Leak Free Diaphragm Pump

In the previous blog, we discussed the common failures of pneumatic diaphragm pumps and analyzed their causes. Now, Anhui Shengshi Datang will guide you on how to troubleshoot these issues and what steps to take when encountering such situations. Troubleshooting and Handling Measures 1. Air Pump Not Working When it is found that the pneumatic diaphragm pump cannot start normally or stops immediately after starting, it should be inspected based on this symptom: (1) First, check whether the connection points of the circuit are broken. If the circuit is damaged or the connections are loose, replace the wires in the circuit or reinforce the connections promptly to restore the equipment to operation and improve the stability of the air pump. (2) If parts that frequently experience friction show significant wear or have aged and lost elasticity, consider replacing them to enhance the stability of the system operation. 2. Inlet/Outlet Pipeline Blockage If the issue with the air pump is determined to be in the inlet/outlet pipeline, and the pump cannot operate normally due to pipeline blockage, inspect and address it based on the following symptoms: Common Faults Cause Analysis Handling Measures Insufficient pressure supply or pressure increase in the diaphragm pump Improper adjustment of the pneumatic diaphragm pump pressure regulating valve or poor air quality; malfunction of the pressure regulating valve; malfunction of the pressure gauge Adjust the pressure valve to the required pressure; inspect and repair the pressure regulating valve; inspect or replace the pressure gauge Pressure drop in the diaphragm pump Insufficient oil replenishment by the oil replenishment valve; insufficient feed or leakage in the feed valve; oil leakage from the plunger seal Repair the oil replenishment valve; inspect and repair the sealing parts; refill with new oil Reduced flow rate in the diaphragm pump Pump body leakage or diaphragm damage; rupture of the inlet/outlet valve; diaphragm damage; low speed that cannot be adjusted Inspect and replace the sealing gasket or diaphragm; inspect, repair, or replace the feed valve; replace the diaphragm; inspect and repair the control device, adjust the rotation speed (1) Disassemble and clean the internal pipelines of the equipment to remove various impurities attached to the pipelines. Improve the cleanliness of the pipe walls and enhance the stability of the equipment operation. (2) Strengthen the management of medium materials to ensure that materials do not mix due to sharing. Ideally, use one device for pumping a specific material. If the same equipment must be used, clean the pipelines promptly to avoid air pump pipeline blockages and improve the stability of the air pump's working condition. 3. Severe Ball Seat Wear If ball seat wear is confirmed through inspection, troubleshoot using the following measures: (1) First, confirm whether its sealing performance can support normal equipment operation. If the ball seat wear is too severe to determine, replace the ball seat to maintain the fit between the ball seat and the ball and avoid poor sealing. (2) Since friction between the ball seat and the ball is inevitable, monitor the operating condition of the ball seat in real time during daily operations to enhance the overall stability of the equipment. 4. Severe Ball Valve Wear If ball valve wear is confirmed through inspection, and the wear is severe, troubleshoot using the following measures: (1) Replace severely damaged ball valves. If no spare ball valve is available, temporarily use a ball bearing as a substitute and replace it with a matching ball valve afterward. (2) Media with excessively high viscosity will increase the resistance of the ball, preventing flexible operation. In this case, clean the ball valve and base to ensure smooth transportation and improve the stability of the equipment operation. 5. Irregular Air Pump Operation For issues related to irregular air pump operation, inspect and address them based on the specific symptoms: (1) Replace severely worn ball valves to improve structural stability. (2) If the diaphragm is damaged, replace it promptly to enhance the reliability of the system's processing. (3) If the issue is due to limitations of the preset system, upgrade the system to improve the stability of the equipment system operation. 6. Insufficient Air Supply Pressure For problems caused by insufficient air supply pressure, inspect and troubleshoot using the following measures: (1) Confirm whether the equipment operating system is stable and check the system pressure condition. If it meets the requirements, continue using it; otherwise, debug it as soon as possible. (2) To maintain the volume and cleanliness of compressed air, add an air filtration device and improve the purity of the compressed air to maintain the equipment output rate and enhance system stability.  

Anhui Shengshi Datang Pump Industry is committed to providing customers with the best technology and services, always putting customers at the core.   Introduction to Pneumatic Diaphragm Pumps A pneumatic diaphragm pump uses compressed air as its driving power source. It typically consists of components such as an air inlet, air distribution valve, balls, ball seats, diaphragms, connecting rods, central bracket, pump inlet, and exhaust outlet. Once it receives a control command, the pump starts operating by utilizing air pressure and its special internal structure to transfer materials. It has low requirements for the properties of the conveyed medium and can handle a wide range of substances, including solid–liquid mixtures, corrosive acid and alkali liquids, volatile, flammable, and toxic fluids, as well as viscous materials. It offers high working efficiency and simple operation. However, due to aging parts or improper use, diaphragm pump failures may occur during operation. A. Materials Pneumatic diaphragm pumps are commonly made from four materials: aluminum alloy, engineering plastics, cast alloy, and stainless steel. Depending on the medium being handled, the pump materials can be adjusted accordingly to meet the diverse needs of users. Owing to its adaptability to different environments, the pump can handle materials that conventional pumps cannot, earning it wide recognition among users. B. Working Principle The diaphragm pump operates by using a power source to drive the piston, which in turn moves hydraulic oil back and forth to push the diaphragm, thereby achieving suction and discharge of liquids. When the piston moves backward, the change in air pressure causes the diaphragm to deform and concave outward, increasing the chamber volume and decreasing pressure. When the chamber pressure drops below the inlet pressure, the inlet valve opens, allowing fluid to flow into the diaphragm chamber. Once the piston reaches its limit, the chamber volume is at its maximum and the pressure is at its minimum. After the inlet valve closes, the suction process is complete, and liquid filling is achieved. As the piston moves forward, the diaphragm gradually bulges outward, decreasing the chamber volume and increasing internal pressure. When the pressure in the chamber exceeds the resistance of the outlet valve, the liquid is expelled. Once the piston reaches the external limit, the outlet valve closes under gravity and spring force, completing the discharge process. The diaphragm pump then proceeds to the next suction and discharge cycle. Through continuous reciprocation, the diaphragm pump effectively transfers the liquid. C. Characteristics 1. Low heat generation: Powered by compressed air, the exhaust process involves air expansion, which absorbs heat, reducing the operating temperature. Since no harmful gases are emitted, the air properties remain unchanged. 2. No spark generation: As it does not rely on electricity, static charges are safely discharged to the ground, preventing spark formation. 3. Can handle solid particles: Due to its positive displacement working principle, there is no backflow or clogging. 4. No impact on material properties: The pump merely transfers fluids and does not alter their structure, making it suitable for handling chemically unstable substances. 5. Controllable flow rate: By adding a throttling valve at the outlet, the flow rate can be easily adjusted. 6. Self-priming capability. 7. Safe dry running: The pump can operate without load without damage. 8. Submersible operation: It can work underwater if needed. 9. Wide range of transferable liquids: From water-like fluids to highly viscous substances. 10. Simple system and easy operation: No cables or fuses are required. 11. Compact and portable: Lightweight and easy to move. 12. Maintenance-free operation: No lubrication needed, eliminating leakage and environmental pollution. 13. Stable performance: Efficiency does not decline due to wear.   Common Failures and Causes Although pneumatic diaphragm pumps are compact and occupy little space, their internal structure is complex, with many interconnected components. Failure of any single part can lead to operational problems. Unusual noise, fluid leakage, or control valve malfunctions are typical warning signs. Timely maintenance is essential. Component wear and aging caused by friction are also major sources of malfunction. A. Pump Not Operating 1. Symptoms: When starting, the pump either does not respond or stops running shortly after starting. 2. Causes: a. Circuit issues such as disconnection or short circuit prevent proper operation. b. Severe component damage — for example, worn ball valves or damaged air valves — leads to loss of pressure and system shutdown. B. Blocked Inlet or Outlet Pipeline 1. Symptoms: Reduced working pressure, weak suction, and slow fluid transfer. 2. Causes: a. High-viscosity materials adhere to the inner pipe walls, reducing diameter and smoothness, increasing resistance. b. Use of multiple materials without thorough cleaning causes chemical reactions between residues, affecting normal operation. C. Severe Ball Seat Wear Continuous friction wears down the surface of the ball seat, creating gaps between the ball and seat. This may cause air leakage and reduced pump output. D. Severe Ball Valve Wear 1. Symptoms: Irregular ball shape, visible surface pitting, or heavy corrosion reducing ball diameter. 2. Causes: a. Manufacturing inconsistencies cause mismatch between the ball and seat. b. Long-term operation under friction and corrosive environments accelerates valve damage. E. Irregular Pump Operation 1. Symptoms: The pump fails to complete normal suction and discharge cycles even after adjustment. 2. Causes: a. Worn or damaged ball valve. b. Aged or broken diaphragm. c. Incorrect system settings. F. Insufficient Air Supply Pressure or Poor Air Quality Insufficient air pressure leads to reduced gas volume entering the air chamber, resulting in inadequate force to drive the connecting rod reciprocation. Increasing air pressure typically resolves this issue. Additionally, poor air quality can hinder the movement of the linkage rod and reduce motor speed, weakening pump output.