Samson DF100 User manual

1
R. 03/12 855 819
Samson Corporation • One Samson Way • N.C. 28778 Swannanoa • Phone: [phone] • Fax: [phone]
2012_03_06-17:30 ENGLISHESPAÑOL
1" DOUBLE DIAPHRAGM PUMP DF-100
Operation and maintenance manual Codes:
DF100_-XXX-XX-XX-XX-X /
5510XX
DF100
Metallic, single inlet
Content
Warnings and cautions 2
Nomenclature of the pump 2 - 3
Description 4
Dimensions 5
Installation 6 - 9
Operating instructions 10 - 11
Parts 12 - 14
Troubleshooting 15 - 16
Maintenance guide 17 - 21
Technical data
Ratio 1:1
Maximum free flow 26.42 gal/min (100 l/min)
Delivery per stroke 8.45 oz (0,25 l)
Air pressure operating range 43.5 psi - 100 psi (3 a 7 bar)
Solid in suspension max size 4 mm
Maximum suction head 14.76 ft (4,5 m) dry - 22.97 ft (7 m) wet
Weight 7.2 kg (Metallic) - 6.5 kg (Plastic)
Fluid inlet (single inlet) 1" NPSM (F) and flange (BSP/NPT (F) and flange with plastic body)
Fluid outlet 1" NPSM (F) and flange (BSP/NPT (F) plastic body)
Air inlet 3/8" NPSM
Wetted part materials See model specifications
Noise level 80 dB
Temperature range (see material temperature range on page 4) 0 - 158 ºF (0 - 70º C)
CAREFULLY READ THE INSTRUCTIONS AND WARNINGS BEFORE
STARTING TO OPERATE THE EQUIPMENT

2855 819 R. 03/12
Samson Corporation • One Samson Way • N.C. 28778 Swannanoa • Phone: [phone] • Fax: [phone]
2012_03_06-17:30
Nomenclature of the pump
Directflo pumps are identified with a numeric code of 6 digits or with an alphanumeric one. Use the next table to find your alphanumeric code for
use with this manual.
Warnings and cautions
In this document you will find warnings and cautions for installation, use and maintenance of the Direcflo pumps.
Here’s the meaning of symbols you may find in this document and general warnings that you should keep in mind.
Warning Caution
This symbol indicates that you should be aware that there is a
danger of serious bodily injury or death if you ignore the
warning. described.
This symbol indicates that you should be aware that there is a
risk of damaging the equipment if you ignore the warning
described.
Warning
Carefully read the instructions and warnings before operating the equipment!
• Carefully read the instructions and warnings before operating the equipment!
• This equipment is for professional use only.
• Do not degrade the integrity of the equipment. Use only original replacement components from Samson Corporation.
• Fluids not suitable for the pump can cause damage to the pump unit and involve risk of serious personal injury.
• Always consult Samson Corporation if you have any questions about the compatibility within the fluids and the pump materials, including
elastomers.
• Install and use the pump according to all local and national regulations and abide all health and safety laws or legislation.
• The pump can produce fluid pressures equal to the air supply pressure. Do not exceed the maximum allowable pressure of 7 bar air supply.
The total hydraulic pressure (differential pressure + system) should never exceed 7 bar.
• Never use a pump that leaks, that is damaged, that is corroded or otherwise it may lack the capacity to contain the fluid.
• Frequently check that the bolts on the diaphragm cover of the pump are torqued correctly.
• Do not use a model with aluminium wetted surfaces to pump fluids for human consumption, there is a possibility of trace contamination of lead.
• Danger of explosion if used 1,1,1-trichloroethane, methylene chloride or other halogenated hydrocarbon solvents with aluminium wetted
materials. It could cause serious injury and property damage.
• Inside the pump, diaphragms separate the fluid that is being pumped from the air supply. If a diaphragm breaks, the fluid can leak out of
the air exhaust and contaminate the environment.
• When handling hazardous fluids, always route the air exhaust into a suitable container and locate it in a safe place.
• When the fluid source level is situated higher than the pump, (flooded suction), the outlet tank must be at a higher level than the product
to prevent spills.
• For pumps handling hazardous fluids that are a danger to humans or to the environment, install a suitable container surrounding the
pump to prevent any leaks or spills.
• Ensure that the operators of this equipment are trained on the operation and limitations. Use safety equipment as safety goggles or other
equipment required.
Single inlet
Numeric code Alphanumeric code
551010.300 DF100AAA11HHNAS
551011.300 DF100ANA22CHNAS
551015.300 DF100APP23HHNAS

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R. 03/12 855 819
Samson Corporation • One Samson Way • N.C. 28778 Swannanoa • Phone: [phone] • Fax: [phone]
2012_03_06-17:30 ENGLISHESPAÑOL
Nomenclature of the pump
Balls
Code Ball material
TTeflon®
GNBR
CAcetal
HHytrel®
SSANTOPRENETM
PPolipropylene
Connections
Code Description
NNPT
BBSP
MNPSM
Accesories
Code Description
AStandard
BThreaded air outlet
CDiaphragm rupture detector
DStroke sensor
EPressure relief valve
Your pump model is identified on the front name plate. Below, you will find your pump configuration and the options included.
Product
customization
Directional valve body Pump body Pump shield
A (Aluminium) A (Aluminium) A (Aluminium)
P (Externally controlled) D (Conductive acetal) P (Polypropylene)
N (Nichel coated aluminium) N (Without pump shields)
F (Cast iron)
S (Stainless steel)
P (Polypropylene)
C (Acetal)
K (PVDF)
Bushing / Seal / Push rod
Code Bushing material Seal material Pushing rod material
1Teflon® NBR Stainless steel
2Teflon® Viton® Stainless steel
3Teflon® Variseal Stainless steel
4Stainless steel Variseal Teflon®
5Conductive acetal Variseal Stainless steel
6Conductive acetal Viton® Stainless steel
7Conductive acetal Epdm® Stainless steel
8Teflon® Epdm® Stainless steel
Ball check seats / O-rings / Ball guides
Code Ball valve seats material O-rings material Ball guides material
1Stainless steel NBR Acetal
2Stainless steel Viton® Acetal
3Stainless steel Viton® Polypropylene
4Stainless steel Viton® Teflon®
5Teflon® Viton® Teflon®
6Stainless steel Epdm® Acetal
7Stainless steel Epdm® Teflon®
8Stainless steel Epdm® Polypropylene
Diaphragms
Code Diaphragms
HHytrel®
SSANTOPRENETM
TTeflon®Diaphragms with Viton®seals
GNBR
ZTeflon®Diaphragms with Epdm® seals
DF-100_ X X X X XXXXXX

4855 819 R. 03/12
Samson Corporation • One Samson Way • N.C. 28778 Swannanoa • Phone: [phone] • Fax: [phone]
2012_03_06-17:30
Description
Directflo concept
Air operated double diaphragm pumps are air-powered, reciprocating positive displacement pumps with two pumping chambers. Two diaphragms,
centrally located in the chambers, separate the compressed air (dry side) from the fluid being pumped (wet side). A shaft transmits the reciprocating
motion of one diaphragm to the other. A directional valve alternatively distributes the air from one chamber to the other; thus a reciprocating
movement of the diaphragms is created. With each stroke, fluid is discharged by one of the diaphragms whilst the opposite diaphragm sucks new
fluid into the expanding chamber. Check valves, two on the discharge side and two on the suction side, control and direct the fluid flow.
Capacity curves
DF100
Temperature working range
Material Temperature range
PTFE 5 ºC - 105 ºC / 41 ºF - 221 ºF
NBR 10 ºC - 80 ºC / 50 ºF - 176 ºF
Acetal 10 ºC - 90 ºC / 50 ºF - 194 ºF
Hytrel® 10 ºC - 90 ºC / 50 ºF - 194 ºF
Neopreno -18 ºC - 93 ºC / 0 ºF - 200 ºF
SANTROPRENETM -29 ºC - 135 ºC / -20 ºF - 275 ºF
Viton® -10 ºC - 120 ºC / -4 ºF - 248 ºF
Tested at room temperature, with water and flooded pump with 3.5 inches, (80 mm), positive suction head.
100 psi 87 psi 72.5 psi 58 psi 43.5 psi
87 psi
100 psi
58 psi
72.5 psi
43.5 psi

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R. 03/12 855 819
Samson Corporation • One Samson Way • N.C. 28778 Swannanoa • Phone: [phone] • Fax: [phone]
2012_03_06-17:30 ENGLISHESPAÑOL
Dimensions
DF 100
A B C D E F G H I J K L
216 mm 189 mm 227 mm 175 mm 154 mm 9 mm 184 mm 210 mm 94,51 mm 1"
BSP
NPT
210 mm 3/8"
NPSM
8,5" 7,44" 8,94" 6,89" 6,06" 0,35" 7,24" 8,27" 3,72" - 8,27" -

6855 819 R. 03/12
Samson Corporation • One Samson Way • N.C. 28778 Swannanoa • Phone: [phone] • Fax: [phone]
2012_03_06-17:30
Installation
Warning
• Incorrect installation can cause serious injury.
• For pumps handling hazardous fluids that are a danger to humans or to the environment, install a suitable container surrounding the pump
to prevent any leaks or spills.
• Install and use the pump according to all local or national regulations and abide all health and safety laws or legislation.
• If the surface temperature of the system or parts exceeds 60 ºC, these areas shall be marked with the warning text “hot surface" to avoid
body injuries.
• Static electricity could be built up during operation. The pumps must be grounded. Use always adequate pumps for flammable
environments. Always follow local safety standards for hazardous environments.
• When moving the pump with a forklift or truck, make sure the pump does not fall. If it falls, it could be damaged and / or cause bodily
injury. Be ware of no one goes under the pump when lifting. There may be a risk if the pump fall.
• When pumping hazardous fluid (hot, flammable, strong acid, etc.), implement protective measures to prevent leakage of fluids and place
warning signs in appropriate places.
• Install shutoff valves on both sides of the pump to close the inlet and outlet before servicing and maintenance. Verify that you can pour
the fluid from the pump without causing personal injury, environmental or adjacent equipment damage.
• Always install the pump so the air valve is easily accessible.
• The pressure variations can cause vibrations in piping systems. Connect the pump to the piping system through flexible pipes or hoses
coupling. Ensure that pipes and fittings are properly fastened to their supports.
• Never use any compressed gases other than air.
• Do not use the pump as part of the support structure of the piping system. Make sure that the different parts of the circuit are properly
secured to prevent damaging the pump.
• Install any kind of vibration isolator, or other element to absorb the vibrations generated by the pump.
• If the pump is submerged during operation, follow the steps below:
- Check the corrosion resistance of each component of the pump and do not pump fluids for which no corrosion resistance is verified.
- The exhaust must be directed outward, not toward the fluid in which the pump is submerged.
- Make sure you can reach all valves without submerging hand into the fluid.
• The operation of this product generates different noise levels under its variable working conditions (fluid pumped, air supply pressure and
discharge pressure). If there are regulations concerning noise levels, implement appropriate measures.
Installation recommendations
• Remove the pump from its package and install it on the chosen location.
• Try to minimize the suction head. Install the pump as close as possible to the fluid being pumped.
• Remember to have enough space around the pump to perform maintenance tasks.
• Keep in mind to connect the inlet and outlet of the pump correctly.
• In case of diaphragm pump failure, the air exhaust will expell the product being pumped.
• When the pump is installed in a place where a spill of fluid can cause an environmental impact, the exhaust should be directed to a place.
where this spill could be contained.
• When installing the pump in its place, use brackets to secure its base.
• Fasten all bolts with the torques contained in this manual. (See page 20).
Caution

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R. 03/12 855 819
Samson Corporation • One Samson Way • N.C. 28778 Swannanoa • Phone: [phone] • Fax: [phone]
2012_03_06-17:30 ENGLISHESPAÑOL
Installation
Installation possibilities
Recommended installation
The figure below shows the recommended configuration for the installation of a diaphragm pump. Read the warnings and recommendations of the
previous page before starting.
NOTE: Use a pressure regulator with built-in filter inlet.
NOTE: The compressed air supply must be between 43.5 psi (3 bar) and 100 psi (7 bar).
FLOODED SUBMERGED SELF-PRIMING
AIR AIR
AIR
EXHAUST
DF-100 pumps are very easily configured and easy to install.
Flooded:
The pumping system was designed with positive pressure at the inlet. This is the best possible installation when you need to evacuate the liquid from the
drum or tank, or when working with viscous fluids. Not recommended for hazardous fluids.
Self-priming:
DF-100 Pump is designed to generate vacuum. It is possible to evacuate all the air from a hose or pipe without damaging the pump. Maximum suction
height is 14.8 ft (4,5 m), with the suction hose empty and up to 23.6 ft (7,2 m) with the hose primed.
Submerged:
All pumps DF-100 can be immersed in fluids. It is important to verify that all components that are in contact with the fluid are chemically compatible. In
this case, air exhaust and fluid must be carried by hoses (optional air connection).
Electrovalve
Suction draining valve

8855 819 R. 03/12
Samson Corporation • One Samson Way • N.C. 28778 Swannanoa • Phone: [phone] • Fax: [phone]
2012_03_06-17:30
Installation
Warning
To avoid personal injury, environmental and equipment next to the pump, make sure that this has been installed in a way that if it leaks or the pump
fails, the spilled fluid is contained by a moat, protective housing , etc.
Air exhaust disposal
• Optional kit is required for remote exhaust.
• Remove the muffler.
• Connect a hose to the exhaust port of the pump and install the muffler at the end of the hose. Use a hose with the same diameter as
the exhaust port. (If the hose is more than 16,4 feet (5 m), consult your dealer or Samoa Industrial, S.A.).
• Have a moat, a protective housing, etc. at the end of the hose.
Warning
The pump exhaust should be directed to a safe place, away
from people, animals and food.
Fluid line connection
• Connect the discharge valve and drain valve to the fluid discharge outlet of the pump (see page 10).
• Connect a valve for maintenance on the fluid inlet.
• Connect a hose to the valve on the suction side of the hole and another hose to the valve discharge port side of the pump.
• Properly connect the suction and discharge hoses to the pump.
Warning
• Use flexible hoses to absorb the vibration of the pump and make a ground connection.
• Make sure that the connections of the pump are not supporting external weight. Take special care that the pump does not support any
part of the weight of the hose and piping.
• Use a properly rated hoses that can support the action of the suction and discharge pressures. Also, make sure that the hoses are
compatible with the product being pumped.
• Use hoses and connectors equal to or greater than the diameter of the connections in the pump. If you use a hose with a smaller diameter
it can decrease the pump performance.
• When pumping a fluid containing solids, verify that the particle size is less than the limitation of the pump. If you exceed the limitation of
particle size indicated in the main specifications, place a filter on the pump to stop the larger particles. Otherwise, the particles can damage
the pump.
• Place a bucket under the relief valve to catch any leakage.
• When testing for a pipeline leak, DO NOT apply pressure to the input and output sides of the pump with compressed air from the outside.
This can cause the diaphragms to rupture.
• For the inspection of the product we use water. To prevent dirty water mixed with the fluid pumped, rinse the inside of the pump before
completing the installation tasks.
• When installing a backup pump or two pumps in parallel, be sure to place a valve on each side (IN and OUT), and change of pump using
the fluid outlet valve. If the valve of the standby pump is open, the discharge pressure pump operating side can go to the backup pump,
causing damage.
EXHAUST AIR

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Samson Corporation • One Samson Way • N.C. 28778 Swannanoa • Phone: [phone] • Fax: [phone]
2012_03_06-17:30 ENGLISHESPAÑOL
Operation
This pump is self-priming. To prime it the first time, you must connect the air pump supply to a low pressure using the pressure regulators
while keeping the outlet valve open.
When fluid begins to flow from the pump outlet, the pump is primed. For regulation of fluid pressure, the unit must be supplied with an air
pressure between 43.5 and 100 psi (3 and 7 bar). Adjust the discharge valve on the discharge side to control flow. For the performance
characteristics of the pump see the capacity curve shown on page 4.
Warning
• DF-100 pumps do not exceed a nominal noise level of 70 dB. It is recommended to use hearing protection when working near a
diaphragm pump. Noise can be significantly reduced using a remote exhaust using a hose attached to the appropriate port in the air
exhaust (optional connection not supplied with the pump).
• Never use the pump under any circumstances with nonconducting flammable fluids or explosives.
• Always wear appropriate protective clothing to handle the pump.
• Never place your face or body against the air exhaust while the pump is running.
• Cut off the air supply before any maintenance. Release all pressure in hoses and pipes before disconnecting the pump for maintenance.
• Make sure the air valve, pressure regulator valve and drain the discharge valve are closed. Also, make sure that the valve on the suction
side is open.
Caution
• Before starting the pump, always ensure that the discharge piping system is secure.
• Check the flow direction before starting.
• Never use compressed gases other than air.
• As you start to close the discharge valve the air supply pressure can increase. Make sure that the pressure stays within normal operating
range. (Main Specifications on page 1).
• The suction flow velocity of the fluid will vary depending on the viscosity and specific gravity of the fluid, the capacity for suction stroke
and other conditions, however, if the speed of the pump (the fluid flow rate) increases significantly, there will can be cavitation of the fluid
and it will reduce pump performance. Adjust air supply pressure and flow to prevent cavitation.
• If there is no flow of fluid after starting the pump, or you hear an unusual noise or notice any irregularities, immediately turn off the pump.
(Troubleshooting on page 15).
• You can stop the pump by closing the discharge valve while the air is on, but if this condition continues for several hours and the pump
is left unattended it can begin pumping automatically if a discharge pipe or connection starts to leak, spilling fluid and causing property
damage. When the dispense is complete, release the internal pressure close the discharge valve.
• When the pump stops while pumping liquids containing heavy loads of solids, the particles in the slurry precipitate in the outlet chamber.
If the pump is restarted without removing the contaminants, the diaphragm may be damaged or the pushing rod can be overloaded and
be damaged. Before restarting the pump, flush the remaining fluid and solids from the pump.
• Place a bucket under the relief valve to catch any waste that might be released.
• If the pump will remain out of use for a long period of time, purge and clean it.
Installation
Warning
Air connection
To ensure that the air supply is sufficient to meet the demand of the pump, the diameter of the pipe must be equal to the diameter of the
supply port of the pump. Choose auxiliary air treatment equipment and fittings with sufficient airflow to exceed the air consumption of the
pump. In addition, peripheral air treatment equipment must be installed as close as possible to the pump unit.
The use of a coupler to connect the hoses aids future operation and maintenance tasks.

10 855 819 R. 03/12
Samson Corporation • One Samson Way • N.C. 28778 Swannanoa • Phone: [phone] • Fax: [phone]
2012_03_06-17:30
Operation
Stopping the pump
• Close the inlet valve of the pump and stop the air supply.
• Make sure for your safety that the air valve is closed.
• Turn off the air compressor, or close the valve on the air supply side of the auxiliary equipment.
• Close the discharge valve on the discharge side, then begin to slowly open the drain valve and discharge pressure fluid.
• Open the air valve of the pump, turn on the pump and flush the remaining fluid.
• After ensuring that the pump was turned off and the pressure was released, fully open and close the regulator valve and drain valve of the
pump.
Operation (options)
Grounding the pump
• When installing the pump, be sure to perform grounding in
the specified location.
• Also connect ground wires for the auxiliary equipment and
piping.
• Use a grounding cable of at least 12 gauge (2.0 mm2).
Warning
• Connect grounding wires to the pump, piping and all other
equipment too.
• When the pump operates ungrounded or with an incorrect
connection, friction between parts and abrasion caused by
some fluids that flow inside the pump, can generate static
electricity. Moreover, according to the type of fluid pump and
the installation environment (such as gases in the air or the
type of the surrounding facilities) static electricity can cause
fire or electric shock.
STICKER THAT SHOWS
THE POSITION OF THE
GROUND WIRE

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Samson Corporation • One Samson Way • N.C. 28778 Swannanoa • Phone: [phone] • Fax: [phone]
2012_03_06-17:30 ENGLISHESPAÑOL
• If the unit is marked with the symbol, it can be used in potentially explosive atmospheres. Below this symbol, in the nameplate of
the pump, are indicated the areas for which the equipment is approved. You will also find the maximum allowable surface temperature in
the same plate.
• Always ground the pump.
• When removing the pump, remember to remove the ground wire.
• Use a grounding cable of at least 12 gauge (2.0 mm2).
• If the pump you have purchased is valid for Atex, a specific Atex manual will accompany this one. Read this manual before operating the
pump.
• Make sure the pump is maintained properly by qualified personnel. Use original components by Samson Corporation for its maintenance.
The use of non-original parts causes the loss of approval for use in potentially explosive atmospheres ATEX (Ex) of the pump.
• Any change or modification is made at your own risk and it will invalidate the approval for the Atex pump atmospheres (Ex).
Operation
Directflo pumps use in potentially explosive atmospheres ATEX (Ex)

12 855 819 R. 03/12
Samson Corporation • One Samson Way • N.C. 28778 Swannanoa • Phone: [phone] • Fax: [phone]
2012_03_06-17:30
Pump parts
DF100

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R. 03/12 855 819
Samson Corporation • One Samson Way • N.C. 28778 Swannanoa • Phone: [phone] • Fax: [phone]
2012_03_06-17:30 ENGLISHESPAÑOL
Pump body parts
No. Code Description CUANT. Notes
1 Table 0 Directional valve 1
*1 Normal exhaust
*2 Driven exhaust
*3 Externally controlled
2 Table 1 Balls -
3 Table 2 Ball check seats / O-rings /
Ball guides -
4Table 3 Bushing / Seal / Push rod -
5Table 4 Diaphragms -
6Table 5 Air sensor - *4 Not available with
externally controlled models
7Table 6 Diaphragm cover 2
8 940334 Diaphragm cover bolts
10 940923 Diaphragm cover nuts 7
12 940319 Diaphragm cover washers 12
13 Table 9 Valves caps 2
14 Table 8 Body 1
17 855604 Cover 2
21 Table 7 Upper shield 1
22 Table 7 Lower shield 1
23 855416 Gajos para apriete de carenas 4 *Only for composite
Identify the part needed for replacement by product code xxxxxx
DF100
* Common tables 0 to 5 suitable for metallic and composite models. (See page 16).
Table 6 - Diaphragm covers
Model DF100 Material
XXX-XX-XX-XX-X 755111 Aluminium
* Externally controlled models fits the same diaphragms covers than normal directional valve.
Table 7 - Pump shields
Model DF100 DF100 Material
Upper shield Lower shield
XXA-XX-XX-XX-X 1 x 755113 1 x 755114 Aluminium
XXP-XX-XX-XX-X 1 x 855637 1 x 855636 Polypropylene
* Externally controlled models fits the same diaphragms covers than normal directional valve.
Table 8 - Body
Model DF100 Material
BSP NPT
XAX-XX-XX-XX-X 755110 755110.300 Aluminium
XNX-XX-XX-XX-X 755110.001 755110.301 Aluminium/
Niquel coated
XSX-XX-XX-XX-X DF100-14-1 DF100-14-2 Stainless steel
XCX-XX-XX-XX-X 855631 855631.300 Acetal
XDX-XX-XX-XX-X 855632 855632.300 Conductive Acetal
XPX-XX-XX-XX-X 855630 855630.300 Polypropylene
* Externally controlled models fits the same pump body than normal directional valve.
Table 9 - Valve caps
Model DF100 Material
XAX-XX-XX-XX-X 2 x 855112 Aluminium
XNX-XX-XX-XX-X 2x 755112.001 Aluminium/
Niquel coated
XSX-XX-XX-XX-X 2x DF100-13-1 Stainless steel
XCX-XX-XX-XX-X 2x 855634 Acetal
XDX-XX-XX-XX-X 2x 855635 Conductive Acetal
XPX-XX-XX-XX-X 2x 855634 Polypropilene
* Externally controlled models fits the same valve caps than
normal directional valve.

14 855 819 R. 03/12
Samson Corporation • One Samson Way • N.C. 28778 Swannanoa • Phone: [phone] • Fax: [phone]
2012_03_06-17:30
Plastic and metallic common parts kits
Table 0 - Directional valve
Model DF100 Directional valve model
XXX-XX-XX-XA-X 558350 Standard air outlet
XXX-XX-XX-XB-X 558351 Driven air exhaust
EXX-XX-XX-XX-X PEXXXX Externally controlled
Table 1 - Balls
Model DF100 Wetted material
XXX-XX-TX-XX-X 558363 Teflon®
XXX-XX-GX-XX-X 558364 NBR
XXX-XX-CX-XX-X 558365 Acetal
XXX-XX-HX-XX-X 558366 Hytrel®
XXX-XX-PX-XX-X 558367 Polypropilene
Table 2 - Ball check seats / O-Rings / Ball guides
Model DF100 Material ball check seats /
O-rings / Ball guides
XXX-X1-XX-XX-X 558357 Stainless steel / NBR / Acetal
XXX-X2-XX-XX-X 558359 Stainless steel / Viton® / Acetal
XXX-X3-XX-XX-X 558360 Stainless steel / Viton® / Polypropylene
XXX-X4-XX-XX-X 558361 Stainless steel / Viton® / Teflon®
XXX-X5-XX-XX-X 558362 Teflon® / Viton® / Teflon®
XXX-X6-XX-XX-X 558391 Stainless steel / Epdm® / Acetal
XXX-X7-XX-XX-X 558392 Teflon® / Epdm® / Teflon®
XXX-X8-XX-XX-X 558393 Stainless steel / epdm® / Polypropylene
Table 3 - Bushing / Seal / Push rod
Model DF100
DF100 with Teflon®
diaphragms
XXX-XX-XT-XX-X
Material bushing/Seal/Push rod
XXX-1X-XX-XX-X 558352 558383 Teflon® / NBR / Stainless steel
XXX-2X-XX-XX-X 558353 558384 Teflon® / Viton® / Stainless steel
XXX-3X-XX-XX-X 558354 558385 Teflon® / Variseal / Stainless steel
XXX-4X-XX-XX-X 558355 558386 Stainless steel / Variseal / Teflon®
XXX-5X-XX-XX-X 558356 558387 Conductive acetal / Variseal / Stainless steel
XXX-6X-XX-XX-X 558380 558388 Conductive acetal / Viton® / Stainless steel
XXX-7X-XX-XX-X 558381 558389 Conductive acetal / Epdm® / Stainless steel
XXX-8X-XX-XX-X 558382 558390 Conductive acetal / Epdm® / Stainless steel
Table 4 - Diaphragms
Model DF100 Wetted material
XXX-XX-XH-XX-X 558368 Hytrel®
XXX-XX-XS-XX-X 558369 SANTOPRENETM
XXX-XX-XT-XX-X 558371 Teflon®diaphragm with viton seals
XXX-XX-XG-XX-X 558370 NBR
XXX-XX-XZ-XX-X 558394 Teflon®diaphragm with Epdm seals
Table 5 - Air sensor
Model DF100 Directional valve model
XXX-XX-XX-XA-X 558301 Standard air outlet
XXX-XX-XX-XB-X 558301 Driven air exhaust
EXX-XX-XX-XX-X ------------ Externally controlled directional valve (no
sensor available)
The following kits comes with the necessary quantity of items for pump’s maintenance.

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Samson Corporation • One Samson Way • N.C. 28778 Swannanoa • Phone: [phone] • Fax: [phone]
2012_03_06-17:30 ENGLISHESPAÑOL
Troubleshooting
The pump does not work.
Cause Recommended measure
The discharge valve on the discharge side is not open. Open the discharge valve on the discharge side.
No air supply. Turn on the compressor and open the air valve and air regulator.
The air supply pressure is low. Check the compressor and the configuration of the air line.
Air leaks in connecting elements. Check the connection elements and the tightening of the screws.
The air pipes or ancillary equipment is clogged with contaminants. Check and clean the air line.
The exhaust port (muffler) of the pump is clogged with contaminants. Check and clean the exhaust port and muffler.
The fluid pipe is clogged with contaminants. Check and clean the fluid line.
Pump is clogged with contaminants. Remove, inspect and clean the pump body.
The pump runs but no fluid comes out.
Cause Recommended measure
The valve on the suction side is not open. Open the valve on the suction side.
Too much suction or discharge height. Confirm the configuration of the pipe and reduce the height of the
same.
Fluid pipe discharge side (including the filter) is clogged with contaminants. Check and clean the fluid line.
Pump is clogged with contaminants. Dismantle the pump, check and clean.
The ball and ball seat is worn or damaged. Inspect and replace parts.
The flow is decreasing.
Cause Recommended measure
The air supply pressure is low. Check the compressor and the configuration of the air line.
The air line or peripheral equipment clogged with contaminants. Check and clean the air line.
Valve discharge side drive will not open normally. Adjust the discharge valve discharge side.
The air mixes with the fluid. Replenish fluid and check the configuration of the pipe on the suction
side.
Cavitation occurs. Adjust air supply pressure and discharge pressure and reduce the
suction.
Vibrations. Adjust air supply pressure and discharge pressure. Reduce the flow of
the inlet valve to adjust pressure and volume of fluid.
Ice formation in the air exhaust. Remove ice from the air bypass valve and check and clean the air
filter. Use a pipe in the exhaust air that the ice does not form in the
muffler.
The fluid line (including the filter) plugged with contaminants. Check and clean the fluid pipe and strainer.
The exhaust port (muffler) of the pump is clogged with contaminants. Check and clean the exhaust port and muffler.
Pump is clogged with contaminants. Remove, inspect and clean. The pump body.
Leakage of fluid through the hollow exhaust (silencer).
Cause Recommended measure
The diaphragm is damaged. Remove and inspect the pump and replace the diaphragm.

16 855 819 R. 03/12
Samson Corporation • One Samson Way • N.C. 28778 Swannanoa • Phone: [phone] • Fax: [phone]
2012_03_06-17:30
Irregular noise.
Cause Recommended measure
The air supply pressure is too high. Adjust air supply pressure.
The pump is clogged with sludge particles larger than the diameter allowed. Remove, check and clean the pump body.
Irregular vibration.
Cause Recommended measure
The elements of connection and the support of the pump are loose. Review each element of connection and tighten the screws.
The air supply pressure is too high. Adjust air supply pressure.
The range and ball valve vibrates. Adjust air supply pressure and exhaust pressure.
Troubleshooting
In fluid with air bubbles.
Cause Recommended measure
Diaphragm damaged. Replace diaphragm.
Suction hose loose or broken. Tighten or replace.
Powered air leak pressure of 3 to 7 bar.
Cause Recommended measure
Worn directional valve. Replace directional valve components.
No start-up and is leaking air without cycles.
Cause Recommended measure
Stiff air sensors. Change air sensor.
Wear directional valve. Replace.

17
R. 03/12 855 819
Samson Corporation • One Samson Way • N.C. 28778 Swannanoa • Phone: [phone] • Fax: [phone]
2012_03_06-17:30 ENGLISHESPAÑOL
Repair and maintenance procedures (DIRECTIONAL VALVE)
There are several models of directional valves mounted on diaphragm pumps DF-100. Externally controlled directional valve, directional valve with
remote exhaust and normal exhaust. To identify the one you have purchased, go to the following chart with your product code, which can be found
on the nameplate of the pump, in the case externally controlled see the parts drawing for your pump on pages 12-15.
DF-100 XXXXXXXXX
Kit DIRECTIONAL VALVE normal exhaust
Kit Pos. Description Cuan Material
558350 A
1 Air inlet circlip 1 Steel
2 O-ring 1 NBR
3 Inlet adaptor 1 Steel
4 Pivoting arm 1 Elastollan Delrin
5Distributor lower
seal 2 NBR
6Directional valve
body DF-100 1 Aluminium
7 O-ring 1 NBR-Ptfe
8 Sealing drum 1 Elastollan Delrin
9 Bolt 1 Stainless steel
10 Muffler 1 Brass
11 Air outlet circlip 1 Steel
Kit DIRECTIONAL VALVE driven exhaust
Kit Pos. Description Cuan Material
558351 B
1 Air inlet circlip 1 Steel
2 O-ring 2 NBR
3 Inlet adaptor 1 Steel
4 Pivoting arm 1 Elastollan Delrin
5Distributor lower
seal 2 NBR
6Directional valve
body DF-100 1 Aluminium
7 O-ring 1 NBR-Ptfe
8 Sealing drum 1 Elastollan Delrin
9 Bolt 1 Stainless steel
11 Air outlet circlip 2 Steel
12 Outlet adaptor 1 Steel
Maintenance (to remove the pivoting arm):
1. Remove 1, 2 ,3 , 10, 11, 12
2. Remove 9
3. Remove 4, 7, 8
X

18 855 819 R. 03/12
Samson Corporation • One Samson Way • N.C. 28778 Swannanoa • Phone: [phone] • Fax: [phone]
2012_03_06-17:30
Repair and maintenance procedures
Torques necessary for the proper functioning of the pump
For proper operation of the pump and to prevent accidents which may damage equipment and in the worst case, people, you must periodically
review the torques of the diaphragms covers and the DIRECTIONAL VALVE. In the next table are shown the appropriate torques for this purpose:
Torques DF100
Diaphragm cover 137.7 lbf·in (15 N·m)
Directional valve 44,25 lbf·in (5 N·m)
Valve cap 35,4 lbf·in (4 N·m) Aluminium - 30,9 lbf·in (2 N·m) composite
Diaphragm replacement
Before any intervention: DISCONNECT AIR SUPPLY OF THE PUMP.
IT IS NOT NECESSARY TO REMOVE THE PUMP FROM THE FLUID LINE.
1. Close fluid valves.
2. Drain the fluid inside the pump. Anticipate a drainage of fluid from
inside the pump.
3. Remove the directional valve while being careful not to damage the
seals shown in the first figure.
4. Remove the diaphragm cap.
NOTE: To tighten these screws you must use a torque wrench calibrated to
137.7 lbf·in (15 N·m).
5. Remove the cover by gently pulling back.
6. Remove the used diaphragm and place the new one in the proper
position
Assemble components.
4
A
6
5
3
Diaphragm replacement (Teflon)
Before any intervention: DISCONNECT AIR SUPPLY OF THE PUMP.
IT IS NECESSARY FOR TEFLON DIAPHRAGMS REPLACEMENT,
TO REMOVE THE PUMP FROM THE FLUID LINE.
1. Follow the steps 1 to 4 from the Hytrel and Santoprene diaphragm
replacement.
2. Remove the diaphragms.
3. With the components supplied in the replacement kit, firstly do the
assmblaje of one of the diaphragms.
3.1 Place the 6,35 x 1.78 o-ring (Pos.4) in the inner groove of
the diaphragm nut (Pos.5).
3.2 With the shaft (Pos.6) in vertical, carefully introduce the
diaphragm nut (Pos.5) in the shaft. Be aware not damaging
the inner o-ring placed before.The exterior groove must be
facing upwards.
3.3 With the help of some mounting grease, place the 18.77x1.78
o-ring (Pos.3) in the exterior groove of the diaphragm nut
(Pos.5).
3.4 Place the diaphragm (Pos.2) with the teflon side in blue,
facing the shaft.
3.5 Finally, after applying some mounting sealent in the
diaphragm washer (Pos.1), thread the washer and thighten
as much as possible with the hands.
1
2
3
4
5
6

19
R. 03/12 855 819
Samson Corporation • One Samson Way • N.C. 28778 Swannanoa • Phone: [phone] • Fax: [phone]
2012_03_06-17:30 ENGLISHESPAÑOL
4. Tightening the diaphragm in the shaft.
4.1 Place the assembly done in the prior step in a vice. Fix it using
the two flat areas in the diaphragm nut (Pos.6).
ATTENTION: BE CAREFULL NOT DAMAGING THE SHAFT IN
THIS OPERATION (POS.7). NEVER GRAB IT WUTH THE VICE
AND DO NOT SCRATCH IT WITH ANY TOOL. THIS COULD
DAMAGE IT IRREPARABLY.
4.2 Tighten the diaphragm (Pos.1) with the hands to get a proper
tighten torque with the two hands .
4.3 Allow the sealant to dry.
5. Introduce the assemblage in the pump’s body.
ATTENTION: DO NOT DAMAGE THE TWO O-RINGS.PLACED IN
THE INNER PART OF THE BUSHING (POS.7) WITH THE SHAFT’S
THREAD (POS.6).
5.1 Once placed the assembly, push the diaphragm (Pos.6) to
make the shaft come out of the body. Then place the pump
in the workbench with the diaphragm facing downwards.
6.Place the last diaphragm.
6.1 Follow the steps in 3, with the pump placed in the workbench
as shown in the figure of the right.
ATTENTION: DO NOT DAMAGE THE O-RING FROM THE INNER
GROOVE OF THE DIAPHRAGM NUT.(POS.5) WITH THE SHAFT
THREAD T(POS.6).
6.2 Place the pump in vertical position. introducing the hands
with in the diaphragm and the pump’s body, tighten both of
them, see figure below.. Try to achive a proper torque.
6.3 Allow the sealant to dry.
6.4 Finally, assamble the diaphragm lids (Pos.8) following
intructions and torques given in the hytrel and Santoprene
diaphragm replacement.
1
6
7
76
6
8
8
1
2
3
4
5
6
Repair and maintenance procedures
Diaphragm replacement (Teflon)

20 855 819 R. 03/12
Samson Corporation • One Samson Way • N.C. 28778 Swannanoa • Phone: [phone] • Fax: [phone]
2012_03_06-17:30
Repair and maintenance procedures
Ball valves replacement
1. Close fluid valves.
2. Drain the fluid from inside the pump. Anticipate a drainage of fluid from inside the pump.
3. Loosen the screws to remove the directional valve. Take special care with the seals.
4. Remove the valve cover by loosening the screws with an Allen wrench. Take note of the orientation of the cap, as it is critical to replace it correctly
during reassembly.
5. Install a new set of valves according to these assembly drawings. Ensure that the ball guides are assembled as shown in the figure on the left, and
tighten the screws with a maximum torque of 35,4 lbf·in (4 N·m) (for metal bodies) and 30,9 lbf·in (2 N·m) (for acetal and polypropylene bodies)
6. Assemble the directional valve with being careful not to damage the O-rings and tighten the screws with a maximum torque of 44,25 lbf·in (5 N·m).
Attention
To avoid fluid restriction and leakages, follow the position of the vall
checks guides in teh figure above. the valves cups must be placed with the
area indicated in the figure below facing the body.