YAMADA NDP-5 series User manual

OPERATION MANUAL
OPERATION MANUALOPERATION MANUAL
OPERATION MANUAL
YAMADA AIR
YAMADA AIRYAMADA AIR
YAMADA AIR-
--
-OPERATED DIAPHRAGM PUMPS
OPERATED DIAPHRAGM PUMPSOPERATED DIAPHRAGM PUMPS
OPERATED DIAPHRAGM PUMPS
NDP-5 series
DP-10/12 series
NDP-10/12 series
NDP-15 series
NDP-20 series
NDP-25 series
NDP-40 series
NDP-50 series
NDP-80 series
DP-F series
Do . No. NDP002U-18
Issue 1998-6
Revised 2008-12

2
DECLARATION OF CONFORMITY
Name of company : YAMADA CORPORATION
Address : No,1-3,1-Chome,Minami-Magome,ohta-ku,Tokyo,143-8504 Japan
Declares, in sole responsibility, that the following product
Equipment : Diaphragm Pumps
Type : NDP- and DP- series
Referred to in this declaration conforms with the following standard(s) or directive(s)
: - European Standard EN 809 / October 1998
: - Directive 98/37/EC
YAMADA CORPORATION will keep on file for review for following
Technical documentation
•operating instructions as required
•plans
•description of measures designed to ensure conformity
•other technical documentation
Importer / Distributor in EU
Name of company : YAMADA EUROPE B.V.
Address : Aquamarijnstraat 50, 7554 NS Hengelo (O), The Netherlands
This product is certificated in TUV Rheinland about safety.
Certificate Number is R9850515
Place and date issued : Sagamihara Factory / May 16 2001
Name and signature as well as position of undersigned :
Hiromasa Kumagai (Quality assurance Dept. Director)

3
·
··
·Introdu tion
Introdu tionIntrodu tion
Introdu tion
Thank you for pur hasing a Yamada Diaphragm Pump. This produ t is a positive-displa ement pump that transfers
fluids by movement of diaphragms driven by ompressed air through a unique swit hing me hanism. The asing that
omes in onta t with the fluid is made of aluminum, stainless steel, forged iron, and polypropylene or fluorine resin,
depending on the model you have sele ted a ording to the type of fluid to be pumped. The diaphragms are made of a
plasti material suitable for the model.
·
··
·For safe operation
For safe operationFor safe operation
For safe operation
This do ument ontains information vital for safe and effi ient operation of this produ t. Before using the pump, be
sure to read this do ument arefully, parti ularly the "warnings and autions," and be fully familiar with the operating
pro edures.
Be sure to keep this do ument handy for future referen e.

4
·
··
·Warnings and autions
Warnings and autionsWarnings and autions
Warnings and autions
For safe use of this produ t, be sure to note the following: In this do ument, warnings and autions are
indi ated by symbols. These symbols are for those who will operate this produ t and for those who will be
nearby, for safe operation and for prevention of personal injury and property damage.
The following warning and aution symbols have the meanings des ribed below. Be sure to remember their
meanings.
If you ignore the warning des ribed and operate the produ t in an
improper manner, there is danger of serious bodily injury or death.
If you ignore the aution des ribed and operate the produ t in an
improper manner, there is danger of personal injury or property damage.
Furthermore, to indi ate the type of danger and damage, the following symbols are also used along with those
mentioned above:
This symbol indi ates a DON'T, and will be a ompanied by an explanation on
something you must not do.
This symbol indi ates a DO, and will be a ompanied by instru tions on something
you must do in a ertain situation.
·
··
·Operating aution
Operating autionOperating aution
Operating aution
Before using this produ t
WARNING
WARNINGWARNING
WARNING
•When using ompressed gas (hereinafter alled " ompressed air") to drive this pump, be sure
it is one of the following:
* Compressed air supplied from an air ompressor
* Nitrogen (N
2
) gas
Use of ompressed air other than the above may ause air pollution, damage to the pump, or
even an explosion.
•The maximum permissible pressure for the ompressed air, and the fluid pumped by one of
these pumps, depending upon the asing material of the model you are using, is as follows:
*Metal asing (aluminum, stainless steel, forged iron): 0.7MPa (7kgf/ m
2
)
*Plasti asing (polypropylene, fluorine resin): 0.7MPa (7kgf/ m
2
)
(0.5MPa for the DP-05F until DP-20F) (0.7MPa for the DP-25F/38F)
If the pressure of the ompressed air and fluid ex eeds the above appli able maximum
permissible pressure spe ified above, there may be leakage of fluid, damage to the asing,
or even a severe, possibly even fatal, a ident.
•When moving this produ t, make sure that the internal pressure is released.
If the pump is moved while under pressure, any sho k imparted by drop page,
et . may damage the pump or even ause an explosion.
•Hazardous fluids (with strong a id or alkali, flammable or toxi ) or gas bubbles generated by su h
fluids may ause serious injury or even death if a identally inhaled or onsumed or if they ome into
onta t with the eyes or adhere to skin. Therefore, the following pre autions are strongly advised.
*Be fully familiar with the properties of the fluid to be pumped and work in stri t a ordan e with
the operating instru tions provided by the suppliers of su h fluids (su h as wearing goggles,
gloves, mask or work lothes).
*When storing a hazardous fluid, stri tly omply with the regulatory pro edures (su h as using
proper ontainers, storage onditions, et .).
*Always install the piping and exhaust port of this pump away from human and animal traffi .
When a diaphragm is damaged, fluid will gush out together with air through the exhaust port.
Provide prote tive measures in onsideration of possible leakage of fluid (see Notes: Arranging
outside exhaust on p.20). When you use the hose and pit et ., be sure you are using a model with
appropriate orrosion resistan e for the fluid to be pumped.
WARNING:
CAUTION
:

5
WARNING
WARNINGWARNING
WARNING
•When installing this produ t, be sure to onne t a ground wire from the spe ified position of
this produ t (ex luded NDP-5FPT, NDP-10, 15FP □ , and DP-F series).
When this produ t is installed and operated without the ground wire properly onne ted, fri tion
between parts, as well as abrasion aused by the flow of some fluids inside the asing, may
generate stati ele tri ity. Also, depending on the type of fluid being pumped and the installation
environment (su h as gases in the air and type of surrounding fixtures), stati ele tri ity ould
be ome a ause of fire or ele tri sho k.
•Improper grounding, poor ventilation, or unshielded fire or spark an reate a danger of fire
or explosion. Therefore, the following pre autions are strongly advised.
*All peripheral equipment and piping onne ted to this produ t should be properly grounded.
*To pump flammable liquids, use an ATEX ompliant model.
*Whenever you noti e any spark while operating this produ t, immediately stop its operation,
and do NOT start using it again unless you are sure of the ause and orre tive a tions have
been taken.
*Depending upon the type of fluid being pumped, bubbles of flammable gas may be generated.
Make sure that ventilation is satisfa tory.
*This produ t itself, its piping and exhaust ports should be kept away from unshielded fire,
spark and other auses of ignition. If a diaphragm is damaged, fluid will gush out together
with air from the exhaust port.
*Do NOT leave gasoline or solvent et . that ontains waste at the work site.
*Ma hinery and other equipment near the pla e of installation of this produ t should be
properly insulated to prevent ondu tion with ea h other.
*Do NOT operate heating devi es that reate flames or have heating filaments anywhere near
the pump or the piping.
*If there are flammable gases in the air while the pump is operating, do NOT swit h ele tri
applian es on and off.
*Do NOT operate a gasoline engine at the work site.
*Restri t smoking at the work site.
•The DP-F series pumps are intended for pumping hazardous fluids su h as those that ontain
strong a ids or organi solvents. If you find any irregularity in this produ t, do
NOT try to disassemble or servi e the produ t yourself. Conta t your dealer or our regional offi e
for servi e.
If you disassemble or servi e this produ t yourself and if further irregularity o urs, it may ause
a great risk, depending upon the kind of fluid to be pumped.
•After you shut down the pump and dis onne t the piping, some fluid may remain inside the pump.
Also, if the pump is left unused for a prolonged period, some fluid may remain inside the pump
and onne ted piping. Therefore, be sure to purge the system of fluid and lean the pump before
prolonged disuse.
If the produ t is left unused for a prolonged period with fluid remaining in the onne ted piping as
well as the pump itself, the fluid may expand, depending on the ambient temperature (be ause of
freezing or heat), whi h may ause damage to the pump and/or piping and possible leakage of fluid.
•Always use genuine Yamada parts when repla ing omponent parts of this produ t.
Do NOT attempt to modify the omponents parts or repla e them with other than
genuine Yamada parts.
•Torque of all tightening parts must be inspe ted before operation.
Designated torques is mentioned in maintenan e manual.

6
WARNING
WARNINGWARNING
WARNING
•When pumping a hazardous fluid (hot, flammable, strong a id, et .) with this produ t,
provide prote tive measures (install a pit, a prote tion box, sensors, et .) in onsideration of
possible leakage of fluid, and post
warning signs at ne essary pla es.
Copy the warning symbols on p.61,
and atta h them to the asing and
piping, et .
Leakage of fluid may ause fire, air
pollution or a serious a ident.
When pumping a hot fluid, the
asing and piping will be ome hot,
whi h may burn the skin when
tou hed.
Fig.0.1
•Before using this produ t, be sure you are familiar with the pre autions regarding the fluid to
be pumped, and verify the orrosion resistan e of the parts that will ome into onta t with the
fluid. NEVER use the produ t with any fluid against whi h it does not have suffi ient orrosion
resistan e or with a fluid that poses a risk of explosion. If you are unsure of the orrosion
resistan e, onta t your dealer or our regional offi e.
If you use this produ t with any fluid against whi h the parts that will ome in onta t with the
fluid do not have suffi ient orrosion resistan e, it may result in damaging the produ t or leakage
of fluid.
•When working in the vi inity of pumping of fluid with this produ t, be sure to wear prote tive
gear (goggles, mask, et .).
•When using this produ t, observe the relevant regulatory rules on erning fire prevention, labor
safety standards, et .
•If you have any questions on the operation of this produ t (method of onne tion or installation),
onta t your dealer or our regional offi e.
CAUTION
CAUTIONCAUTION
CAUTION
•When operating this produ t, it may generate loud operating noise, depending upon the ondition
of use (fluid pumped, supply air pressure and dis harge pressure).
If regulatory rules apply, provide appropriate a ousti measures where ne essary. (For the noise
value of this produ t, see 10.1 Main spe ifi ations after p.30.)
•To drive this produ t, use supply air with minimum moisture ontent.
•If a diaphragm of this produ t is damaged, supply air may mix with the fluid or the fluid may flow
into the main body (air-swit hing portion). If air supply is inadequate or ontaminated, do NOT
operate the pump.
•While operating this produ t, do NOT over the intake port by hand.
•If more than two years have elapsed sin e this produ t was shipped from the fa tory, notify your
dealer or our regional offi e, and do NOT operate it without assuran e from the dealer or our
regional offi e that the pump may be operated safely.

7
Table of ontents
Table of ontentsTable of ontents
Table of ontents
·
··
·De laration of Conformity
De laration of ConformityDe laration of Conformity
De laration of Conformity ····························································2
·
··
·Introdu tion
Introdu tionIntrodu tion
Introdu tion ················································································3
·
··
·For safe operation
For safe operationFor safe operation
For safe operation ·······································································3
·
··
·Warnings and aution
Warnings and autionWarnings and aution
Warnings and autions
ss
s ································································4
·
··
·Operating aution
Operating autionOperating aution
Operating aution ·······································································6
·
··
·Table of ontents
Table of ontentsTable of ontents
Table of ontents ·········································································7
1. Names of parts and materials
1. Names of parts and materials1. Names of parts and materials
1. Names of parts and materials
1.1 NDP-5 series··········································································8
1.2 DP-10/12 series ······································································9
1.3 NDP-10/12 series ·································································· 10
1.4 NDP-15 series ······································································ 11
1.5 NDP-20, 25 series ································································· 12
1.6 NDP-40 series ······································································ 14
1.7 NDP-50 series ······································································ 15
1.8 NDP-80 series ······································································ 16
1.9 DP-F series·········································································· 17
2. Assembly
2. Assembly2. Assembly
2. Assembly
2.1 Installation of a essories ········································· ············· 18
3. Installation
3. Installation3. Installation
3. Installation
3.1 Method of transport················································· ············· 19
3.2 Installing the pump················································· ············· 19
3.3 Conne ting the ground wire ······································ ············· 21
3.3.1. Use in potentially explosive atmospheres·················· ············· 21
4. Conne tion
4. Conne tion4. Conne tion
4. Conne tion
4.1 Conne ting fluid piping ············································ ············· 23
4.2 Conne ting air piping ·············································· ············· 24
5. Operation
5. Operation5. Operation
5. Operation
5.1 Method of operation················································· ············· 25
5.2 Flow adjustment····················································· ············· 25
5.3 Shutdown······························································ ············· 26
5.4 Releasing the pressure············································· ············· 26
6. Method of leaning
6. Method of leaning6. Method of leaning
6. Method of leaning ···································· ········· 27
7. Daily he k
7. Daily he k7. Daily he k
7. Daily he k ············································ ········· 28
8. Troubleshooting
8. Troubleshooting8. Troubleshooting
8. Troubleshooting
8.1 Pump does not run ·················································· ············· 28
8.2 Pump runs, but fluid does not ome out······················· ············· 28
8.3 Flow (dis harge quantity) de reased ··························· ············· 28
8.4 Liquid leakage from exhaust port (silen er)·················· ············· 29
8.5 High air onsumption during in operation···················· ············· 29
8.6 Irregular noise ······················································· ············· 29
8.7 Irregular vibration ·················································· ············· 29
9. Returning the produ
9. Returning the produ9. Returning the produ
9. Returning the produ t for servi ing
t for servi ingt for servi ing
t for servi ing
9.1 How to use the FAX sheet········································· ············· 29
9.2 Before returning the produ t····································· ············· 29
10. Main body spe ifi ations
10. Main body spe ifi ations10. Main body spe ifi ations
10. Main body spe ifi ations
10.1 Main spe ifi ations ················································ ············· 30
10.2 Appearan e and dimensions ···································· ············· 36
10.3 Performan e urve················································· ············· 52
11. Trouble
11. Trouble11. Trouble
11. Trouble-
--
-Reporting FAX Sheet
Reporting FAX SheetReporting FAX Sheet
Reporting FAX Sheet ························ ········· 58
12. Warning s
12. Warning s12. Warning s
12. Warning symbols
ymbolsymbols
ymbols ····································· ········· 59
13.
13.13.
13. Limited warranty
Limited warrantyLimited warranty
Limited warranty ···································· ········· 60

8
1. Names of parts and materials
1. Names of parts and materials1. Names of parts and materials
1. Names of parts and materials
1.1 NDP
1.1 NDP1.1 NDP
1.1 NDP-
--
-5 series
5 series5 series
5 series
NDP-05-FAT NDP-05-FPT
NDP-05-FST NDP-05-FVT
NDP-05-FDT
Type FAT FST FPT FVT FDT
Swit hing Portion PPS
Fluid onta t Portion AC4C-T6 SCS14 PPG PVDF ACETAL
Diaphragm PTFE
Flat Valve SUS316 PTFE
O Ring PTFE
Valve Seat SUS316 PPG PVDF ACETAL
Center Disk A5056 SUS316 PPG
(SUS304) PVDF (SUS304) ACETAL (SUS304)
*Only PTFE diaphragm is setup in NDP-5 series.
■
■■
■ List of a essories
List of a essoriesList of a essories
List of a essories
•Operation Manual ························ 1
•Maintenan e Manual ················ 1
•Air Valve···························· 1
•A essory Tool······························ 1 (FPT, FVT, FDT: 2)
A: Air Valve
B: Reset Button
C: Out Manifold
D: Out Chamber
E: In Manifold
F: Pump Base
G: Dis harge Port
H: Intake Port
I: Lift Point
J: Ground Conne tion Point

9
1
11
1.2
.2.2
.2 DP
DPDP
DP-
--
-10
1010
10/12
/12/12
/12 series
series series
series
DP-10/12BA □ DP-10/12BS □ DP-10/12BP □ BDP-10/12BA □
BDP-10/12BS □
•Aluminum type ([ ]: Drum type B
BB
B)
Type BAC BAN BAT BAH BAS BAE
Swit hing Portion ADC12
Fluid onta t Portion ADC12 [ADC12, SUS304]
Diaphragm CR NBR PTFE TPEE TPO EPDM
Ball/O Ring CR/NBR NBR PTFE PTFE EPDM EPDM
Valve Seat A5056
Center Disk A5056
•Stainless-steel type ([ ]: Drum type B
BB
B)
Type BSC BSN BST BSH BSS BSE
Swit hing Portion ADC12
Fluid onta t Portion SCS14 [SCS14, SUS304]
Diaphragm CR NBR PTFE TPEE TPO EPDM
Ball/O Ring CR/NBR NBR PTFE PTFE EPDM EPDM
Valve Seat SUS316
Center Disk SUS316
•Polypropylene type ([ ]: Drum type B
BB
B)
Type BPC BPN BPT BPH BPS BPE
Swit hing Portion ADC12
Fluid onta t Portion PPG
Diaphragm CR NBR PTFE TPEE TPO EPDM
Ball/O Ring CR/NBR NBR PTFE PTFE EPDM EPDM
Valve Seat CR NBR PPG PPG PPG PPG
Center Disk PPG (SUS304)
■
■■
■ List of a essories
List of a essoriesList of a essories
List of a essories
•Operation Manual·························1 •Silen er····································· 1
•Maintenan e Manual ··············· 1 •Hexagon Wren h ························· 1
•Air Valve·····································1 •Su tion Pipe Set·························· 1 (only BA □ ,BS □ )
A: Air Valve
B: Reset Button
C: Out Manifold
D: Out Chamber
E: In Manifold
F: Pump Base
G: Dis harge Port
H: Intake Port
I: Lift Point
J: Ground Conne tion Point

10
1
11
1.
..
.3
3 3
3 NDP
NDPNDP
NDP-
--
-10
1010
10/12
/12/12
/12 series
series series
series
A: Air Valve F : Pump Base
B: Reset Button G: Dis harge Port
C: Out Manifold H: Intake Port
D: Out Chamber I: Lift Point
E: In Manifold J: Ground Conne tion Point
NDP-10-BPC, NDP-10-BPN
NDP-10-BPT, NDP-10-BPS
NDP-10-BPH, NDP-10-BPE
•Polypropylene type
Type BPC BPN BPT BPH BPS BPE
Swit hing Portion PPS
Fluid onta t Portion ADC12
Diaphragm CR NBR PTFE TPEE TPO EPDM
Ball/O Ring CR/NBR NBR PTFE PTFE EPDM EPDM
Valve Seat CR NBR PPG PPG PPG PPG
Center Disk PPG (SUS304)
█ List of a essories
List of a essoriesList of a essories
List of a essories
•Operation Manual ·············· 1
•Maintenan e Manual ·········· 1
•Air valve··························· 1
•A essory tool ···················· 1