Low Energy Air Pump (LEAP)

70% Energy Saving

Reducing air consumption to save your company money

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!

Graph showing fluid flow against air pressure required for a Diaphragm Pump

Features & Benefits of Low Energy Diaphragm Pump

• Available on the complete range of Tapflo Air Operated Diaphragm Pumps

• Retro-fittable Switching to low energy technology is as simple as switching the centre section of your Tapflo Diaphragm Pump to a LEAP centre section. This is also applicable to several of our competitors’ pumps.

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

• Reduced energy consumption saving up to 70% using our Low Energy Diaphragm Pump

•  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 – TC50, 70 & 80

Position	Quantity	Description	Material	KIT AIR
12E	1	Centre Block	Aluminium
1204E	2	Bushing	Aluminium
16E	1	Diaphragm Shaft	AISI 316L, Zinz Plated, Neodynium	X
25	1	Muffler	PP	X
26E	1	Quick Connector Pneumatic Fitting	Brass
261E	1	External Pilot Screw	A4-70
27E	2	Air Valve Retaining Screw	A4-70
36E	2	Shaft War Ring	NBR	X
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	A4-70
973E	2	Control Module Fixing Screw	A4-70
974E	4	Washer	A4-70

Spare Parts – TC100, 120, 125

Position	Quantity	Description	Material	KIT AIR
12E	1	Centre Block	Aluminium
1204E	2	Bushing	Aluminium
16E	1	Diaphragm Shaft	AISI 316L, Zinc Plated Neodynium	X
25	1	Muffler	PP	X
26E	1	Quick Connector, Pneumatic Fitting	Brass
261E	1	External Pilot Screw	A4-70
27E	2	Air Valve Retaining Screw	A4-70
36E	2	Shaft Wear Ring	NBR	X
61E	1	Air Valve Complete	Body: PTFE coated hard ironized Aluminium, Delrin O-Rings: NBR	X
97E	1	Control Module	Aluminium
971E	1	IP/EP Gasket	NBR	X
972E	2	Control Module Fixing Screw	A4-70
973E	2	Control Module Fixing Screw	A4-70
974E	4	Washer	A4-70

Spare Parts – TC200, 220, 225

Position	Quantity	Description	Material	KIT AIR
12E	1	Centre Block	Aluminium
1201E	2	Diaphragm Back Plate	Aluminium
1202E	8	Back Plate Retaining Screw	A4-70
1204E	6	Bushing Back Plate	Aluminium
1211E	2	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	Retaining Screw	A4-70
1204e	6	Bushing Back Plate	Aluminium
1211E	2	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
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

Spares

Even during normal operating conditions, some parts of the pump will be subject to wear & tear. In order to avoid expensive breakdowns, we recommend having a few spare parts in stock. Depending on the severity of the operation and the importance of assuring continuous operation we offer three different spare part KITS, please check full HDPE & PTFE, Metal, Sanitary IOM manuals* for further instructions. Please keep in mind that Low Energy Air Pump KIT AIR differs from standard HDPE & PTFE, Metal or Sanitary pump*. NOTE! Even though the Control Module [97E] is not a subject to wear, remember to replace it in case of leakage through muffler.
*depends on the product series

Recommended spares to keep in stock for the Low Energy Air Pump:

	TC50, 70 & 80
	Position	Description	Quantity
KIT AIR	16E	Complete Diaphragm Shaft	1
	18	O-Ring Set (Inlet/Outlet)	4
	25	Muffler	1
	61E	Complete Air Valve	1
	971E	IP/EP Gasket	1

 

	TC100 – 425
	Position	Description	Quantity
KIT LIQUID	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 for 36E)	1
	25E	Muffler	1
	61E	Complete Air Valve	1
	971E	IP/EP Gasket	1

 

Technical Information

Drive Type	Electric, Pneumatic
Flow Rate	up to 820 l/min
Pressure	up to 16 Bar
Material	Aluminium, Cast Iron, PE & PTFE, Stainless Steel AISI 316L
Self-Priming	Yes
Solids Handling	up to 100mm
Viscosity	0-200+ cSt

Tapflo Low Energy Air Pump has been recognised by the PPMA Group Industry Awards for the category ‘Innovative Processing Systems’. For its innovative technology, LEAP was granted a Highly Commended recognition.

LEAP has also been recognised as a finalist at the Pump Industry Awards for ‘Technical Innovation of the Year – Products’ in 2018.