As a maintenance manager responsible for a plant full of equipment and machinery, you know the importance of keeping everything running smoothly to maintain your production schedule and minimize downtime. After all, production interruptions lead to lost revenue and should be avoided whenever possible.
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Though air-operated double-diaphragm (AODD) pumps are known for their consistency and reliability, just like any piece of equipment, they need routine maintenance and repair to ensure long-term durability.
When a pump comes to an unexpected stop, it can be detrimental to the system or process. You first need to understand if the issue is on the air end (pilot valve, main air valve) or on the wet end (diaphragms, balls, seats). Once understood, you can begin diaphragm pump maintenance and repair.
Air End
If it is determined that the root cause is on the air side, you will be focusing on both the pilot valve assembly and the main air valve assembly.
Dirty air is the most common cause of air end issues. If pipe sealant, weld berries or dirt is seen during disassembly and evaluation of components, an inline filter may be necessary. If dirt and debris are not present, but process fluid is, you may have a diaphragm failure or loosened diaphragm plate assembly. Once the components are cleaned, inspected and replaced, the main air valve and pilot valve can be reinstalled on the pump.
In many cases, to save time and rule out wet-end components, end users will keep spare air valves and pilot valves on the shelf to test their pump. Wear components on the main air valve are a series of O-Rings and Glyd Rings or U-Cup Seals. These can be replaced as individual components or purchased as a complete kit.
On the pilot valve, the self-sealing floating pneumatic O-Rings are to be evaluated and replaced if needed. Aside from wear items, you&#;ll want to ensure all air passages are free and clear of debris before reinstallation.
Many other technologies require factory representation, special tools or testing prior to reinstalling the pump into the system. This can be costly.
The inherently simple design of the AODD pump allows for repair virtually anywhere, with complete rebuilds commonly performed on the tailgate of a truck. In addition to being simple to work on, Versamatic pumps are backed by some of the best technical support in the industry, including the following:
- Data Sheets: Flow curves, weights, dimensions
- Manuals: Exploded view of the pump, materials of construction
- Videos: Repair videos (air/wet side)
Wet End
One clear indicator of diaphragm failure is exiting the pump through the exhaust. If this occurs, the pump needs to be shut down, isolated via suction and discharge valves, and removed from the system for repair. After the pump has been flushed and disassembled, you will want to inspect the diaphragms.
Depending on what is being pumped, you might see:
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Since , Versamatic&#;s AODD pumps have become the first choice for customers around the globe who value reliability, quick delivery and convenience. Our AODD pump parts and accessories improve performance and productivity, while extending mean time between failures.
We offer a variety of tools and resources to support your AODD pump, from initial selection to troubleshooting and diaphragm pump maintenance. Let our experienced staff solve your maintenance, repair and performance issues quickly to keep your operations running smoothly and efficiently.
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Common Diaphragm Pump Problems and Their Solutions
by Patrick Harmon
Diaphragm pumps offer a cost effective solution to delivering a large volume of coatings at a relatively low cost. They are also relatively simple in design consisting of a gasket like diaphragm that air causes to switch back and forth and in the process of doing so moves material into and out of the pump. Given all their benefits a diaphragm pump makes a lot of sense. However, if your having problems with your diaphragm pump it can quickly become a solution you do not like. This guide will cover common diaphragm pump problems and their solutions. Please note if your regularly having problems with your diaphragm pump, you may want to evaluate if the pump was properly chosen for your application.
Common Diaphragm pump problem # 1 &#; Fluid is delivered inconsistently
A common problem that is mentioned with a diaphragm pump is an issue called a wink. A wink is seen when the material comes out of a diaphragm pump at an inconsistent pace. This can be problematic especially if your diaphragm pump is being used in an application where consistency in fluid delivery is important, like in painting. A wink coming from a diaphragm occurs when the air diaphragm switches from using one half of the pump to the other resulting in a brief change in fluid volume output which results in a slight wink. This is actually not a problem but more of a common challenge with a diaphragm pump. If your diaphragm pump winks when you are using it and this is problematic, you can consider a fluid outlet regulator. A fluid outlet regulator evens out the pressure at which material exits the diaphragm pump to your spray gun or through the system. By regulating the fluid output pressure the fluid will be consistent as it reaches the end of your fluid line on your diaphragm pump which will eliminate any winks that you may see.
The other potential issue that can create inconsistent fluid delivery is the diaphragm inside your pump has worn. Over time the diaphragm can wear down and even rupture. When this happens the pump will not move evenly side to side which can create uneven fluid delivery. Typically when this happens the pump will move relatively slow to one side and then rapidly move to the other. While it may be the diaphragm it could also be the ball and seats in the diaphragm pump (see photo below for greater detail on problem areas please note the photo doesn&#;t show ball and seats). Ultimately if the pump moves unevenly on one side, the diaphragm, air check valve, or ball and seats in the pump are probably worn too much or not clean and as a result, will not have controlled even delivery of material when the pump moves from one side to the other. The right steps to solve this if it is occurring is first to try to ensure your ball and seats are clean. Second, review the diaphragm for any tears, and finally if both seem to be working well consider that the air check valves are too worn. If any doubts you can rebuild each component or contact us for additional help troubleshooting.
Common Diaphragm Pump Problem # 2 &#; My pump breaks down excessively
If your constantly rebuilding your diaphragm pump, this is typically a sign that your diaphragm pump is working too hard. Diaphragm pumps are specified with a maximum working fluid delivery rate. However, this maximum rate is a bit misleading because it is showing the fastest the diaphragm pump can possibly go. Most of the time you want the actual GPM that the diaphragm pump is operating at to be about 40 &#; 50 percent of its maximum GPM ability. This will result in the pump moving slower and help improve the life of the pump.
Common Diaphragm Pump Problem #3 &#; My pump freezes and becomes Stuck
Another problem that occasionally happens with diaphragm pumps is that the diaphragm can become stuck as it attempts to switch from being on one side of the pump to the other. While this was a lot greater issue when diaphragm pumps first came out, over time it has been addressed greatly. However, if you find this issue occurring routinely it can again be a good time to review the internal diaphragms as well as the air check valves with the pump that control air delivery to each side of the pump and create the back and forth motion that keeps the pump working. You may also need more CFM of air to operate the diaphragm pump. If the pump physically freezes this also is typically an indicator that your diaphragm pump is being overworked. This typically happens when the GPM of the pump is not enough to support your application.
Final thoughts
Ultimately a diaphragm pump is a durable solution for fluid delivery. Common problems that can occur are typically related to the ball and seats in the diaphragm pump, a worn diaphragm, or worn air check valves. Otherwise, it may be that the diaphragm pump that has been chosen is not large enough for your application or doesn&#;t have the proper accessories like a fluid regulator to keep uneven fluid delivery. If you need additional help with a diaphragm pump you can contact us.
For more information, please visit Pneumatic Diaphragm Pump.
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