Low Energy Air Pump – HDPE/PTFE

Reduced Air Consumption

Our LEAP technology reduces air consumption, saving energy and reducing operating costs.

Fluid Flow Against Air Pressure Required

The graph below shows fluid flow against the air pressure required when comparing a standard Air-Operated Diaphragm Pump against Tapflo’s Low Energy Air Pump (LEAP). As you can see, at 0.5 bar air pressure, the LEAP pump was able to produce approx. 27.5 l/min whereas the standard pump didn’t even start operating until it was supplied with 1.1 bar air pressure, and only produced 5 l/min. This demonstrates that standard Air-Operated Diaphragm Pumps require a lot of energy to simply overcome the resistance within the pump. The energy required to do this is a direct correlation to the pressure you have to put in. By reducing the air pressure required to operate you can significantly reduce the operating costs of the pump. To put this into monetary terms,  Tapflo customer required a 2” pump to run continuously for 5 days a week, 48 weeks/year, producing 150 l/min @ 1 Bar operating pressure. Based on the British Compressed Air Society figures of between £0.01 to £0.03 to produce 1000 Litres of compressed air, a standard pump would cost an average of £1843.20 / year. By converting to the LEAP technology, the customer would save £652.64 / year per pump!

Features and Benefits of the Low Energy Diaphragm Pump

• Available on the complete range of Tapflo Air Operated Diaphragm Pumps as well as Dellmeco & Almatec

• Can be retro-fitted: To switch an existing Tapflo, Dellmeco or Almatec Air-Operated Diaphragm Pump over to LEAP only the centre section needs replacing.

• Ultra-Low starting pressure: 0.2 Bar (3psi)

• Reduced energy consumption: LEAP can achieve savings of up to 70% compared to standard Diaphragm Pumps

•  Impossible to stall (mid-port)

• 24vdc starting signal (2.3w/1w) & Dry contact (VFC) feedback on completed strokes – provides control & feedback to the operator for preventive maintenance as well as performance monitoring such as:

• Batch dispensing: Simply counting the strokes of the diaphragms and stopping the pump after the required volume has been dispensed.

• Dry Running: By analysing the frequency of the pulses you can monitor whether the pump is dry-running or not. When the pump starts to dry run the frequency of the pulses will increase.

• Dead Heading: When the frequency of the pulses slows down or stops this means that the pump has deadheaded, indicating closed valve operation or a blockage in the pipework.

• Flow Monitoring: Counting the frequency of the pulses can also be used to monitor the flow rate of the media in the process. The diaphragms displace a set amount per stroke therefore by multiplying the strokes by the volume displaced per stroke provides an accurate indication of flow. Or indeed, in the case of one of our customers, wiring in a coreolis flow meter with pulse feedback into their system to provide real-time monitoring of flow to within an even greater degree of accuracy. Coreolis Flow Meters are NEVER used with diaphragm pumps as they are susceptible to pulsing flow. This is testament to the ability of the LEAP Pump to reduce the pulsing effect usually associated with traditional diaphragm pumps.

• Easy to maintain – Air Valve can be replaced in under 2 minutes, pump disassembly isn’t required!

• Reduced pulsation – negates the need for a pulsation dampener in many instances!

• EP Mode for high-pressure applications and start control: As standard, the unit is supplied with an internal pilot signal, however, should the unit be required to be used in a high-pressure application, in excess of 10 bar, i.e. Filter Press applications, the unit can be easily modified to use a lower pressure external pilot.

• One seal design: reduced frictional losses

• Noise reduction: lower air pressures reduces the noise of the pump

• Control simplification: No need for an external pneumatic solenoid valve, reducing costs and simplifying control

• Improved Life of main Air Valve: Tapflo have developed their own air valve for use with the LEAP technology using a lapped spool and sleeve construction. This provides a life expectancy in excess of 200 million cycles!

 

For more information and a case example of where our Low Energy Air Pump (LEAP) has been integrated into a production line with control and monitoring from a central control system, visit our case studies section. The valve is also balanced to prevent any issues associated with high-pressure applications.

Spare Parts – TC200, 220, 225

Position	Quantity	Description	Material	KIT AIR
12E	1	Centre Block	Auminium
1201E	2	Diaphragm Back Plate	Aluminium
1202E	8	Back Plate Retaining Screw	A4-70
1204E	6	Bushing	Aluminium
1211E	2	Back Plate Square O-Ring	NBR	X
1212E	4	Back Plate O-Ring	NBR	X
1213E	8	Back Plate O-Ring	NBR	X
1214E	4	Back Plate O-Ring	NBR	X
16E	1	Diaphragm Shaft	AISI 316L, Zinc Plated Neodynium	X
25	1	Muffler	PPM-F	X
251E	1	Muffler Retaining Plate	Aluminium
252E	4	Muffler Retaining Screw	A2-70
261E	1	External Pilot Screw	Brass
27E	2	Air Valve Retaining Screw	A2-70
361E	2	Shaft Cut Wear Ring	NBR	X
362E	1	Shaft Wear Ring (Back up for 47E)	NBR	X
47E	1	O-RING
61E	1	Air Valve Complete	Body: PTFE coated hard ionized Aluminium, Delrin O-Rings: NBR	X
97E	1	Control Module	Aluminium
971E	1	IP/EP Gasket	NBR	X
972E	2	Control Module Fixing Screw	A2-70
973E	2	Control Module Fixing Screw	A2-70
974E	4	Washer	A2-70

Spare Parts – TC400, 420, 425

Position	Quantity	Description	Material	KIT AIR
12E	1	Centre Block	Aluminium
1201E	2	Diaphragm Back Plate	Aluminium
1202E	12	Back Plate Retaining Screw	A4-70
1203E	4	Back Plate Retaining Screw	A4-70
1204E	6	Bushing	Aluminium
1211E	2	Back Plate Square O-Ring	NBR	X
1212E	4	Back Plate O-Ring	NBR	X
1214E	4	Back Plate O-Ring	NBR	X
16E	1	Diaphragm Shaft	AISI 316L, Zinc Plated Neodynium	X
25	1	Muffler	PPM-F	X
251E	1	Muffler Retaining Plate	Aluminium
252E	4	Muffler Retaining Screw	A2-70
261E	1	External Pilot Screw	Brass
27E	2	Air Valve Retaining Screw	A2-70
361E	2	Shaft Cut Wear Ring	NBR	X
362E	1	Shaft Wear Ring (Back up for 47E)	NBR	X
47E	1	O-Ring
61E	1	Air Valve Complete	Body: PTFE coating hard ionized Aluminium, Delrin O-Rings: NBR	X
97E	1	Control Module	Aluminium
971E	1	IP/EP Gasket	NBR	X
972E	2	Control Module Fixing Screw	A2-70
973E	2	Control Module Fixing Screw	A2-70
974E	4	Washer	A2-70

TC100-425
	Position	Description	Quantity
	18	O-Ring Set (Inlet/Outlet)	4
	16E	Complete Diaphragm Shaft	1
	1211E	Back Plate Square O-Ring	2
	1212E	Back Plate O-Ring	4
	1213E	Back Plate O-Ring	8
	1214E	Back Plate O-Ring	4
	361E	Shaft Cut Wear Ring	2
	362E	Shaft Wear Ring (back up to 36E)	1
	25E	Muffler	1
	61E	Complete Air Valve	1
	971E	IP/EP Gasket	1