Low Energy Air Pump (LEAP) - Sanitary Diaphragm Pump

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WHAT MAKES OUR LOW ENERGY DIAPHRAGM PUMP DIFFERENT?

Tapflo UK have developed the LEAP (Low Energy Air Pump) technology, which is a breakthrough in energy saving for Air Operated Diaphragm Pumps. Airflow through the Diaphragm Pump is controlled using an innovative new technology, which transforms the performance of the pump. The benefits are:

  • Diaphragm Pump starts up at a much lower air pressure, typically 0.2 bar compared with an industry standard of 1.2 bar
  • Operation is much smoother throughout
  • Users of LEAP could save up to 70% on enrgy consumption 

This technology can be retro-fitted to any Tapflo, Dellmeco & Almatec Air Operated Diaphragm Pump or supplied as a complete pump for fresh applications. We’re finding that there is increasing demand for this revolutionary technology and users are telling us that they need these pumps to help them achieve their energy saving targets. 

Speak to us to learn how LEAP can help your business today!

Additional 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

REDUCED AIR CONSUMPTION

Reduced Air Consumption

Graph showing 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!

Flow Rate LEAP Pump

Additional 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

FEATURES & BENEFITS OF TAPFLO'S LOW ENERGRY DIAPHRAGM PUMP

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

  • - Retro-fittable: 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 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 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!

LEAP Pump Features LEAP Pump Features

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.

Additional 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

Spare Parts, TC50, 70 & 80 

LEAP Pump Spare Parts TC50-70 & 80

Pos. Qty 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 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 

LEAP Spare Parts TC100-1120-125

Pos. Qty 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 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, TC200, 220, 225 

LEAP Spare Parts TC200-220-225

Pos. Qty 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 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 

LEAP Pump Spare Parts TC400-420-425

Pos. Qty 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
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  

 

Recommended Spares for Stocking for the Low Energy Air Pump

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 PE & PTFE, Metal, Sanitary IOM manuals* for further instructions. Please keep in mind that Low Energy Air Pump KIT AIR differs from standard PE & 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

TC50, 70 & 80
Pos. Description Qty
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
Pos. Description Qty
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

Additional 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. Download the Entry for the PPMA Awards 2017

Additional 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

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