintenance 1. Troubleshooting..............................................................25
2. Maintenance & Inspection .............................................28
3. Spare & Wear parts ........................................................29
4. Dismantlement & Assembly ..........................................30
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.

- 1 -
Important instructions
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.
Nonobservance or misapplication of “Caution” sec-
tions could lead to personal injury or property dam-
age.
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 personal injury or property damage.
●Observe the instructions accompanied with "WARNING" or "CAUTION" in this manual. These
instructions are very important for protecting users from dangerous situations.
●The symbols on this instruction manual have the following meanings:
WARNING
Nonobservance or misapplication of “Warning” sec-
tions could lead to a serious accident which may
result in death.
CAUTION
Types of Symbols
Indicates that “Warning” or “Caution” must be exercised. Inside this triangle, a con-
crete and practical image provided as a warning or caution message is depicted.
Indicates a prohibited action or procedure. Inside or near this circle, a concrete and
practical image of the activity to be avoided is depicted.
Indicates an important action or procedure which must be performed or carried out
without fail. Failure to follow the instructions herein can lead to malfunction or
damage to the pump.

- 2 -
Safety instructions
WARNING
Turning off power
Prohibited
Wear protective
gear
No Remodeling
● Turn off power before service
Risk of electrical shock. Be sure to turn off power to stop the pump and relat-
ed devices before service is performed.
● 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.
● Use strong ropes (chains) for lifting up the pump
Keep away from the pump while it is lifted up for installation. Serious injury
may result if lifting ropes (chains) break. Check lifting ropes (chains) are
strong enough before use. Observe the maximum weight of the rope (chains).
● Do not lay the pump on its side
Lubricant oil may leak from the gear box and wet the motor.
● Qualified personnel only
This product should be handled or operated by qualified personnel with a full
understanding. Any person not familiar with the product should not take part
in the operation or maintenance of this product.
● Do not modify the product
Alterations to the product carries a high degree of risk. It is not the manufactur-
er's responsibility for any failure or injury resulting from alterations to the pump.
● 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 stand on the pump
Do not use the tank as a platform. Injury or damage may result when the tank
turns over.
● Do not get access to the inside of the drive unit during operation
Risk of personal injury. A reciprocating diaphragm/shaft may catch the finger
or hand.
● Closed-discharge operation is not allowed
Do not close a discharge line during operation. Otherwise, liquid leakage or
pump-head/motor/piping breakage may result due to overpressure.
● Starting
The pump doesn't have an ON-OFF switch. The pump starts as a power
cable is plugged in.
Caution
Prohibited
Prohibited
Caution
Prohibited
Prohibited
Caution

- 3 -
● Ventilation
Fumes or vapours can be hazardous with certain solutions. Ensure proper
ventilation at the operation site.
● Do not bring the pump close to a flammable substance
Keep the pump away from a flammable substance for the prevention of fire.
● 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.
● Do not use a damaged pump
Use of a damaged pump could lead to an electric shock or death.
●Grounding
Risk of electrical shock! Always properly ground the pump. Conform to local
electric codes.
● Use specified power only
Do not apply power other than that specified on the nameplate. Otherwise,
failure or fire may result. Ensure the pump is properly grounded.
● Install an earth leakage breaker
An electrical failure of the pump may adversely affect other devices on the
same line. Purchase and install an earth leakage breaker separately.
● Do not install/store the pump:
• In a flammable/explosive/corrosive atmosphere.
• In a dusty/humid environment.
• Where ambient temperature can exceed 0-40ºC.
• In direct sunlight or wind & rain (except outdoor-use models).
CAUTION
Prohibited
Caution
Fire ban
Safety instructions
Caution
Prohibited
Grounding
Electrical
shock
Prohibited

- 4 -
CAUTION
Safety instructions
Caution
Caution
Prohibited
Requirement
Requirement
● Do not cover the pump with cloth
The motor temperature may build up and a fire or an electric/mechanical fail-
ure may result.
● Non-freezing
Frozen liquid may damage the pump and piping. Drain liquid before leaving it
for a long time or use measures to prevent liquid from freezing in winter.
● Do not close a suction valve in operation
Operation with a closed suction-line may damage the diaphragm.
● Depressurize piping before disassembly
Release a pressure from a discharge line before dismantling the pump or
removing piping.
● Spill precautions
Ensure protection and containment of solution in the event of plumbing or
pump damage (secondary containment).
● Foreign matter
When foreign matters enter the pump, turn off power at once and remove
them. Using the pump with foreign matters may result in failure.
● Disposal of the product
Dispose of any used or damaged product in accordance with local rules and
regulations. If necessary, consult a licensed industrial waste disposal com-
pany.
● Be sure to turn off all the related power supplies prior to any inspec-
tion/maintenance and installation works (motor fan cover).
Working on the pump with power ON, any rotating part may catch the hand,
finger, hair, or clothes, and it may result in serious injury.
Requirement
Caution

- 5 -
Outline
1. Unpacking & Inspection ........................ 6
2. Product outline...................................... 6
3. Pump mechanism................................. 7
4. Specification ......................................... 8
5. Model code........................................... 8
6. Overview............................................... 9
7. Part names (pump head) .................... 10
8. Precautions for use............................. 11

- 6 -- 6 -
Outline
1. Unpacking & Inspection
On unpacking the product, check the following points.
If you find any problems, contact your nearest dis-
tributor.
1. Check the information on nameplate (model code,
flow rate, discharge pressure and stroke rate) to see if
the product is delivered as per order.
2. Check for transit damage, deformation, and loose
bolts.
2. Product outline
The LK-A/-B TC series is mechanically-driven dia-
phragm pump. Fluoroplastic and alumina ceramic wet
ends allow for delivery of various chemicals including
strong acid in water treatment and chemical, paper &
food industries.
■ Principle of operation
Motor rotation is transmitted to an worm wheel shaft
and then converted to the reciprocating motion of the
pump shaft. Volumetric change occurs in the pump head
as the diaphragm moves back and forth and liquid is
pumped because of the suction and discharge check
valves (ball valves).
Suction process
When the diaphragm moves back, negative pressure
in the pump head closes the discharge check valve and
open the suction check valve to take in liquid.
Discharge process
When the diaphragm moves forward, positive pressure
in the pump head opens the discharge check valve and
closes the suction check valve to deliver liquid.
: Liquid flow
: Motor rotation
: Diaphragm reciprocation
: Valve movement
Reduction
gear
Outlet
Inlet
Check valve
Pump shaft
Diaphragm
Pump head
Suction processDischarge process
IWAKI Metering Pump
LK-A/-B TC
Instruction Manual
Instruction manual

- 7 -
3. Pump mechanism
■ Gear unit
The gear unit of the LK-A/-B TC is spring back design consisting of a worm wheel shaft, a slider and a spring, etc.
Motor rotation is transmitted to an worm wheel shaft and then converted to reciprocating motion of the pump shaft
with the assistance of a slider and a spring.
■ Stroke length knob
Use the stroke length knob at the end of the control shaft to determine a flow rate in between 0 and 100%, changing a
slider position. See page 22 for detail.
Outline
0
1
2
9
8
020406080100020406080100
Main scale
Sub scale
Stroke length knob
Diaphragm
Pump shaft
Spring
Control shaft
Stroke length knob
Slider
Worm wheel shaft
Ball valve
:Diaphragm reciprocation

- 8 -
4. Specification
Model
Max flow
ℓ/min Max discharge
pressure
MPa
Stroke rate
spm Max stroke
length
mm
Flange
size
JIS 10K
Motor
output
kW
Approx
weight
(with
motor)kgf
50Hz 60Hz
50Hz 60Hz
LK-A55 2.8 3.3 1.0 (0.7) 48 58 10 25A 0.4 63
LK-A57 6.0 7.2 0.7 (0.5) 96 116
LK-A65 9.0 10.8 0.3 (0.2) 48 58 17.5 40A 72
LK-B65 0.5 0.75 100
*The above information is based on pumping clean water at ambient temperature.
*Metering accuracy : ±2%FS or below
*Linearity : ±3%FS or below
*Allowable liquid temperature range : 0-50ºC
*Suction lift : 1m or below (with full stroke length)
*Allowable ambient temperature : 0-40ºC
*Figures in parenthesis are collected with 0.37kW motor.
5. Model code
LK - A65TC - 04 FES
a b c d e f g h i
a. Series name
LK : Mechanically-driven diaphragm pump with fluoroplastic pump head and valve seat
b. Drive unit
A : 0.4kW motor B : 0.75kW motor
c. Diaphragm size
5, 6
d. Reduction gear ratio
5 : 1/30 7 : 1/15
e. Wet end materials
Part names Wet end materials
Pump head PVC
Ball valve Highly alumina ceramics
Valve seat PVDF
O ring FKM
Valve gasket PTFE
Diaphragm PTFE+EPDM (EPDM is not a wet end.)
Allowable liquids Strong sulfuric acid
PTFE : Polytetrafluoroethylene PVDF : Polyvinylidene fluoride
EPDM : Ethylene-propylene rubber FKM : Fluorine-contained rubber
f. Motors
04 : 0.4kW 07 : 0.75kW
g. Inverter
No code : No inverter F : Inverter motor
h. Servo
No code : No servo E : Servo unit
i. Special version
No code : Standard S : Custom design
Outline

- 9 -
Motor nameplate
Apply the power voltage
specified on the name-
plate.
Outline
"Arrow" label
The arrow indicates a rotational
direction of the motor. Make sure the
motor runs in a correct direction.
Motor fan cover
Base
Be sure to fix the base.
Reduction gear
Reduces motor rotation
speed and converts into
reciprocating motion.
Pump nameplate
Operate the pump in
accordance with specifica-
tions.
CAUTION
● Wet a cloth with tap water and wring it out for cleaning the pump. Use a neutral deter-
gent for greasy dirt and then rub with a dry cloth. Do not wipe nameplates, labels or
pump body with any solvent.
● Risk of fire or electric shock. Be sure to turn off all the related power supplies prior to
any inspection/maintenance and installation works. Keep the terminal box, motor fan
cover and electric wiring dry.
6. Overview
Stroke length knob
Determines liquid volume
per shot in between 0 and
100%.
Outlet
Inlet
Pump head
Tightening torque indi-
cation label
Observe the indication
when tightening torque.

- 10 -
Outline
7. Part names (pump head)
LK-A55/-A57 TC
No. Names Q'ty
1 Pump head 1
2 Valve 2
3 Valve guide 2
4Valve seat 2
5 Valve gasket 2
7 O ring 2
20 Hex head bolt 8
21 Spring washer 8
29 Reinforcing plate 1
30 Diaphragm 1
31 Retainer 1
50 Nut 2
51 Union 2
54 Flange 2
55 Flange adapter 2
LK-A65/-B65 TC
No. Names Q'ty
1 Pump head 1
2 Valve 2
3 Valve guide 2
4Valve seat 2
7 O ring 2
20 Hex head bolt 10
21 Spring washer 10
26 Insert bumper 2
29 Reinforcing plate 1
30 Diaphragm 1
31 Retainer plate 1
32 Hex head bolt 6
55 Setting flange 1
73 Port 2
74 Flange 2
82 Spring washer 6
83 Rear seat 1
84 Flange adapter 1
32
82
30
3
83
31
7
3
2
4
20
21
29
1
2
4
7
84
74
55
73
55
73
74
84
26
7
3
2
4
5
1
29
30
31
21
5
20
3
2
4
7
50
51
54
55
55
54
50
51
Flange unit
(discharge side)
Flange unit
(discharge side)
Flange unit
(suction side)
Flange unit
(suction side)

- 11 -
Outline
8. Precautions for use
Always observe the following points.
1. Use care handling the pump. Do not drop. An impact may affect pump performance. Contact us or your nearest dis-
tributor if a pump has been damaged.
2. Be careful not to exceed the maximum flow rate and discharge pressure. A flow rate and discharge pressure change
with piping length, piping I.D., piping layout. Use the pump only for liquid delivery.
3. Do not close the discharge/suction valves during operation, or the pump/piping system may be damaged by over-
pressure. Do not leave the valves opened after operation.
4. Keep the supply tank free from foreign matters. Foreign mattes may clog the pump/piping system, causing flow
fluctuation or a poor flow.
5. Release a pressure from a discharge line before dismantling the pump or removing piping.
6. The metering pump by nature keeps working, exceeding the limit pressure of discharge line. This may damage the
pump/piping system and burn out the motor. Install a relief valve close to the pump and fix its set pressure below the
maximum allowable pressure of the pump/piping system.
7. Install an air chamber in order to reduce flow pulsation, piping vibration and overfeeding*1.
8. Install a back pressure valve in order to reduce the possibility of overfeeding.
9. Provide a strainer at the end of a suction line for the prevention of foreign matter interfusion (Clean the strainer
periodically.). Otherwise, clogging may result.
10. Install a pressure gauge to monitor the discharge line pressure.
11. Be sure to turn off all the related power supplies prior to any inspection/maintenance and installation works
(motor fan cover). Working on the pump with power ON, any rotating part may catch the hand, finger, hair, or
clothes, and it may result in serious injury.
12. Use the stroke length knob to determine the liquid volume per shot. See page 22 for detail.
13. Check the oil condition and level. Remove deteriorated oil and feed the new oil until it reaches the middle of the oil
gauge. See page 29 for detail.
14. Do not make intermittent operation. Frequent ON-OFF operation damages internal parts of the pump and motor
in a short time.
Glossary*¹ A condition check valves in the pump head stay open and liquid continues flowing into discharge line. Overfeeding occurs
when the discharge line pressure is much lower than the suction line pressure.

- 12 -
Installation
1. Before installation ............................... 13
2. Installation........................................... 14
3. Pipework............................................. 15
4. Wiring ................................................. 17

- 13 -
Installation
1. Before installation
Always observe the following points. Observe information on the drawing and specification sheet. Allow sufficient
space around the pump for easy access and maintenance.
CAUTION
● Use care handling the pump.
Do not drop. An impact may affect pump performance. Keep the pump
level when lifting it up.
● Ventilation
Fumes or vapours can be hazardous with certain solutions. Ensure proper
ventilation at the operation site.
● Qualified electrician only
Electrical work should be performed by a qualified electrician. Otherwise,
personal injury or property damage could result.
● Keep the pump free from stress
Use measures to keep the pump connections free from stress. Weight and
thermal expansion/contraction of the piping can stress connection points.
● Do not lay the pump on its side
Lubricant oil may leak from the gear box and wet the motor.
■ Do not install the pump in the following places:
• Where liquid will be held.
• Where the pump is not accessible.
• Where ambient humidity can exceed 35-85%RH.
• Where the pump can not be kept dry (except outdoor-use type).
• In a dusty environment.
• Where ambient temperature can exceed 0-40ºC.
• Under vibration
Caution
Prohibited
Requirement
Prohibited
Requirement

- 14 -
Installation
2. Installation
Check if installation doesn't adversely affect facility, surrounding equipment and the pump.
Install the pump according to the following instructions to ensure the optimum performance, safety and service.
■ Installation location
• Allow sufficient space around the pump for easy access and maintenance.
• Select a level location, free from vibration, that won't hold liquid. Always use a level gauge.
• Ensure protection and containment of solution in the event of plumbing or pump damage (secondary containment).
■ Pump position
Install the pump according to the following instructions.
• Install the pump as close to a supply tank under flooded suction lift.
NOTE: See "3. Pipework" for more information on pipework. The pipework section describes a
basic layout and precautions.

- 15 -
Installation
3. Pipework
Foreign matters such as sand and scale may enter pipework while you are working. They may cause fatal damage
to the pump. Be sure to blow them out before operation. Also, do not apply adhesive too much or leave a screw or
nut. If pipework directory weighs on the pump, the pump may deform. Be sure to install pipe supports.
NOTE: Design an efficient layout to meet NPSHr, especially when planning to deliver slurry.
1. Built an optimal piping system, taking account of the maximum pressure resistance and possible pressure dorp.
Always use a corrosion resistant pipe material.
2. Always build up a flooded suction system. Have a suction line shortest with the minimum number of bends. Support
piping by pipe supports so that the pump is not subject to piping weight or thermal stress. Do not allow any arched
line where air may be trapped. A suction line should be laid on a rising gradient of 1/100 toward the pump.
3. Install a gate valve on a discharge line not only for adjusting a discharge flow but also smooth operation, inspection
and maintenance. Make sure that a discharge or an air vent line is open during self-priming operation.
4. Install a drain valve if it is possible for liquid in a discharge line to freeze.
5. Connect the pump to pipework, fastening the flange tightening bolts evenly in diagonal order. No gap is allowed.
Always use a rubber gasket in between flange connection if a metal pipe flange is used.
6. Flange connection must be free from any tension or distortion, or a leak or pipe damage may result.
7. Use measures to keep the pump connections free from stress. Weight and thermal expansion/contraction of the pip-
ing can stress connection points.
8. Do not allow any inverted arch line in pipework when handling slurry. Provide a drain port as necessary.
9. Install a flushing line for cleaning the pump after handling a harmful liquid.
P
Discharge pressure monitoring gauge
Back pressure valve
(overfeeding prevention)
Pipe support
Air chamber (Pulsation reduction)
Discharge valve
Flooded suction Air vent valve
Drain valve
Air relief/supply valve
Y shaped strainer
Suction valve
(Shut off valve)
Supply tank
Relief valve
Drain valve

- 16 -
Installation
10. If the pump is used to transfer a high or low-temperature liquid, install the flexible piping to protect the pump
from the expansion and contraction of piping by thermal stress.
11. Do not apply adhesive too much, especially when using PVC discharge line.
12. Flush the inside of the pump and piping with pure water or the liquid to be delivered before the start of operation.
Inlet and outlet of some models are covered with a cap. Remove before installation.
13. Install a relief valve close to the pump and fix its set pressure below the maximum allowable pressure of the pump/
piping system.
■ Suction line
1. The suction line I.D. should be equal to or wider than the I.D. of the pump so that NPSHr is satisfied.
2. The maximum suction lift changes with pump size, operating conditions and liquid characteristics. Always keep the
inlet of the pump below the liquid level of the supply tank (flooded suction).
3. Joints of the suction line must be air tight. Otherwise output may be affected.
4. Foreign matters in the pump head may prevent check valve action. Install a strainer at the end of the suction line.
■ Discharge line
1. Install a relief valve on the discharge line, close to the pump. Do not install a gate valve in between the relief valve
and the pump.
2. Install a pressure gauge on a discharge line for monitoring operating conditions.
3. The set pressure of the relief valve must not exceed the maximum allowable pressure of the discharge line.
4. Discharge line pressure must be 0.03MPa or higher than suction line pressure. Otherwise, ball valve may not check
flow and overfeeding may result. Install a back pressure valve on the discharge line to keep the minimum pressure
difference as necessary.

- 17 -
Installation
4. Wiring
Electrical work should be performed by a qualified electrician. Otherwise, personal injury or property damage
could result. Wiring work should be done in accordance with the relevant regulations, using the recommended wir-
ing accessories.
3-phase motor wiring diagram
1. Install an electromagnetic switch according to motor
specifications (voltage, capacity, etc.).
2. The pump and motor do not have protection equip-
ment. Install an overcurrent protection or earth leak-
age breaker according to motor specification.
3. Electromagnetic switches and push buttons should be
installed away from the pump.
4. If the pump is used out of doors, protect switches from
rainwater.
M: Motor
MC: Electromagnetic switch
PB: Push button
CB: Breaker
V: Voltmeter
A: Ammeter
F: Fuse
■ Electrical motor
1. Read through a motor instruction manual before operation.
2. Observe the rotational direction shown on the motor. Three phase motors rotate clockwise when U, V and W motor
terminals are connected in line with R, S and T power supply terminals. The motors rotate anticlockwise if two out
of these three terminal combination are interchanged.
NOTE: Do not remove the motor-fan cover while power is ON, any rotating part may catch the
hand, finger, hair, or clothes, and it may result in serious injury.
3. Be sure to earth the motor.
4. Install an ammeter into the pump system to monitor operating condition.
RST
CB
F
A
V
M
MC
MC
PB
(OFF)
PB
(ON)
UVW

- 18 -
Operation
1. Operational precautions...................... 19
2. Commissioning ................................... 19
3. Operation............................................ 21
4. Flown rate adjustment......................... 22
5.
Before/After a long period of stoppage ..... 23