IWAKI LK-A/-B TC Instruction 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” sec­tions could lead to personal injury or property dam­age.

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” sec­tions 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 p ower

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 relat­ed 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 manufactur­er'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

Ele ct ric al

sho ck

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

0

204060

80

100

0

204060

80

100

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 - A 6 5 TC - 04 F E S

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 : Polytetraf luoroethylene 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 name­plate.

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 specifica­tions.

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 indi­cation 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
4 Valve 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

4 Valve 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)