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©2014 IWAKI CO., LTD.

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Please read through this instruction manual before use.

This instruction manual describes important precautions and instruc-
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Instruction manual

FLP-75W

Iwaki
Pneumatic Drive Bellows Pump

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(   )Country codes

IWAKI CO.,LTD.

 6-6 Kanda-Sudacho 2-chome Chiyoda-ku Tokyo 101-8558 Japan

TEL:(81)3 3254 2935 FAX:3 3252 8892(http://www.iwakipumps.jp)

T911 '15/02

Australia IWAKI Pumps Australia Pty. Ltd.

TEL : (61)2 9899 2411 FAX : 2 9899 2421

Italy

IWAKI Europe GmbH, Italy Branch

TEL : (39)0444 371115 FAX : 0444 335350

Austria

IWAKI EUROPE GmbH

TEL : (49)2154 92540 FAX : 2154 9254 48

Korea

IWAKI Korea Co.,Ltd.

TEL : (82)2 2630 4800 FAX : 2 2630 4801

Belgium IWAKI Belgium n.v.

TEL : (32)1367 0200

FAX : 1367 2030

Malaysia IWAKIm Sdn. Bhd.

TEL : (60)3 7803 8807 FAX : 3 7803 4800

China

IWAKI Pumps (Shanghai) Co., Ltd.

TEL : (86)21 6272 7502 FAX : 21 6272 6929

Norway

IWAKI Norge AS

TEL : (47)23 38 49 00 FAX : 23 38 49 01

China

IWAKI Pumps (Guangdong) Co., Ltd.

TEL : (86)750 3866228 FAX : 750 3866278

Singapore IWAKI Singapore Pte. Ltd.

TEL : (65)6316 2028 FAX : 6316 3221

China

GFTZ IWAKI Engineering & Trading (Guangzhou)

TEL : (86)20 8435 0603 FAX : 20 8435 9181

Spain

IWAKI Europe GmbH, Spain Branch

TEL : (34)93 37 70 198 FAX : 93 47 40 991

China

GFTZ IWAKI Engineering & Trading (Beijing)

TEL : (86)10 6442 7713 FAX : 10 6442 7712

Sweden

IWAKI Sverige AB

TEL : (46)8 511 72900 FAX : 8 511 72922

Denmark IWAKI Nordic A/S

TEL : (45)48 24 2345 FAX : 48 24 2346

Switzerland IP Service SA

TEL : (41)26 674 9300 FAX : 26 674 9302

Finland

IWAKI Suomi Oy

TEL : (358)9 2745810 FAX : 9 2742715

Taiwan

IWAKI Pumps Taiwan Co., Ltd.

TEL : (886)2 8227 6900 FAX : 2 8227 6818

France

IWAKI France S.A.

TEL : (33)1 69 63 33 70 FAX : 1 64 49 92 73

Taiwan

IWAKI Pumps Taiwan (Hsin-chu) Co., Ltd.

TEL : (886)3 573 5797 FAX : (886)3 573 5798

Germany IWAKI EUROPE GmbH

TEL : (49)2154 9254 0 FAX : 2154 9254 48

Thailand IWAKI (Thailand) Co.,Ltd.

TEL : (66)2 322 2471 FAX : 2 322 2477

Holland IWAKI Europe GmbH, Netherlands Branch

TEL : (31)74 2420011 FAX : 2154 9254 48

U.K.

IWAKI Pumps (UK) LTD.

TEL : (44)1743 231363 FAX : 1743 366507

Hong Kong IWAKI Pumps Co., Ltd.

TEL : (852)2 607 1168 FAX : 2 607 1000

U.S.A.

IWAKI AMERICA Inc.

TEL : (1)508 429 1440 FAX : 508 429 1386

Indonesia IWAKI Singapore (Indonesia Branch)

TEL : (62)21 690 6606 FAX : 21 690 6612

Vietnam IWAKI pumps Vietnam Co.,Ltd.

TEL : (84)613 933456 FAX : 613 933399

Summary of Contents for FLP-75W

Page 1: ...g Co Ltd TEL 86 7503866228 FAX 7503866278 Singapore IWAKI Singapore Pte Ltd TEL 65 63162028 FAX 63163221 China GFTZIWAKIEngineering Trading Guangzhou TEL 86 2084350603 FAX 2084359181 Spain IWAKI Europ...

Page 2: ...e if the information such as model codes are as ordered b Check if the required number of accessories is provided Attached accessories Four straight fittings displacement sensor cooling air inlets out...

Page 3: ...ntrol panel 15 LEDs 16 Operating conditions 17 Pump stroke 17 Supply air pressure range 17 Liquid temperature range 17 Liquid characteristics 17 Do not run the pump with the following liquid 17 Use ca...

Page 4: ...ve cross sectional area required for decompression process 27 Composite effective cross sectional area required for compression process 27 Air supply capacity of pneumatic devices 28 Preventive measur...

Page 5: ...operation 50 Operation programming 51 Feedback control 4 SETTING 1 QUANT CONST CTRL 52 Target flow setting 52 Electropneumatic regulator EPREG setting 53 Liquid volume per shot setting 54 Alarm outpu...

Page 6: ...RM RESET 61 Maintenance 62 Troubleshooting 62 Inspection 65 Daily inspection 65 Periodic inspection 65 Wear part list 66 Specification Outer dimension 67 Specification 67 Pump 67 LPC 1 controller 67 P...

Page 7: ...tes mishandling could lead to personal injury or prop erty damage A symbol accompanies each precaution suggesting the use of Caution Prohibited actions or specific Requirement Export Restrictions Tech...

Page 8: ...er s responsibility for any failure or injury resulting from alterations to the pump Wear protective clothing Always wear protective clothing such as an eye protection chemical re sistant gloves a mas...

Page 9: ...operly grounded Ventilation Fumes or vapours can be hazardous with certain solutions Ensure proper ventilation at the operation site Do not install or store the pump In a flammable atmosphere In a dus...

Page 10: ...ructions Before returning product Be sure to drain chemicals and clean the inside of the pump before return so that a harmful chemical does not spill out in transit Observe the maximum stroke rate Ope...

Page 11: ...ts breaks Hold the pump by the handgrips to lift it up The pump and controller are not waterproof Do not operate the pump and controller while wet with solution or water Failure or injury may result I...

Page 12: ...he LPC 1 controller determines and keeps the optimal movement of the bellows with the right and left dis placement sensors and timely supply air switching This mechanism ensures the minimum discharge...

Page 13: ...ects an accidental leak by bellows damage Operation mode MAN mode Manual operation Start Stop of the pump operation with the LPC 1 controller AUTO mode Automatic operation Start Stop of the pump opera...

Page 14: ...es Supply air port Inlet Outlet Base Always anchor the pump through the base Supply air port Silencer Cable outlet for the laser displacement sensor proximity switch and leak sensor Quick exhaust valv...

Page 15: ...econds MENU key Used to display the main menu screen if pushed once or to point 1 PUMP MODEL of the main menu if pushed twice ENTER key Used to determine setting RETURN RESET key Used to return to a p...

Page 16: ...ation FAST LED Lights red when the pump speed rises to the fast alarm speed or above and stops lightening when it falls below that speed TIME UP LED Lights red when neither the right nor left proximit...

Page 17: ...ce the risk of solution spray A flow rate changes with supply air pressure Use a regulator to keep the pressure constant The minimum supply air pressure should satisfy the minimum operating pressure o...

Page 18: ...r example by reducing the tube I D Or the residual pressure in the pump may damage the bellows Always observe the minimum composite effective cross sectional area Do not extend the air exhaust port to...

Page 19: ...es name FLP W Medium high liquid temperature low pulsation b Bellows size c Allowable liquid temperature range H 5 180 C d Pump connection Inlet Outlet C Connector standard e Pump head bellows connect...

Page 20: ...ping the right and left cylinder head covers or the top and bottom covers The pump can drop unintentionally as one of those parts breaks Hold the pump by the handgrips to lift it up Pump mounting Moun...

Page 21: ...ounting the pump on a mounting rail the rail may apply stress to the under cover The cover when it is deformed may disturb the reciprocation of a connecting shaft Anchor the pump so it doesn t vibrate...

Page 22: ...than the pump outlet inlet I D General joints can be used however no leakage is allowed under hot liquid transfer or heat cycle NOTE Use measures to keep the pump connections free from stress Points...

Page 23: ...ned to the full during operation NOTE Operating the pump with a suction side valve close negative pressure increases in the bellows and deforms the bellows inwardly Discharge line When installing a va...

Page 24: ...seconds every two minutes Some filtering area may be too small to release air Select a suitable filter size Program an open time according to the system perfor mance Pinpoint degassing Install an air...

Page 25: ...mp will not run correctly Regulator Provide a regulator to each solenoid valve Use of the sole regulator for both the valve can run the pump but then increases pulsation Air line piping layout FLP 75W...

Page 26: ...r attach silencers to exhaust ports The air consumption increases as installing two or more pumps and the number of pumps increases Optimise the air compressor capacity and the air line I D between th...

Page 27: ...ffective cross sectional area required for decompression process The effective cross sectional area required for decompression in the air line piping diagram is composed of the silencer on the pump on...

Page 28: ...of each pneumatic device mm2 See the catalogues issued by device pipe manufacturers for each effective cross sectional area Preventive measures against condensation If condensation is likely to occur...

Page 29: ...O D is recommended e Solenoid valve SV If supply air pressure is 0 15MPa or more use the 5 port 2 position single solenoid valve of the SMC SY9140 5 04 X90 or the CKD 4GB410 15 A 3 If supply air pres...

Page 30: ...tail j Connection between the compressor and the regulator Lay the supply air line shortest with a wider I D than the regulator inlet to keep the composite effective cross sectional area as much wide...

Page 31: ...information below and the end terminal pages and use them with the attached male connectors Lead wires Required spec LPC 1 controller power lead 24V 0 6A or more Connection between the 5 port SV and t...

Page 32: ...ht and left SV are connected CN4 Alarm signal OUT An alarm signal is sent out to a user PLC CN5 Control signal IN User PLC can control the LPC 1 via this terminal CN6 Sensor signal IN Displacement sen...

Page 33: ...r SMC PSE540A 01 User PLC PIN4 GND Green wire PIN5 Dry running start stop External signal input Yellow wire PIN6 GND Brown wire PIN3 Time up alarm External signal output Red wire PIN1 Leak alarm Exter...

Page 34: ...ow wire PIN24 White Brown wire PIN3 Alarm reset External signal input Red wire PIN2 GND White wire PIN1 START STOP External signal input Black wire Red White Left electropneumatic regulator CKD EVD350...

Page 35: ...Ground 2 N C Not used 3 GND 4 24V in 24VDC power input Capacity of the 24VDC power supply must be 2A or more Single solenoid valve CN3 SV output controller Connector CN3 Connector manufacturer JST Ho...

Page 36: ...CN4 Connector manufacturer JST Housing PHDR 18VS Contact SPHD 001T P0 5 Applicable power lead AWG 26 22 Pin Assignment 1 Leak alarm 2 24VDC 3 Time up alarm 4 24VDC 5 Life alarm 6 24VDC 7 Fast alarm 8...

Page 37: ...tart stop 6 GND 7 Electropneumatic regulator error 8 GND 9 Not used 10 Not used Pin 9 and 10 are not used Use the combination of pin 1 2 3 4 and 5 6 at each purpose assignment 1 3 5 7 9 2 4 6 8 10 Ele...

Page 38: ...used 12 Not used 13 Right displacement sensor 24VDC 14 Right displacement sensor GND 15 Left displacement sensor 24VDC 16 Left displacement sensor GND 17 Right displacement sensor input 18 Right displ...

Page 39: ...electropneumatic regulator pressure sensor input 10 Left electropneumatic regulator pressure sensor input 11 Not used 12 Not used 13 Right electropneumatic regulator pressure sensor SGND 14 Left elec...

Page 40: ...imity switches leak sensors solenoid valves displacement sensors and elec tropneumatic regulators pressure sensors NOTE A proximity switch may break Always ensure correct wiring Check if air piping is...

Page 41: ...erature fluctuation Loose stud bolts can cause an air leak from the joint of the cylinder head and pump head Be sure to tighten the M14 nuts by 30N m to secure the stud bolts before operation Unscrew...

Page 42: ...ate 2 FAST ALARM Fast alarm speed setting 3 LIFE ALARM Pump shot setting for a reminder of the end of service life 3 SET VALUE CONFIRM Setting confirmation 56 page 1 STROKE LENGTH Stroke length confir...

Page 43: ...s also can be selected in the same way The follow ing shows the steps to enter the AUTO mode through basic key operation Move the cursor to 7 MANU or AUTO with the UP and DOWN keys Push the ENTER key...

Page 44: ...ER key Select FLP 75 and push the ENTER key FLP 75 SELECT OK appears on the screen Always choose a correct model Otherwise malfunc tion results The controller refuses the start of operation and asks f...

Page 45: ...of a spring in the con necting shaft But then it will not adversely affect the pump operation as long as the origin position is deter mined Select 2 TEACHING and push the ENTER key Use the UP and DOW...

Page 46: ...he TEACHING LED goes off when the MENU or RESET key is pressed during teaching behaviour Push any key other than the START STOP key to return to the main menu Push the ENTER or MENU key if teaching is...

Page 47: ...key to choose YES and push the EN TER key to start operation The two different displays below will show up depending on whether feedback control is chosen or not Pushing the START STOP key in the main...

Page 48: ...plate Push the START STOP key Select YES and push the ENTER key Two different displays below will show up depending on whether feedback control is chosen or not The main menu shows up when the pump st...

Page 49: ...he SELECT key to choose YES and push the EN TER key if feedback control is required Or choose No Two different displays below will show up depending on whether feedback control is chosen or not After...

Page 50: ...nput for speed compensation operation In AUTO mode input of the external signal CN5 PIN5 dry running start stop signal from user PLC to the LPC 1 controller can also start the speed compensation Note...

Page 51: ...ode confirmation 3 SET VALUE CONFIRM and defaulting the LPC 1 4 RESET ALL DATA Select 4 SETTING in the main menu and push the ENTER key Sub menu options will appear Select one of the sub menu options...

Page 52: ...he LPC 1 controller Select 1 QUANT CONST CTRL feedback control setting in the sub menu and push the ENTER key Further options will show up Select 1 FLOW QUANTITY target flow rate set ting and push the...

Page 53: ...commended CKD EVD3500 010AN __ 3 elec tropneumatic regulator is used the supply air pressure to this EPREG must be 0 1MPa or higher than the max pressure set to the controller Adjust the supply side r...

Page 54: ...r of pump shots Select 3 1 shot d CAPA in the sub menu and push the ENTER key Set liquid volume per shot and push the ENTER keys Move between digits with the SELECT key and change numerical values wit...

Page 55: ...LPC 1 controller stops the pump at the third shots after the pump speed rises to the interlock speed fast alarm speed plus 10spm or above The controller performs teaching and speed compensation see p...

Page 56: ...ation Stroke length confirmation The LPC 1 controller shows stroke length measured through teaching LEFT Stroke length measured with the left displacement sensor RIGHT Stroke length measured with the...

Page 57: ...b menu or the MENU key to return to the main menu Default setting 4 SETTING 4 RESET ALL DATA Default the LPC 1 controller through the following procedure below Select 4 RESET ALL DATA in the sub menu...

Page 58: ...b menu options will appear Select 1 PROTECT and push the ENTER key Any key operation is disabled Push the ENTER RESET SELECT UP or DOWN key to return to the keypad lock sub menu or the MENU key to ret...

Page 59: ...LED lights when reciprocation times TOTAL COUNT1 exceeds the set number of times max 999 999 999 Confirmation Select 6 TOTAL COUNT and push the ENTER key Sub menu options will appear Select one of TO...

Page 60: ...o both regulators max allowable deviation is 0 01MPa Select 8 PRESSURE SENSOR and push the ENTER key When a pressure sensor is provided to the regulator or directory on the supply air line in operatio...

Page 61: ...the life alarm signal to the user PLC and the LIFE LED lights when reciprocation times accumulated in TOTAL COUNT1 exceeds the set number of times max 999 999 999 Default the accumu lation in TOTAL C...

Page 62: ...ns suspend operation immediately and inspect solve problems Before stopping the pump release the pressure from the discharge line Otherwise the bellows may deform Do not close a discharge valve as sto...

Page 63: ...failure If the SV switches correctly Replace as necessary Liquid can not be pumped up A check valve is clogged with debris A check valve for clogging Install a guard filter in a suction line Clean or...

Page 64: ...tops Air line I D and length Closed suction line Replace the bellows if damaged Observe pump spec and composite effective cross sectional area Excessive air con sumption Worn shaft packing Air leak fr...

Page 65: ...ith liquid temperature See page 67 for detail Periodic inspection Check the following items every month 1 Stroke rate reduction Stroke rate reduces as air leaks The wear of shaft packing is a cause of...

Page 66: ...ode and manufacturing number see pump nameplate 3 Drawing number if you have our approval drawing Parts No Parts names Q ty 1 Estimated life 2 1 12 Pump head bellows UNIT 1 1 year 24 25 Connecting sha...

Page 67: ...m flow rate is based on pumping clean water at 25 C and supply air pressure at 0 3MPa 2 The suction lift is based on pumping clean water at an ambient temperature and the maximum spm Stroke rate Air c...

Page 68: ...pacity 200pF DA conversion Trigger source signal Software trigger Digital output Number of output channels 7 Output type Open collector Max output current SV ch1 ch2 300mA Insulation Photocoupler insu...

Page 69: ...Outer dimension Outer dimension FLP 75W Weight 42kg LPC 1 controller 482 542 14 5 14 5 14 5 96 5 180 221 98 129 5 180 15 92 159 5 315 377 Supply air port 2 Rc1 2 185 98 175 88 4 4 5 2 152 163 165 175...

Page 70: ...S 4 23 Connecting shaft L 2 STNLS STL 67 Hex holder 4 PP 24 Connecting shaft R 2 STNLS STL 68 Hex nut 8 STNLS STL M4 25 Slide shaft 2 STNLS STL HC plating 69 Plate washer 4 STNLS STL M4 26 Retainer 4...

Page 71: ...71 Specifications Specification Outer dimension...

Page 72: ...g Co Ltd TEL 86 7503866228 FAX 7503866278 Singapore IWAKI Singapore Pte Ltd TEL 65 63162028 FAX 63163221 China GFTZIWAKIEngineering Trading Guangzhou TEL 86 2084350603 FAX 2084359181 Spain IWAKI Europ...

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