SPX JOHNSON PUMP TopAir TA-5 User manual

Instruction Manual
TopAir TA-5/15
Air operated diaphragm pumps
Read and understand this manual prior to
operating or servicing this product.
A.0200.301 – IM-TA/03.00 EN (03/2007)

EC Declaration of conformity
(Directive 98/37/EC, Annex IIA)
Manufacturer
SPX Process Equipment BE NV
Evenbroekveld 2-6
BE-9420 Erpe-Mere, Belgium
We declare under our sole responsibility that the product:
TopAir
Air Operated Diaphragm Pumps
Type: TA-5/15
is in conformity with COUNCIL DIRECTIVE on the
approximation of the laws of the Member States relating to
Machinery 98/37/EG.
Declaration of incorporation
(Directive 98/37/EC,Annex IIB)
TheTopAir,Air Operated Diaphragm Pumps,
must not be put into service until the machinery
into which it is to be incorporated has been declared
in conformity with the provisions of the Directive.
Erpe-Mere, 1 July 2007
Gerwin Schaafsma
Operational Manager Europe
ATEX 95
(Directive 94/9/EC)
Manufacturer
SPX Process Equipment BE NV
Evenbroekveld 2-6
BE-9420 Erpe-Mere, Belgium
We declare under our sole responsibility that the product:
TopAir
Air Operated Diaphragm Pumps
Type: TA-5 FAT
TA-5 FST
TA-5 FVT
TA-15 BAN, BAC, BAE, BAH, BAS, BAT
TA-15 BSN, BSC, BSE, BSH, BSS, BST
TA-15 FVT
all serial numbers
are compliant with ATEX 95 regualtions and may be used
in potentially explosive atmospheres – Directive 94/9/EC
Complicance with the essential health and safety
requirements has been assured by conformation with the
following standards or directives:
• European Standard EN 13463-1:2001
• European Standard EN 809/ October 1998
• Directive 98/37/EC
The marking of the equiment includes the following:
|| 2 GD ||B/||C 95°C
The producer will keep on file for review the technical file
YE ATEXJPV01X. The Assessment is registered at the
notified body KEMA, Arnheim, the Netherlands.
Erpe-Mere, 1 July 2007
Gerwin Schaafsma
Operational Manager Europe

A.0200.301 – IM-TA/03.00 EN (03/2007) 3
Index
1.0 Introduction ..............................................................................................................5
2.0 For safe operation ....................................................................................................5
3.0 Principles of operation.............................................................................................5
4.0 Ordering replacement parts....................................................................................5
5.0 Operating caution.....................................................................................................6
6.0 Tools, etc. ...................................................................................................................8
6.1 General tools............................................................................................................... 8
6.2 Special tools ................................................................................................................ 8
6.3 Misc. ............................................................................................................................. 8
7.0 Names of parts and materials..................................................................................9
7.1 TA-5 series .................................................................................................................. 9
7.2 TA-15 series .............................................................................................................. 10
8.0 Assembly .................................................................................................................11
8.1 Installation of accessories........................................................................................ 11
9.0. Installation ..............................................................................................................12
9.1 Method of transport................................................................................................. 12
9.2 Installing the pump .................................................................................................. 12
9.3 Connecting the ground wire.................................................................................... 14
9.4 Use in potentially explosive atmospheres ........................................................... 14
10.0 Connection..............................................................................................................15
10.1 Connecting fluid piping............................................................................................ 15
10.2 Connecting air piping............................................................................................... 16
11.0 Operation ................................................................................................................17
11.1 Method of operation................................................................................................ 17
11.2 Flow adjustment ....................................................................................................... 17
11.3 Shutdown.................................................................................................................... 18
11.4 Releasing the pressure.............................................................................................. 18
12.0 Method of cleaning ................................................................................................19
13.0 Daily check..............................................................................................................19
14.0 Trouble shooting.....................................................................................................20
15.0 Main specifications .................................................................................................22
15.1 TA-5 series ................................................................................................................ 22
15.2 TA-15 series .............................................................................................................. 22

A.0200.301 – IM-TA/03.00 EN (03/2007)
4
16.0 Balls and valve seats...............................................................................................23
16.1 Disassembly .............................................................................................................. 23
16.1.1 FAT, FST, BA_, BS_ types .......................................................................................................23
16.1.2 FP_, FVT types .........................................................................................................................24
16.2 Checking.................................................................................................................... 25
16.2.1 Ball valve type ........................................................................................................................... 25
16.2.2 Flap valve type .......................................................................................................................... 25
16.3 Assembly .................................................................................................................. 25
17.0 Diaphragm and Center rod ...................................................................................26
17.1 Disassembly .............................................................................................................. 26
17.1.1 FAT, FST, BA_, BS_ types .......................................................................................................26
17.1.2 FP_, FVT types .........................................................................................................................27
17.2 Checking.................................................................................................................... 28
17.3 Assembly ................................................................................................................... 28
17.3.1 B_H, B_S, FPH, FPS - types ....................................................................................................28
17.3.2 B_C, B_E, B_N, B_T, FPC, FPN, F_E, F_T - types ...............................................................29
18.0 Pilot valve, Guide and Bushing.............................................................................30
18.1 Dissambly.................................................................................................................. 30
18.1.1 TA-5 ...........................................................................................................................................30
18.1.2 TA-15 ........................................................................................................................................30
18.2 Checking.................................................................................................................... 31
18.3 Assembly .................................................................................................................. 31
19.0 Seal ring and sleeve ....................................................................................................32
19.1 Disassembly ............................................................................................................. 32
19.2 Checking.................................................................................................................... 33
19.3 Assembly ................................................................................................................... 33
20.0 Exploded views.......................................................................................................34
20.1 TA-5 FAT, FST.......................................................................................................... 34
20.2 TA-5 FPT, FVT ......................................................................................................... 37
20.3 TA-5 FTT, FXT......................................................................................................... 40
20.4 TA-5 – Airmotor Kit and and Airmotor Seal Kit................................................. 43
20.5 TA-15 BA_, BS_ ....................................................................................................... 44
20.6 TA-15 FP_, FVT ....................................................................................................... 49
20.7 TA-15 FTT, FXT....................................................................................................... 52
20.8 TA-15 – Airmotor Kit and Airmotor Seal Kit ...................................................... 55
21.0 Dimensional drawings................................................................................................56
21.1 TA-5 ........................................................................................................................... 56
21.2 TA-15 ......................................................................................................................... 57
22.0 Performance curves................................................................................................58
22.1 TA-5 ........................................................................................................................... 58
22.2 TA-15 ......................................................................................................................... 59

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A.0200.301 – IM-TA/03.00 EN (03/2007) 5
1.0 Introduction
Thank you for purchasing a TopAir Diaphragm Pump. This product is a positive-displacement
pump that transfers fluids by movement of diaphragms driven by compressed air through a
unique switching mechanism. The casing that comes in contact with the fluid is made of
aluminium, stainless steel, forged iron, polypropylene or fluorine resin, depending on the model
you have selected, according to the type of fluid to be pumped. The diaphragms are made of a
plastic material suitable for the model.
2.0 For safe operation
This document contains information vital for safe and efficient operation of this product. Before
using the pump, be sure to read this document carefully, particularly the “warnings and cautions”,
and be fully familiar with the operating procedures. Be sure to keep this document handy for
future reference.
3.0 Principles of operation
There are two diaphragms fixed to the center rod, one at each end. When compressed air is
supplied to air chamber B (right side, see Fig. 1.1.), the center rod moves to the right, the
material in material chamber B is pushed out, and at the same time material is sucked into
material chamber A.
When the center rod is moved full-stroke to the right, the air switch valve is switched,
compressed air is sent to air chamber A (left side, see Fig. 1.1.), and the center rod moves to the
left. The material in material chamber A is pushed out, and at the same time material is sucked
into material chamber B.
Through repetition of this operation, material is repeatedly taken in and discharged out.
4.0 Ordering replacement parts
For accurate and speedy shipment of parts, be sure to order the right parts for your model to
your dealer or one of our regional offices. Indicate the part number, descriptions, quantities and
reasons for replacement, in as much detail as possible.
4. Air Supply
5. Center Rod
6. Material Intake Port
1. Material Chamber A
2. Air Chamber A
3. Diaphragm
7. Air Chamber B
8. Material Chamber B
9. Material Discharge port
10. Exhaust Vent
Fig 1.1

A.0200.301 – IM-TA/03.00 EN (03/2007)
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5.0 Operating caution
Before using this product
Warning
• When using compressed gas (hereinafter called “compressed air”) to drive this pump, be
sure it is one of the following:
- Compressed air supplied from an air compressor
- Nitrogen (N2) gas
Use of compressed air other than the above may cause air pollution, damage to the pump,
or even an explosion.
• The maximum permissible pressure for the compressed air, and the uid pumped by one of
these pumps, depending upon the casing material of the model you are using, is as follows:
- Metal casing (aluminium, stainless steel, forged iron): 0.7 MPa
- Plastic casing (polypropylene, fluorine resin): 0.5 MPa
If the pressure of the compressed air and fluid exceeds the applicable maximum permissible
pressure specified above, there may be leakage of fluid, damage to the casing, or even a
severe, possibly even fatal, accident.
• When moving this product, make sure that the internal pressure is released. If the pump is
moved while under pressure, any shock imparted by droppage, etc, may damage the pump or
even cause an explosion.
• Hazardous uids (with strong acid or alkali, ammable or toxic) or gas bubbles generated
by such fluids may cause serious injury or even death if accidentally inhaled or consumed or
if they come into contact with the eyes or adhere to skin. Therefore, the following
precautions are strongly advised:
- Be fully familiar with the properties of the fluid to be pumped and work in strict
accordance with the operating instructions provided by the suppliers of such fluids
(such as wearing goggles, gloves, mask or work clothes).
- When storing a hazardous uid, strictly comply with the regulatory procedures
(such as using proper containers, storage conditions, etc).
- Always install the piping and exhaust port of this pump away from human and animal
traffic.When a diaphragm is damaged, fluid will gush out together with air through the
exhaust port. Provide protective measures in consideration of possible leakage of fluid
(see Notes: Arranging outside exhaust). When you use the hose and pit etc, be sure you
are using a model with appropriate corrosion resistance for the fluid to be pumped.
• When installing this product, be sure to connect a ground wire from the specied position of
this product (excluded TA-5 FPT, 5 FVT, 15 FP_, 15 FVT). When this product is installed
and operated without the ground wire properly connected, friction between parts, as
well as abrasion caused by the flow of some fluids inside the casing, may generate static
electricity. Also, depending on the type of fluid being pumped and the installation
environment (such as gases in the air and type of surrounding fixtures), static electricity
could become a cause of fire or electric shock.

A.0200.301 – IM-TA/03.00 EN (03/2007) 7
• Improper grounding, poor ventilation, or unshielded re or spark can create a danger of
fire or explosion. Therefore, the following precautions are strongly advised:
- All peripheral equipment and piping connected to this product should be properly
grounded.
- To pump flammable liquids, use a model with an aluminium or stainless-steel casing.
- Whenever you notice any spark while operating this product, immediately stop its
operation, and do NOT start using it again unless you are sure of the cause and
corrective actions have been taken.
- Depending upon the type of fluid being pumped, bubbles of flammable gas may be
generated. Make sure that ventilation is satisfactory.
- This product itself, its piping and exhaust ports should be kept away from unshielded
fire, spark and other causes of ignition. If a diaphragm is damaged, fluid will gush out
together with air from the exhaust port.
- Do NOT leave gasoline or solvent etc, that contains waste at the work site.
- Machinery and other equipment near the place of installation of this product should be
properly insulated to prevent conduction with each other.
- DoNOToperate heating devicesthat createflames orhave heatingfilaments anywhere
near the pump or its piping.
- If there are flammable gases in the air while the pump is operating, do NOT switch
electric appliance on and off.
- Do NOT operate a gasoline engine at the work site.
- Restrict smoking at the work site.
• After you shut down the pump and disconnect the piping, some uid may remain inside the
pump. Also, if the pump is left unused for a prolonged period, some fluid may remain inside
the pump and connected piping.Therefore, be sure to purge the system of fluid and clean
the pump before prolonged disuse. If the product is left unused for a prolonged period with
fluid remaining in the connected piping as well as the pump itself, the fluid may expand,
depending on the ambient temperature (because of freezing or heat), which may cause
damage to the pump and/or piping and possible leakage of fluid.
• Always use genuine TopAir parts when replacing component parts of this product. Do
NOT attempt to modify the components parts or replace them with other than genuine
TopAir parts.
• Torque of all tightening parts must be inspected before operation. Designated torque are
mentioned in maintenance manual.
• When pumping a hazardous uid (hot,
flammable, strong acid, etc) with this
product, provide protective measures
(install a pit, a protection box, sensors,
etc) in consideration of possible
leakage of fluid, and post warning signs
at necessary places. Leakage of fluid
may cause fire, air pollution or a
serious accident. When pumping a
hot fluid, the casing and piping will
becomehot, which may burn the skin
when touched.
Fig. 2.1
Air

A.0200.301 – IM-TA/03.00 EN (03/2007)
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Fig 3.1 –
Part No. 271-771132
Fig 3.2 –
Part No 271-713148
• Before using this product, be sure you are familiar with the precautions regarding the uid
to be pumped, and verify the corrosion resistance of the parts that will come into contact
with the fluid. NEVER use the product with any fluid against which it does not have
sufficient corrosion resistance or with a fluid that poses a risk of explosion. If you are un-
sure of the corrosion resistance, contact your dealer or our regional office. If you use this
product with any fluid against which the parts that will come in contact with the fluid do
not have sufficient corrosion resistance, it may result in damaging the product or leakage
of fluid.
• When working in the vicinity of pumping of uid with this product, be sure to wear
protective gear (goggles, mask, etc).
• When using this product, observe the relevant regulatory rules concerning re prevention,
labour safety standards, etc.
• If you have any questions on the operation of this product (method of connection or
installation), contact your dealer or our regional office.
Caution
• When operating this product, it may generate loud operating noise, depending upon the
condition of use (fluid pumped, supply air pressure and discharge pressure). If regulatory
rules apply, provide appropriate acoustic measures where necessary. (For the noise value of
this product, see 15.0 Main specifications after)
• To drive this product, use supply air with minimum moisture content.
• If a diaphragm of this product is damaged, supply air may mix with the uid or the uid may
flow into the main body (air-switching portion). If air supply is inadequate or contaminated,
do NOT operate the pump.
• While operating this product, do NOT cover the intake port by hand.
• If more than two years have elapsed since this product was shipped from the factory, notify
your dealer or our regional office, and do NOT operate it without assurance from the dealer
or our regional office that the pump may be operated safely.
6.0 Tools, etc.
6.1 General tools
• Socket wrenches: 10 mm (TA-5), 13 mm (TA-15)
• Open-end wrenches: 10 mm (TA-5), 13 mm, 21 mm (TA-15)
• Plyer
6.2 Special tools
• Accessory tool (Accessories) (Fig 3.1)
Purpose: Removing the center disk
of FP_ and FV_types.
• Sleeve remover (sold separately) (Fig 3.2)
Purpose: for removing sleevse
6.3 Misc.
• Lubrication oil: Turbine oil equivalent to #32
• Nuts: M6x1 (TA-5), M8x1,25 (TA-15)

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B
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A.0200.301 – IM-TA/03.00 EN (03/2007) 9
Type FAT FST FPT FTT FVT FXT
Switching Portion PPS PPS PPS PPS PPS PPS
Fluid contact AC4C-T6 SCS14 PPG PTFE PVDF PVC
Portion
Diaphragm PTFE PTFE PTFE PTFE PTFE PTFE
Flap Valve SUS316 SUS316 PTFE PTFE PTFE PTFE
O Ring PTFE PTFE PTFE PTFE PTFE PTFE
Valve Seat SUS316 SUS 316 PPG PTFE PVDF PTFE
Center Disk A5056 SUS316 PPG PFA PVDF PFA
(SUS304) (SUS304)
7.0 Names of parts and materials
7.1 TA-5 series
TA-5 FAT
TA-5 FST
TA-5 FPT, FTT
TA-5 FVT, FXT
A: Air Valve
B: Reset Button
C: Out Manifold
D: Out Chamber E:
In Manifold
F: Pump Base
G: Discharge Port H:
Intake Port
I: Lift Point
J: Ground Connection
Point

A
EDF H
BGIC
DEFH
A
B
JICG
A.0200.301 – IM-TA/03.00 EN (03/2007)
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Polypropylene type, Polyvinylidene flouride type = FVT
Type FPC FPN FPT FVT FPH FPS
Switching Portion PPS PPS PPS PPS PPS PPS
Fluid contact PPG PPG PPG PVDF PPG PPG
Portion
Diaphragm CR NBR PTFE PTFE TPEE TPO
Flap valve/O Ring PTFE/NBR PTFE/NBR PTFE PTFE PTFE/NBR PTFE/EPDM
Valve Seat PPG PPG PPG PVDF PPG PPG
Center Disk PPG (SUS304) PPG (SUS304) PPG (SUS304) PVDF (SUS304) PPG (SUS304) PPG (SUS304)
7.2 TA-15 series
TA-15 BA_
TA-15 BS_
TA-15 FP_
TA-15 FVT
Aluminum type
Type BAC BAN BAT BAH BAS
Switching Portion PPS PPS PPS PPS PPS
Fluid contact ADC12 ADC12 ADC12 ADC12 ADC12
Portion
Diaphragm CR NBR PTFE TPEE TPO
Ball/O Ring CR/NBR NBR PTFE NBR EPDM
Valve Seat A5056 A5056 A5056 A5056 A5056
Center Disk A5056 A5056 A5056 A5056 A5056
Stainless-steel type
Type BSC BSN BST BSH BSS
Switching Portion PPS PPS PPS PPS PPS
Fluid contact SCS14 SCS14 SCS14 SCS14 SCS14
Portion
Diaphragm CR NBR PTFE TPEE TPO
Ball/O Ring CR/NBR NBR PTFE NBR EPDM
Valve Seat SUS316 SUS316 SUS316 SUS316 SUS316
Center Disk SUS316 SUS316 SUS316 SUS316 SUS316
PTFE = FTT, PVC = FXT
Type FTT FXT
Switching Portion PPS PPS
Fluid contact PTFE PVC
Portion
Diaphragm PTFE PTFE
Flap valve/O Ring PTFE PTFE
Valve Seat PTFE PVC
Center Disk PFA PFA
A: Air Valve
B: Reset Button
C: Out Manifold
D: Out Chamber E:
In Manifold
F: Pump Base
G: Discharge Port H:
Intake Port
I: Lift Point
J: Ground Connection
Point

A.0200.301 – IM-TA/03.00 EN (03/2007) 11
8.0 Assembly
8.1 Installation of accessories
1. Remove all packing materials immediately after reception. Check the consignment for
damage immediately on arrival and make dure that the name plate/type designation is in
accordance with the packing slip and your order.
2. Attach the air valve and the silencer (nipple) (see 7.0 and 20.0).
Caution
• All of the connection parts are capped or taped for shipment. Remove the caps and tapes.
• When installing accessories, make sure that no foreign matter falls into the product, as it
could cause malfunction of the switching portion.
• Cover each screw with sealing tape to prevent leakage.
• See 15.0 Main specications. Remember that the pump is heavy, so extreme care must be
taken when lifting it.

A
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C
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A.0200.301 – IM-TA/03.00 EN (03/2007)
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9.0. Installation
9.1 Method of transport
• When lifting the pump using a chain host or crane before transporting it, be sure to lift it by
the specified lift point (see 7.0 Names of parts and materials).
Warning
• Be careful that nobody will pass under the pump when you lift it. It would be very
dangerous if the pump should fall.
Caution
• See 15.0 Main specications. Remember that the pump is heavy, so extreme care
must be taken when lifting it.
• When moving the pump with a forklift or truck, make sure that the pump will not fall. If it
does, it may be damaged and/or cause bodily injury.
• NEVER try to move the pump by pulling the hose connected to the pump. The hose or the
pump may be damaged.
9.2 Installing the pump
1) Decide where the pump should be installed an secure a suitabla
space (see Fig 4.1 A to D).
Note:
• Try to keep the suction lift as short as possible
Protect diaphragm from abnormal breakage,
inlet pressure must be kept below the following values:
- PTFE diaphragm:
0.02 MPa (height 2 m) during operation
0.05 MPa (height 5 m) not in operation
- Other diaphragms: 0.1 MPa (height 10 m)
(Condition with fresh water under ambient temperature)
• Remember to provide sufcient space around the
pump for maintenance.
• The direction of uid intake port and the discharge
port can be changed so that they are opposite from
each other. (For switching, see the maintenance manual).
• The exhaust from the pump will contain some sludge.
When operating the pump where it would have an
impact on the environment, the exhaust should be
directed to a place where there will be no
environmental impact.
2) Remove the pump from the
package and install it in the
designated location.
3) When fixing the pump in
place, use the flexible mount
on the pump base, and secure
the pump by tightening the
tied-down bolts a little at
a time.
Air
Exhaust
Air
Air
Fig 4.1
Air

A.0200.301 – IM-TA/03.00 EN (03/2007) 13
Caution
• Even if you do not use the exible mount to secure the pump in place, mount it in such a
way that vibration generated by pump will be absorbed.
• If the pump will be submerged during operation, follow the steps below:
- Verify the corrosion resistance of each component of the pump, and do NOT expose
the pump to any fluid for which it does not have proper corrosion resistance.
- Exhaust should be directed outside, not into the fluid in which the pump is submerged.
For information on how to arrange the exhaust, see Note:Arranging outside exhaust
and Fig. 4.2 below.
- Make sure that you can reach all of the valves without submerging your hand.
• When operating the pump, operation noise may be generated, depending upon conditions of
use (kind of fluid being pumped, supply air pressure and discharge pressure).
If any regulatory rules apply, provide appropriate acoustic measures. (For the noise level of
this product, see 15.0 Main specifications)
• When pumping a hazardous uid (hot, ammable, strong acid, etc) provide protective
measures (installation of a pit or sensors, etc) in consideration of possible leakage of fluid,
and post warning signs at necessary places. For details, see 5.0 the applicable operating
caution.
Warning
• If using the pump with a ammable uid or in a ammable environment, read 5.0
Operating caution.
Notes: Arranging outside exhaust
• Remove the silencer.
• Connect a hose with a ground wire to the
pump’s exhaust port, and attach the silencer
to the tip of the hose. Use a hose of the
same diameter as the exhaust port. (If the
hose is longer than 5 metres, consult your
dealer or our regional office).
• Have a pit, a protection box, etc. at the
end of the hose.
Warning
• Be sure to have a pit, a protection box, etc, at the end of the hose in preparation for the ow
of fluid in case of damage to a diaphragm. For details, see 5.0 Operating caution.
• Pump exhaust should be directed to a safe place, away from people, animals and food.
Fig 4.2Fig 4.2
Air
Exhaust

Serial No
Prod. year
Max air press
Pump type
TopAir
SPX Process
Equipment BE NV
Evenbroekveld 2-6
BE-9420 Erpe-Mere
www.johnson-pump.com/
www.spxpe.com
MPa
YE ATEXJPV01X II2GDIIB/IIC95ºC
A.0200.301 – IM-TA/03.00 EN (03/2007)
14
9.3 Connecting the ground wire
a) When installing the pump, be sure to
connect the ground wire at the
specified position. For the specified
position for connecting the ground wire,
see 7.0. Names of parts and materials
(excluded TA-5 FPT, 5 FVT, 15 FP_, 15 FVT).
b) Also connect ground wires to peripheral
equipment and piping.
c) Use 2.0 mm2 minimum ground wire.
Caution
• Be sure to connect ground wires to the connected piping and any other connected equipment.
For details, see 5.0 Operating caution.
When the pump is operated without a ground wire or otherwise not properly grounded, friction
between parts and abrasion caused by some fluids flowing inside the casing may generate static
electricity. Also, depending on the type of fluid being pumped and the installation environment (such
as gases in the air or the surrounding fixtures), it may be a cause of fire or electric shock.
9.4 Use in potentially explosive atmospheres
(for pumps specified in the ATEX 95 declaration)
1. Your pump can be used in potentially
explosive atmospheres if the symbol of
fig. 4.4. is visible on the name plate.
Below the symbol is indicated what zones
and equipment group is applicable. The
maximum allowable surface temperature is
indicated on the name plate fig. 4.5.
2. Always connect the ground wire, which is
attached to the pump.When removing the
pump from the system, remove the ground
wire last. When installing the pump to the system, install the ground wire first.
3. Use 2.0 mm2minimum ground wire.
4. The equipment can be used for group II gases (above ground, group I is applicable for mining) in
Zones 1 and 2. For use in combination with group IIC gases, the media must be conductive to prevent
built up of static electricity. For group IIA and IIB gases and for Dust, there are no limitations other
than the maximum allowable media temperature of 95ºC.
5. Make sure that the pump is serviced according the appropriate service instructions, by aqualified
repair station. Use only original parts for servicing. Use of non-original parts will make the
EX approval invalid.
6. No modifications or changes to the pump are allowed, this will make the EX approval invalid.
Caution
• Be sure to connect ground wires to the connected piping and any other connected equipment.
For details, see the applicable 5.0 Operating caution.
Do not operate the pump without a ground wire or otherwise not properly grounded, friction caused
by some fluids flowing inside the casing may generate static electricity. Also, depending on the type of
fluid being pumped and the installation environment (such as gases in the air or the surrounding
fixtures), it may become an ignition source, resulting in a possible explosion.
• Be careful when using tools at or in the environment of the pump. Dropping of metal objects or tools
on the pump can cause impact sparks, resulting in an explosion if explosive gas is present.
• Make sure that the pump is serviced according the appropriate service instruction, by a qualied
repair station. Use only original parts for servicing. Use of non-original parts will make the EX-
approval invalid. Doing so can result in dangerous situations, resulting in an explosion if explosive
gas is present.
• No modications or changes to the pump are allowed, this will make the EX- approval invalid. Doing
so can result in dangerous situations, resulting in an explosion if explosive gas is present.
Fig. 4.3
Position for connecting
the ground wire
Fig. 4.4
Fig. 4.5

A.0200.301 – IM-TA/03.00 EN (03/2007) 15
10.0 Connection
10.1 Connecting fluid piping
1) Connect a flow valve and a drain valve to the fluid discharge port of the pump.
2) Connect a valve for maintenance to the fluid suction intake port of the pump.
3) Connect a hose to the valve on the suction-port side and the valve of the discharge-port side
of the pump.
4) Connect a hose on the suction-side intake and the discharge-port side to the respective
vessels.
Caution
• Use a exible hose to absorb pump vibration, and ground the hose.
• Make sure that there will be no external force on any connection part of the pump.
Be especially careful not to have the pump support part of the weight of the hose and the
piping.
• Use a sturdy hose that will not collapse under the strong suction of the pump. Also, make
sure the hose is of more than sufficient pressure rating.
• Use a hose of a diameter the same as or larger than the pump’s ports. If you use a hose of
smaller diameter, the pump’s performance will be adversely affected, and it may even
malfunction.
• When pumping a uid that contains slurry, verify that the particle size is below the slurry
limitation (15.0 Main specifications). If it exceeds the limitations of slurries indicated in the
main specifications, attach a strainerto the pump to stop larger particles. Otherwise, such
particles may cause a malfunction.
• If, depending upon the place of pump installation,
the volume of the pumped fluid changes drastically,
install a relief valve on the discharge side, and
bring the pressure down below the maximum
permissible value. If, owing to a change in the
volume of fluid, the pressure inside the pump
exceeds the maximum permissible pressure,
it may cause damage.
• Keep a vessel below the relief valve to catch
any drain off.
• When testing piping for leakage, do NOT
apply pressure to the pump’s inlet and outlet
sides with compressed air from outside. It may cause abnormal breakage to the diaphragm
or the switching portion. When testing the piping, either install a valve between the pump’s
suction inlet and the discharge outlet and piping, or disconnect the pump from the piping
and install plugs so that there will be no pressure from outside.
• In our product inspection, clear water is used. To prevent mixture of dirty water into the
fluid to be pumped, clean the inside of the pump before finishing installation work.
Relief valve
Valve for
maintenance
Fig. 5.1
Drain valve
Flow valve
Fig. 5.2

SMC
A.0200.301 – IM-TA/03.00 EN (03/2007)
16
10.2 Connecting air piping
Warning
Before starting work, make sure that the air compressor is shut off.
1) Connect an air valve, air filter, regulator and if necessary lubricator (hereinafter called the
“peripheral equipment”) to hose which connected to compressor. Refer (NOTE) for detail
information.
2) Install these peripheral items supported by brackets, etc, near the pump.
3) Connect the hose from the peripheral equipment to the air valve of the pump’s supply port.
Caution
• Use a exible hose to absorb pump vibration, and ground the hose.
• Make sure that there will be no external force on any connection part of the pump.
Be especially careful not to have the pump support part of the weight of the hose and the
piping.
• The piping and the peripheral equipment may become clogged with sludge.
Clean the inside of the piping for 10 to 20 seconds before connecting it to the pump.
• Be sure to sufciently ground the piping and peripheral equipment.
Note:
• So that sufcient air can be supplied to meet the needs of the pump, the diameter of the
piping should be the same as the diameter of the supply port of the pump.Also choose
peripheral equipment with sufficient airflow to meet the requirement of air consumption of
the pump. Usage and stability of air pressure must be considered. Also must be installed at
nearest position of pump unit.
• If you use a solenoid valve as the air valve, be sure it is a three-way valve. When the valve is
closed, the internal compressed air of the pump will be released, and this will switch the
spool to its normal position.
• Use of a coupler for the connection part of each hose will make operation and maintenance
easier.
• In case of intermittent operation, lubrication is not required during operation. However,
when pump is operating by dry air and in case of continuous operation and/or transferring
high temperature liquid (exceeded 70°C), lubrication must be required.
Must be used turbine oil (Equivalent VD32 grade) for lubricants. Adjust lubricator to
supply minimum amount of oil to pump unit.
Fig 5.3

A.0200.301 – IM-TA/03.00 EN (03/2007) 17
11.0 Operation
11.1 Method of operation
Caution
• Before starting the pump, make sure that all piping is properly connected.
• Also, before starting the pump, make sure that all the bolts are securely tightened.
(Refer to the maintenance manual for the bolts that a regulation torque are explained).
• Make sure that the air valve, regulator and the drain valve on the discharge side are closed.
Also, make sure that the valve on the suction side is opened.
1) Start the air compressor
2) Open the air valve in front of each piece of peripheral equipment, and adjust the
supply air pressure with a regulator to within the permissible range (see 15.0 Main
specifications).
3) Open the flow valve on the discharge side.
4) Press the reset button, and then slowly open the air valve of the pump.
5) First, verify that fluid is flowing inside the piping and is being pumped to the discharge side,
and then fully open the air valve.
Caution
• Do not open the valve suddenly.
• Turbine oil (equivalent VD 32 grade) must be used for lubricants.
Do not apply lubricants more than required and also do not use any other lubricants, which
is designated on this instruction manual. This maybe the cause of pump problem and there
is danger of serious bodily damage.
11.2 Flow adjustment
• Adjust the ow valve on the discharge side. For the relationship among the ow, supply air
pressure and discharge pressure, see 22.0 Performance curves.
Caution
• As you start closing the ow valve, the supply air pressure may rise. Make sure that the
pressure is kept within the normal operating range (see 15.0 Main specifications).
• Depending upon the viscosity and specic gravity of the uid, the suction stroke and other
conditions, the permissible suction flow speed of fluid into the pump will vary; however, if
the pump speed (flow speed of fluid) increases greatly, cavitation will occur, and this will not
only reduce pump performance, but it may cause a malfunction. Adjust the supply air
pressure as well as the flow in order to prevent cavitation.
• If uid is not discharged after you start the pump, or if you hear an abnormal noise or notice
any irregularity, shut down the pump immediately (see 14.0 Trouble shooting).

A.0200.301 – IM-TA/03.00 EN (03/2007)
18
11.3 Shutdown
Close the air valve of the pump and shut off the supply air.
Caution
• There is no problem in shutting down the pump with the ow valve closed while air is being
supplied; however, if this condition continues for many hours while there is nobody watching
the pump, it may continue running when there is a leak from the pump or piping, and fluid
may continue flowing out of the position of leakage. Upon finishing your work, release the
internal pressure from the pump and close the air valve (see 11.4 Releasing the pressure).
• When the pump is shut down while pumping slurry, particulate matter contained in the
slurry will be deposited and get stuck inside the out chamber. If the pump is started again
as-is, the diaphragm may be damaged or the centre disk may be overloaded, and this may
cause damage such as bending of the centre rod. After finishing your work, purge the
remaining fluid from the pump (see 12.0 Method of cleaning).
11.4 Releasing the pressure
1) Make sure that the air valve of the pump is closed.
2) Shut down the air compressor or close the valve on the air-supply side of the peripheral
equipment.
3) Close the flow valve on the discharge side, start slowly opening the drain valve, and
discharge the fluid under pressure.
4) Open the air valve of the pump, start running the pump, and discharge the remaining air.
5) After making sure that the pump has been shut down and the pressure has been released,
fully open the regulator, and close the air valve and drain valve of the pump.
Caution
• Keep a vessel below the relief valve to catch any drain off.
• Fluid under pressure will gush out as soon as you open the valve, so be careful.
• If the pump will be unused for a prolonged period, purge and clean the pump (see 5.0
Operating caution).

A.0200.301 – IM-TA/03.00 EN (03/2007) 19
12.0 Method of cleaning
Caution
• Before starting operation, make sure that compressed air is not supplied to the pump.
• Before starting operation, make sure that the pump is not pressurised.
1) Remove the hose from the suction side of the pump.
2) Close the flow valve on the discharge side, open the drain valve, and then operate a pump
by starting air pressure for a while to discharge any fluid remaining inside the pump as much
as possible.
3) Remove the hose from the discharge side, and attach different hoses to the suction side and
the discharge side for cleaning.
4) Be ready with a vessel with cleaning solution, select cleaning solution appropriate for the
type of fluid pumped, and then connect the suction-side and the discharge-side hoses of the
pump.
5) Operate a pump by starting air pressure slowly, and let the cleaning solution circulate for
sufficient cleaning.
6) Finally, flush with clean water.
7) Remove the hose from the suction side of the pump, run the pump for a while and purge the
pump of remaining fluid as much as possible.
Caution
• Be careful when removing piping. Fluid will gush out.
• After cleaning with clean water, turn the pump upside-down to drain out the water.
13.0 Daily check
• Before starting pump operation, be sure to conduct the following check every day. If any
irregularity is found, do NOT start running the pump until the cause of the irregularity has
been found and corrective measures have been taken.
a) Verify the drain flow through the air filter.
b) In the case of using a lubricator, verify the quantity of lubricating oil.
c) Make sure that there is no leakage of fluid from any connection part or the pump.
d) Make sure that there are no cracks in the pump casing or piping.
e) Check the tightness of every bolt of the pump.
f) Make sure that the connection parts of the piping and peripheral equipment are not
loose.
g) Make sure that the time has not elapsed for replacing any parts of the pump that are to
be replaced at regular intervals.

A.0200.301 – IM-TA/03.00 EN (03/2007)
20
14.0 Trouble shooting
Cause Action to be taken
Pump does not rum
The exhaust port (silencer) of pump is Check and clean the exhaust port and
clogged with sludge. silencer.
Air is not supplied. Start the compressor and open the air valve
and air regulator.
The supply air pressure is low. Check the compressor and the configuration
of air piping.
Air leaks from connection parts. Check the connection parts and tightness of
bolts.
Air piping or peripheral equipment is Check and clean the air piping.
clogged with sludge.
The flow valveon the discharge side is not Open the flow valve on the discharge side.
open.
The spool stopped in neutral position. Press the reset button.
The fluid piping is clogged with sludge. Check and clean the fluid piping.
The pump is clogged with sludge. Disassemble the casing, check and clean.
Pump runs, but fluid does not come out
The sucion lift or discarge head is long. Confirm the piping configuration and
shorten the length.
The discharge-side fluid piping (including Check and clean the fluid piping.
the strainer) is clogged with sludge.
The valve on the suction side is not open. Open the valve on the suction.
The pump is clogged with sludge. Disassemble the casing, check and clean.
The ball and valve seat are worn out or Disassemble the manifold, check and
damage. replace parts.
Flow (discharge volume) decreased
The supply air pressure is low. Check the compressor and configuration
of air piping.
Air piping or peripheral equipment is Check and clean the air piping.
clogged with sludge.
The discharge-side flow valve opens Adjust the discharge-side flow valve.
differently.
Air is taken in together with fluid. Replenish fluid and check the configuration
of the sucion-side piping.
Cavitation occurs. Adjust the supply air pressure and discharge
pressure, and shorten the sution lift.
Chattering occurs. Adjust the supply air pressure and discharge
pressure. Reduce inlet flow valve to adjust-
ing liquid pressure and volume.