IWAKI PUMPS FDC-1 Bedienungsanleitung



Read this manual before use of product

IWAKIController

ModelFDC-1

InstructionManual

Thank you for purchasing Iwaki Controller Model FDC-1.

This controller is an exclusive use for Iwaki pneumatic bellows pump. This document provides

“Notice and warnings”, “Overview”, “Set up”, “Operation” and “Maintenance”, and explains

handling and how to operate the controller.

To make sure for your safety and correct use, please read this manual entirely before using the

controller, and comprehend thoroughly for each clause.

Contents

NOTICE AND WARNING FOR HUMAN SAFETY ························ 1

OVERVIEW ··················································································· 3

1. Unpacking and inspection ····················································· 4

2. Specification ·········································································· 4

3. External dimensions ······························································ 5

4. Names and explanations of component devices ··················· 6

5. Explanation of work ······························································· 7

6. Main functions ······································································· 8

SETUP ··························································································· 9

1. Installation ·········································································· 10

2. Connection ·········································································· 10

Operation ···················································································· 17

1. How to operate ···································································· 18

2. How to set controller ···························································· 18

3. Operation screen ································································· 21

4. Setting confirming and setting change procedure ··············· 22

5. Pump operation ··································································· 22

6. Alarm reset procedure ························································· 23

Maintenance ··············································································· 24

1. Troubleshooting ··································································· 25

Please keep this document at customer’s site in order to review

whenever it is necessary. For additional information, please inquire

our local representatives in your area, or call us directly.

−1−

Important Instruction

Types of Symbols

Indicates that “Warning” or “Caution” must be exercised. Inside this

triangle, a concrete and practical image provided as a warning or cau-

tion 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.

Nonobservance or misapplication of the

contents of the “Caution” section could lead to

serious physical injury to the user or serious

damage to the product.

Warning Nonobservance or misapplication of the

contents of the “Warning” section could lead to

a serious accident, including death or injury.

Caution

For the Safe and Correct Handling of the Pump

•Read the "Safety Instructions" sections carefully to prevent accidents involving your customers

or other personnel and to avoid damage or loss of other assets. Always follow the instructions

and advice found in these sections.

•Observe and abide by the instructions described in this manual. These instructions are very

important for protecting pump users from potentially dangerous conditions and situations related

with the use of the pump system.

•The symbols relate to the following meanings described below:

Safety Section

WARNING

•For specified application only

Model FDC-1 is the exclusive use controller designed for IWAKI pneumatic drive bel-

lows pump FA, FF, FH, FW and FS Series. Do not use this controller for other pumps

or application.

•Do not disassemble and remodel

Do not disassemble and remodel the controller.

CAUTION

•Qualified operator only

The controller must be operated or maintained by the person who has enough knowl-

edge of the product and experience of handling of product.

•Place to be installed and stored

This controller is not explosion-proof design. Do not install or store the controller at

flammable atmosphere. Do not install or store the controller at corrosive

atmosphere.Otherwise, it may be failed or cause accident.

•Precautions for wiring proximity switches

Wrongly wired proximity switches (Right and Left) may cause the seizure of contacts.

Pay attention to the wiring.

•Specified voltage only

Do not use the controller with other voltage than specified one. Otherwise it may

causes fire or electrical shock.

- 2 -

Caution

No Remodeling

Prohibited

−3−

OVERVIEW

1. Unpacking and inspection.................... 4

2. Specification......................................... 4

3. External dimensions............................. 5

4. Names and explanations

of component devices......... 6

5. Explanation of work.............................. 7

6. Main functions...................................... 8

−4−

1) Please inspect immediately on the followings as soon as you receive the product, and inquire the shop you ordered if

any objectionable was found.

(1) Identify if the model number described on the front panel is the same as you ordered.

(2) Check if there is any damage(s) suffered from accident(s) during transportation.

(3) Confirm all of accessories were included. (if specified)

*Standard accessories: one each connector (CN1~CN6), total 6 connectors and a set of contact for the connectors.

*Optional accessories: Cable exclusively used for Electro- pneumatic regulator. (Only if ordered as an optional)

General

Spec.

Power supply DC24V + / - 10%

Power Consumption 24VA or less

Ambient temp. 0 ~ 50 °C

Ambient humidity 85% or less (No condensing)

Input

Spec. Leak sensor input Voltage between electrodes DC24V + / - 10%

Operating resistance Detect:0~15kohm (25k ohm or more: no detection)

Proximity switch input Input signal Proximity Switch (negative logic operation)

ON voltage level 3V or less

OFF voltage level 5V or more

External start input Input signal Potential free contact or NPN open collector output

ON voltage level 3V or less

OFF voltage level 18V or more

External alarm reset

input

Input signal Potential free contact or NPN open collector output

ON voltage level 3V or less

OFF voltage level 18V or more

Output

Spec. Solenoid valve

operation output

Output NPN open collector output

Output load voltage DC 24V + / - 10%

Output load current 1A (MAX)

Leak alarm output

Time-up alarm output

Life alarm output

Fast alarm output

Output NPN open collector output

Output load voltage DC 24V + / - 10%

Output load current 1A (MAX)

Electro-pneumatic

Regulator control output

Output signal Analog signal

Voltage range 0 ~ 10V

Resolution 8bit D/A converter

1. Unpacking and inspection

2. Specification

−5−

Fig. 1

PUMP CONTROLLER MODEL FDC-1

IWAKI

RUN

LEAK

TIME

LIFE

FAST CN1 CN2 CN3 CN4 CN5 CN6

141

+1

0

148

0.3

4.5

44+1

0

38±0.3

136



152

158



SELECT

ENT

AUTO MANU

148



42.3



(2)

Fig. 2

−

PT 1

／

PT 1

／

，

EXH.

(9)

22.5

×

OUT

SUP

PUSH OPEN

Zero span adjusting window

M12.4 pin, connector plug

(1) Controller (Fig. 1)

(2) Electro-pneumatic regulator (Option) (Fig. 2)

3. External dimensions

−6−

Fig. 3

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PUMP CONTROLLER MODEL FDC-1

IWAKI

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RUN

LEAK

TIME

LIFE

FAST CN1 CN2 CN3 CN4 CN5 CN6

SELECT

ENT

AUTO MANU

①

②

⑦

⑥

④③

⑤

⑨⑩⑧ ⑪

①LCD panel:

Describes setting item, operating condition and contents of alarm for each pump in English abbreviation. (2 lines, 16

alphabets)

②key, key and key :

key: To be used for writing selection of each setting value. At that time, ENTER key will be used for

confirmation of figure down of value and operation.

By the combination of MENU key and SELECT key, it is able to access to each setting screen individually.

key: The designation of setting screens No., changeover of Stop & Run and Alarm reset can be executed.

③Controller operation mode selection key (MANU operation):

When LED turns on by depressing key, operation mode can be switched to manual operation mode.

Manual mode can effect all sort of setting and work on the panel manually.

④Controller operation mode selection key (AUTO operation):

When LED turns on by depressing key, operation mode can be switched to automatic operation mode.

Automatic operation mode can effect all sort of setting on the panel manually, and remote operation can be effected

for pump start, pump stop and alarm reset respectively by zero voltage contact signal or open collector signal.

⑤LEDs:

There are 5 LEDs in total. The explanation of each LED is as follows.

RUN: Turns on while pump is operating. (Green)

LEAK: Turns on when leak alarm is detected. (Red)

TIME: Turns on when time-up alarm is detected. (Red)

LIFE: Turns on when life alarm is detected. (Red)

FAST: Turns on when fast alarm is detected. (Red)

⑥Exclusive connector for alarm output signal (CN1):

At the same time of each alarm detection, each alarm output signal are made out to the external. Connect this

controller and your equipment with an output cable (optional).

⑦Connector exclusively used for driving solenoid valve (CN2):

Solenoid valve driven signal will be generated. Then, connect this controller and solenoid valve (single or double

solenoid valve) with an output cable (optional).

⑧Connector exclusively used for pump input (CN3) :

This connector effects to input the signal of proximity switch and leak sensor. Connect this controller and pump

with an input cable (optional).

⑨Connector exclusively used for external input (CN4):

This connector effects to input signals of pump start, pump stop and alarm reset respectively from the external.

Connect this controller and your equipment with an input cable (optional).

⑩Connector exclusively used for electro-pneumatic regulator (CN5):

This connector generates regulator control signal for flow rate control. Connect this controller and electro-

pneumatic regulator with an output cable (optional).

⑪Connector exclusively used for power supply (CN6):

This connector supplies DC24V + / - 10%.

Connect this controller and power supply with a cable for power supply (optional).

AUTO

MANU

ENTER

SELECT

ENTER

SELECT

4. Names and explanations of component devices

−7−

(1) Pump operation:

①When proximity switch R input is on, solenoid valve operation output keeps ON condition.

②Even if proximity switch R input is off, solenoid valve operation output keeps ON condition.

③At the condition of proximity switch L input is on, solenoid valve operation output becomes off.

④Then, until proximity switch R input comes on, solenoid valve operation output keeps off condition.

⑤The above operations (①~④) shall be repeated in order.

②

①

Proximity switch L

Proximity switch R

Solenoid valve

operation output L

Solenoid valve

operation output R

(2) Flow rate control:

1 shot flow rate for F pump has been arranged; discharge capacity shall be “pump stroke rate times 1 shot flow rate”.

When the flow rate was set arbitrarily, stroke rate shall be converted automatically within the controller. Comparing

this converted stroke rate and operating cycle of proximity switch, which is effected to input into controller while

pump is operating, control voltage (DC0~10V) to Electro-pneumatic regulator (ER1) shall be adjusted. Varying

secondary air pressure of electro-pneumatic regulator (ER1), discharge capacity shall be controlled.

(3) Leak alarm:

This function effects to stop pump with alarm signal when pump brings about leakage.

It detects leakage and makes output signal by that leaked liquid conducts between electrodes (C1- C2 or D1-D2) of

which set up corresponding to each bellows (left and right).

Receiving this alarm, the controller effects warning, and put control signal off to Electro-pneumatic regulator

simultaneously. Then, it makes stop pump.

On this occasion, pneumatic pressure to drive inside of pump shall be released and becomes no-pressure only when

Electro-pneumatic regulator (optional) is being used.

(4) Time up alarm:

This function effect to alarm when pump stops or stroke speed becomes abnormally slow down for some reason.

Output for solenoid valve still keeps operating condition, though. Time set for criterion of warning shall be

executed on setting screen No.8.

It makes output as an alarm in case of whatever longer stroke time (t1, t2 and t3), than preset time t0. When all of

t1, t2 and t3 become shorter than t0, this alarm shall be reset automatically, and starts operation again.

5. Explanation of work

t1t2t3

t0t0t0

Proximity switch L

Proximity switch R

Time up alarm

−8−

(5) Life alarm:

This function effects to alarm and notice when accumulated count number becomes beyond the fixed total count

number which was set manually.

Output for solenoid valve and Electro-pneumatic regulator (optional) still keep operating condition, though.

Total count number setting can be executed at setting screen No.9, and also, it is able to reset by manual reset or

reset signal from the externals. After input of reset, Life alarm detection is neglected for 2 minutes. After 2 minutes

past, it detects again if pump is operating condition.

(6) Fast alarm:

This function effects to alarm when pump stroke became abnormally faster than the preset stroke rate for some

reasons. Output for solenoid valve and Electro-pneumatic regulator (optional) still keep operating condition,

though.

Stroke rate setting for criterion of warning shall be executed on setting screen No.10.

If actual operating stroke becomes slower than the fixed stroke, then it resets automatically. Also it is able to reset

by reset signal from manual reset device. After reset signal input, it neglects detection for 2 minutes. After

2minuites, it may start again if it is in alarm condition.

①Possible to fix a specified flow rate control against the load fluctuation at discharge side.

②Possible to set flow rate freely.

③Possible to display stroke rate, flow rate and total count number while pump is operating.

④In case of bellows broken, leak alarm will be output to the externals. Pump stops simultaneously with alarm output.

⑤Possible to set necessary time set for 1 shot of pump operation. When the time for 1 shot of pump is beyond the

setting time, time up alarm will be output to the externals.

⑥Possible to set total counts number of pump. When count number for 1 shot of pump is beyond the setting number,

life alarm will be output to the externals.

⑦Possible to set maximum counts stroke rate. When count number for stroke is beyond the setting number while its

operation, first alarm will be outputting to the externals.

⑧Possible to set alarm reset for start / stop of pump by signals from the externals.

⑨Possible to select operation mode of controller from MANU and AUTO.

⑩In case of proximity switch broken, possible to operate pump by timer mode until proximity switch is replaced.

6. Main functions

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