Almatec BIOCOR Series User manual
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CONTENTS
Page
Introduction…………………………………..…………………………………………….3
Generaldescriptionofthemachine,appropriateuseandresidualdangers…………….……….3
Storage.......................................................................................3
Codesystem.......................................................................................4
Operationinexplosion‐proofareas.......................................................................................5
Technicaldata.......................................................................................5
Performancecharts.......................................................................................6
Installation.......................................................................................7
Recommendedinstallation .......................................................................................7
Start‐upoperations .......................................................................................7
Torquevalues.......................................................................................8
Safetyinstructions.......................................................................................8
Additionaltemperaturehints.......................................................................................10
Usageofthevalveliftingmagnets.......................................................................................11
CIPandSIPcleaning,EHEDGconformity................................................................................11
Maintenance........................................................................................12
Requiredtools.......................................................................................12
Disassembly.......................................................................................12
Hintsforassembly.......................................................................................14
Troubleshooting.......................................................................................16
Sparepartlist.......................................................................................18
Explodedview.......................................................................................19
Dimensions.......................................................................................20
Optionalequipment…………………………………………….…………………………………….21
Strokecounting(codeC2,C3,C4) ………………………..………………………………………….21
Pneumaticstrokecounting(codeC9,C10)……………………………………………………..…………….21
Diaphragmmonitoring(codeD1,D3) ………………………………………………..………………….22
DiaphragmsmadeofmodifiedPTFE(codeP)………………………………………………..………………….22
3
INTRODUCTION
ALMATECair‐operateddiaphragmpumpsareconstructedaccordingtothestateoftheartandtheyare
reliable.Imminentdangerbyoperatingerrorormisusecanleadtodamagesofpropertiesand/orpersons.
Thepumpsaretobeappliedfortheintendeduseandinasafety‐relatedproperconditiononly.
EachpersonworkingontheALMATECair‐operateddiaphragmpumpsconcerninginstallation,start‐up,
handlingormaintenancehastoreadthismanualcompletelyandinanattentivewayandhastofollowall
mentionedproceduresandsafetynotes.
GENERALDESCRIPTIONOFTHEMACHINE,APPROPIATEUSEANDRESIDUALDANGERS
TheALMATECBIOCORpumpsareoscillatingpositivedisplacementpumpsand
arebasedonthefunctionalprincipleofdoublediaphragmpumps.Thebasic
configurationconsistsoftwoexternalsidehousingswithacenterhousing
betweenthem.Eachofthesidehousingscontainsaproductchamberwhichis
sealedagainstthecenterhousingbyadiaphragm.Thetwodiaphragmsare
interconnectedbyapistonrod.Directedbyanaircontrolsystem,the
diaphragmsarealternatelyloadedwithcompressedairsothattheymove
backandforth.Inthefirstfigure,thecompressedairhasforcedtheleft‐hand
diaphragmtowardstheproductchamberanddisplacedtheliquidfromthat
chamberthroughtheopenvalveatthetoptothedischargeport.Liquidis
simultaneouslydrawninbytheright‐handdiaphragm,thusrefillingthe
secondproductchamber.Whentheendofthestrokeisreached,itreverses
automaticallyandthecycleisrepeatedintheoppositedirection.Inthe
secondfigure,liquidisdrawninbytheleft‐handdiaphragmanddisplacedby
theright‐handdiaphragm.
TheappropriateuseofanAlmatecair‐operateddiaphragmpumpoftheBIOCORseriesreferstotheliquid
transporttakingintoaccounttheoperationparametermentionedinthismanualandincomplianceofthe
giventermsforcommissioning,operation,assembly,disassemblyandmaintenance.
Evenifallnecessarysafetymeasuresdescribedinthismanualhavebeenmet,aresidualdangerexistsby
leakagesormechanicaldamages.Atsealingareasorconnectionsliquidcanbereleaseduncontrollably
then.
STORAGE
IngeneraltheALMATECpumpisdeliveredoperationalandpackaged.Iftheunitisnotinstalledrightaway,
properstorageconditionsareimportantforatroublefreeoperationlater.Thepumphastobeprotected
fromwetness,coldness,dirtying,UV‐radiationandmechanicalinfluences.Thefollowingstorageconditions
arerecommended:
‐Steadyventilated,dustandvibrationfreestorageroom
‐Ambienttemperaturebetween15°Cand25°Cwitharelativehumiditybelow65%
‐Preventionofdirectthermalinfluences(sun,heating)
4
CODESYSTEM
TheALMATECMaschinenbauGmbHiscertifiedasamodern,quality‐orientatedenterpriseaccordingto
DINENISO9001:2008and14001:2004.Beforereleasefordispatch,anypumpoftheBIOCORserieshasto
undergoanextendedfinalcontrol.Theperformancedataregisteredduringthisarearchivedinourrecords
andcanbereadbackatanytime.
AsageneralruleinthecountriesoftheEUonlysuchmachinesareallowedtotakeintooperation,which
aredeterminedtomeettheregulationsoftheEUmachinerydirective,theharmonizedstandards,
Europeanstandardsandtherespectivenationalstandards.Hencetheoperatorhastoverifywhetherthe
ALMATECpumpmanufacturedanddeliveredproperlyaccordingtothecustomer’sordermeetsthe
mentionedrequirements.
Thereforemakesure,beforeputtingthepumpintooperation,thatthepumpandtheusedmaterialsof
constructionaresuitablefortheprovidedapplicationandtheinstallationsite.Tocheckthis,theexact
pumpcodeisrequired.Thiscode,theserialnumberandtheyearofconstructionarenotedonthe
identificationplatesonthepumpitself.
Exampleforapumpcode:
B 32 BN - T - 1 - C
Thenumberinbrackets,whichisaddedtoeverypartmentionedinthefollowingexplanations,referstoits
positioninthesparepartlistandtheexplodedview.
BIOCOR Series Size, port dimension
Material combinations:
1 = Diaphragms/valve balls
PTFE,O-ringsEPDM
2 = Diaphragms/valve balls/
O-ringsPTFE
3 = Diaphragms/valve balls/
O-ringsEPDM
4 = Diaphragms/valve balls
PTFE, O-rings FKM
5 = Diaphragms/O-rings EPDM,
valve balls PTFE
All materials are FDA compliant.
W1-W5 = as above, but with
valve balls without metal
core, shock absorbers made
of stainless steel and
without magnets
Suction/discharge ports suitable
for:
A = Aseptic DIN 11864
N1 = Sanitary thread Naue
N2 = Sanitary thread Neumo
N2X= Neumo Connect S*
M = DIN 11851 connection
T = Tri-Clamp
Optional equipment:
BS = Barrier chamber
C = Stroke counting
D = Diaphragm monitoring
Housing material:
BN= SS316L (1.4435)
Baseler Norm II
electrolytic
polishing
5
OPERATIONINEXPLOSION‐PROOFAREASANDFORFLAMMABLELIQUIDS
Forinflammableliquidsaswellasforapplicationsinexplosion‐proofareas,BIOCORpumpshavetobe
groundedtooneoftheM6tappingholeslocatedintheframe[7].Allotherhousingpartsareconnectedin
aconductiveway,thereforeitisnotnecessarytogroundsingleparts.
GroundedBIOCORpumpsaresuitabletobeusedinexplosionareasofthecategory2and3(„zone1“resp.
„zone2“),atmosphereG/D,whichareliabletothe2014/34/EU.Conductivediaphragms(liquidside)are
applicablewithoutrestrictionsfortransferringliquidsofanyexplosion‐group.
Whenusingnon‐conductivediaphragmmaterials,thefollowingexemplaryprotectionmeasureshavetobe
respected:
‐Thepumpisalwaysusedforthetransferofexclusivelyfluidswhichareconductiveorsolubleinwateror
‐Dry‐runningisavoidedbyactionstepswithinthefacilityand/oritscontrolor
‐ Thesystemisinertisatedincaseofdryrunningbynitrogen,water,carbondioxideetc.whenthefluid
transferends.
Pipingsystemsandproductconnectionshavetobegroundedseparately.Toavoidignitionhazardsthe
formationofdustdepositsonthepumpsmustbeprevented.Inexplosionproofareasrepairworkingonly
aftercarefulinspectionofthepracticabilityandonlywithappropriatetools.Forthemarkingaccordingto
2014/34/EUpleaseseetheattachedconformitydeclarationandtheaccordingpumplabel.
CIPandSIPcleaningprocesses(seepage11),whichbrieflyexceedingthemax.surfacetemperatureT80°C,
havetobecheckedconcerningitsATEXpermissibilitybytheoperator.
TECHNICALDATA
B20B32B40
Dimensionsseepage
20
seepage
20
seepage
20
Nominalportsize(pleaseseepage20)
Airconnection(BSP)
‐
1/4"
‐
1/4"
‐
1/2“
Weightkg(lbs)12(27)26(57)67(147)
Max.particlesizeofsolidsmm(“)3(0.12)5(0.20)9(0.35)
Suctionlift,drymWC(‘)
Suctionlift,wetmWC(‘)
2(6.6)
9(29.5)
2,5(8.2)
9(29.5)
3(9.8)
9(29.5)
Max.drivingandoperatingpressurebar(psig)7(100)7(100)7(100)
Max.operatingtemperature°C(°F)80(176)80(176)80(176)
Theoreticaldisplacementvolumepersinglestroke
(l)0.110.310.9
Soundpressurelevelacc.toDIN45635,part24,
dependingontheoperatingdata[dB(A)]:
drivingpressure3bar
drivingpressure5bar
drivingpressure7bar
68‐71
73‐75
74‐78
69‐71
71‐75
73‐76
76‐78
77‐80
78‐82
6
PERFORM
A
Thedatar
e
9906.
A
NCECHAR
T
e
fertowate
r
T
S
r
(20°C),wit
h
h
outusingo
f
f
apulsationdampener
a
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ndinaccor
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ancewith
D
D
INENISO
7
INSTALLATION
Recommendedinstallation
Start‐upoperations
Ingeneral,thepumphastobeconnectedloadfree.Neglectingthiscausesleakageandmaybeeven
damages.Toavoidvibrations,pulsationdampersandcompensatorsarerecommended.Beforeconnecting
thepump,taketheyellowblindplugsoutofthesuctionanddischargeconnections[4,6]aswellastheair
inlet[23].Theairinletislocatedbelowthebilingualstickerwithsafetyinstructions.
Theoperatorisresponsibleforanadequatelystabilityandanappropriatefixationofthepipingaccording
tothestateoftheart.Tofacilitatetheinstallationandmaintenanceshutoffvalvesshouldbeinstalled
rightbeforeandafterthepump.Thenominalwidthoftheconnectionpipeshastobechosenin
accordancetotheconnectionsofthepump.Asmallerpipingcancausecavitation(suctionline)aswellasa
lossofperformance(suctionanddischargeline).Incasethepipeistoobig,thedrysuctioncapacityofthe
pumpcandecrease.Connectthesuctionlinetothelowermanifold[4].Hosepipesshouldbesuitably
armoured.Asuctionlinecontinuouslyrisingwillpreventtheformationofairlocksinthelinewhichwould
affectthesuctionlift.Thedischargelinehastobeconnectedtotheuppermanifold[4].
Theairinlet[23]islocatedinthemiddleofthecenterblock[20].Whendelivereditiscoveredbya
bilingualstickerwithsafetyinstructions,whichcanbeeasilyremoved.Beforeinstallation,makesurethat
theairsupplypipeisfreeofsolids.Tosupplythepumpwithdrivingairsufficiently,thepipediameter
shouldmatchthesizeoftheairinlet.Takecarethatnodirtorparticlescanintrudeintothepumpduring
theconnection,asthesecanaccumulateinsidethepumpandcancausemalfunctions.Anairfilter[22]
directlybehindtheairinlet[23]preventstheentryofbulkparticles.
TheintegratedaircontrolsystemPERSWINGP®[22]isaprecision‐controlthatrequiresoil‐free,dryand
cleancompressedairforoptimalfunction.Ifhumidityisexpected,awaterseparatororairdryerhastobe
8
fittedtoprotectthepumpfromblockingbyice.Theidealconditionisthedewpointofairat‐20°C.In
humidsurroundings,icingfromtheoutsidemayoccurdespitethedrivingairisdried.Ifso,aprolonged
waste‐air‐exhaust(ca.500mmbypipeorhose)canbehelpful.Wheninstallingthepumpintoboardsor
cabinets,ithastobeensuredthatcoldairdoesnotgetcaughtbehindthemuffler.Inapplicationswitha
tendencytofreezingatthewasteairexhaust,goodexperiencesinpractisehavebeenachievedbypre‐
heatingthedrivingairtoincreasethedistancetothedewpointoftheair.Doingso,ithastobeconsidered
thatthedrivingairtemperaturegenerallymaynotexceed50°Ctoavoidexpansionandstickingeffectson
theairside.Thismax.airtemperatureisawellvalidwhenusingacompressorproducingwarmairwhichis
e.g.oftentruefortruckcompressors.
Thepressureofthedrivingairshouldbelimitedtotheamountrequiredtomeettheperformanceneeded.
Excessivepressureincreasesboththeairconsumptionandthewearofthepump.Thepumpisregulated
bytuningtheflowrateoftheair.Foraproperoperationatthelowerperformancerangetheregulationvia
aneedlevalveisrecommended.Anemptypumphastobedrivenslowly(e.g.viaaneedle‐valve).The
pumpstartsautomatically.PumpsoftheBIOCORseriesareself‐primingwhendry,thusitisnotnecessary
tofillthesuctionlineofthepump.Duringslowoperationofthepumpthedrysuctionliftisbetterthan
duringhighstrokefrequency.Thesuctionliftcapacityofaliquid‐filledpump,however,ismuchhigher.The
pumpisappropriateforrunningdryduringslowoperation.Dryrunningathighstrokefrequencycauses
prematurewear.Thepumpscanbriefly(uptomax.onehour)beoperatedagainstacloseddischargeline.
Throttlingonthesuctionsidemaydamagethepump.Whenthepumpoperationhasbeenstoppedbya
closeddischarge,thepressureequilibriumofthediaphragmsmustbeensured.Thiscanbeachievedby
keepingthepumpconnectedtotheairsupplypressure;forlongerstoppage,thepumpmustbereleased
fromthepressurewithinthesystemonbothfluidsideandairsupplyside.
Torquevalues
Beforeputtingthepumpintooperationaswellasaftersomehoursofoperation,the
housingbolts[8,9]havetobefixedaccordingtothetorquedataofthefollowingschedule,
astheelementsofconstruction"settle".Fixingtheboltsisnecessaryaswellafterlonger
periodsofstoppage,atextremetemperaturevariations,aftertransportanddismantling
thepump.Incaseoftemperaturevaryingbetweenextremesorhightemperature
differencebetweentheliquidandthesurrounding,thehousingboltsshouldbecontrolled
morefrequently(intervalproposalsareavailableonrequest).
PumpsizeB20B32B40
Torquevaluesforhousingbolts(Nm) 152720
Safetyinstructions
Installation,operation,andmaintenancebyqualifiedstaffonly.
Beforestart‐upofthepumpanyoneshouldacquaintoneselfwiththeexplanationsofthe
chaptertroubleshooting(seepages16/17).Onlybythisthedefectquicklycanberealized
andeliminatedincaseoftrouble.Problemswhichcannotbesolvedorwithanunknown
reasonshouldbepassedontothemanufacturer.
Beforeanymaintenanceandserviceproceduresarisingonthepumporontheoptional
equipments,thecompleteinstallationhastobeturnedoffandprotectedagainst
accidentalturnon.Thisispossiblebyalockableemergencystopfortheairsupplyofthe
pump.Additionaladangersignagainstrestartshouldbeattached.
Pressuretestsoftheplantapumpisincludedinmayonlybecarriedoutwiththepump
disconnectedfromthepressureonbothportsorbyusingthepressurethepump
developswhileoperating.Theloadofapressureintheplantmaydamagethepump.
9
AODDpumpsmustnotbeoperatedwithapositivesuctionpressure.
Dependingontheconditionsofoperation,theliquidconveyedmightescapefromthe
pumpthroughthemufflerincaseofadiaphragmrupture(inthiscasemufflerhastobe
replaced).Forfurthersafetyrequirementstheoptionalequipmentdiaphragmmonitoring
andbarrierchambersystemarerecommended.
Incaseofadiaphragmrupture,itmightbepossibleforthefluidpumpedtointrudeinto
theairsideofthepump.Inveryadverseconditions‐e.g.pressurewithinthefluidsystem
duringstoppedairsupply‐thefluidmightaswellfinditswayintotheairsupplylines.To
protectotherdeviceslikepulsationdampersorevenpneumaticvalves,itis
recommendedtoprotecttheairsupplylineaccordingly,e.g.viaanon‐returnvalve.This
wouldaswellavoidpollutingtheairsupplyline.
Thestateofthemufflerhastobeinspectedregularly,asablockedmufflercanbeforced
outofthepump.Ifthishappens,damagesofpropertiesand/orpersonscannotbe
excluded.
Iftheproducttendstosettle,thepumphastobeflushedregularly.Forlargersolidsa
filterhastobeinstalledinthesuctionline.
Incaseofdeliveryofhotliquidsthewettedpumpmustnotstandstillforalongertime,
becauseitcouldleadtotemporaryleaksinthevalveareaandtoablockadeoftheair
controlsystem.
Therelevanteffectivesecurityadviseshavetoberespected.
Poolsofliquidwhichappearinthenearouterareaofthepumphavetobeinspectedon
dangerpotential,ifnecessarysafetymeasuresaretobetaken.
Chemicalandbiologicalreactionsintheproductchamberofthepump(mixtureof
differentsubstances)andthefreezingoftheliquidhavetobeavoided.
Beforestartingtodisassemblethepump,takecarethatthepumphasbeenemptiedand
rinsed.Bothportspipingaretobeclosedanddrainedifapplicable.Furtherthepumphas
tobecutofffromanyenergyontheairandproductside.Ifthepumpisbeingdeported
fromtheplant,areferenceaboutthedeliveredliquidhastobeattached.Atemplateis
availableontheAlmatecwebsite.
Pleaserespecttherelevantadditionalsecurityadvices,ifthepumphasbeenusedfor
aggressive,dangerousortoxicliquids(e.g.suitableprotectiveequipmentaccordingto
thesafetydatasheetoftheliquid).Incaseofadiaphragmrupture,itispossiblethat
residuesoftheliquidremainbehindthediaphragms,intheareaoftheaircontrolsystem
andatthemuffler,despiteofseveralflushingprocesses.Hence,appropriatesafety
equipmentaccordingtothesafetydatasheetoftheliquidisindispensable.
Beforeputtingthepumpbackintooperation,thetightnessofthepumphastobe
checked.
PumpsoftheBIOCORseriesmustnotbesubmerged.
Air‐operateddiaphragmpumpscanleadtobruiseswhenlifting,sinkingorassembling
them.Appropriateaccessoriesandsafetyequipmentsaretobeused.Bigandheavy
moduleshavetofixedandsecuredtoliftinggearswhentransporting/replacingthem.
Especiallywhendelivercriticalliquids,wearparts,likediaphragms,shouldbereplaced
withinapreventivemaintenance.
Theuseofnon‐originalALMATECsparepartsandstructuralchangesleadtothelapseof
thewarrantyimmediately.Whenoperatingsuchapump,damagesofpropertiesand/or
personscannotbeexcluded.
Theoperationofthepumpwithnitrogenasdrivinggasispossible.Inclosedrooms
sufficientventilationmustbeprovided.
Possibleelectricalconnections(e.g.whenusingoptionalequipmentwithcontrollers)may
beexecutedbyaqualifiedpersononly.Theregulationsoftherespectivemanufacturers
aretobefollowed.
Atanyworkarisingithastobemadesurethatnoexplosiveatmospherecanappear.
Appropriatesafetyequipmentisrecommended.
10
Procedureforpumpreturn:Accordingtotherequirementsofour14001‐certification,
everyunitwhichissendtoALMATECfordiagnosisormaintenancereasonshastobe
accompaniedbyafilledoutdecontamination‐sheet.Otherwiseaprocessingisnot
possible.Thedecontamination‐sheetisenclosedtothismanual.Pleasepayattentionto
thefurthersafetyregulations.
Additionaltemperaturehints
Thetemperatureandpressurelimitationslistedonpage5aresolelybasedonmechanicaltemperature
limitsofthehousingmaterialused.Dependingonthefluidpumped,themaximumsafeoperating
temperatureofthehousingmaterialcanbereducedsignificantly.
Ageneralaspectoflowertemperaturesis,thatbelow0°Ccold‐brittlingoftheelastomersusedwithinthe
pumpscanresultsinacceleratedwear.ALMATECpumpscanthereforebeoperatedsafelyaswellwithin
low‐temperatureinstallations:However,withliquidsbelow0°Cacceleratedwearofinternalpartshasto
beaccepted.Moreover,freezing,boggingorcrystallisationofthefluidpumpedmustbeavoided,
especiallywithinthepump.
Pleaseconsider,thatviscosityandspecificgravityofmostfluidschangewithtemperature(mostoften
increasingatlowertemperature).Dependingontheapplication,thisfactmaynotonlyresultinresultina
reducedflowrate,thepumpmayevenbeunabletoprimethethickerand/or“heavier“fluidanymore.
Incaseofvaryingapplicationtemperatures,thehousingbolttensionhastobecontrolledverythoroughly,
asvariationslikethesecanchangetheeffectivetensionofthehousingboltsviathedifferentthermal
expansioncharacteristicsofsingle.
11
Abb. 5.1
USAGEOFTHEVALVELIFTINGMAGNETS
ValveliftingmagnetsareattachedtoB20andB32BIOCORpumps
withthematerialcombinations1‐5.Thesecanbemountedatthe
positionlocationofthefourballvalvesfromtheoutsidetothe
pumphousing.Theballvalvesareraisedupmagneticallyoutof
theirseatsandthepumpisdrainedentirelywithouthavingtobe
dismounted.
TheusedmagnetsarestrongNdFeBmagnets.
Thereforeanappropriatesafetydistance(500mm)
mustabsolutelybekepttoalldevicesandobjects,
whichcanbedamagedbymagnetismorimpairedin
theirfunction.Thisappliesinparticulartopersons
withcardiacpacemakers;themanufacturerdataof
theimplantaretobeconsidered.Further
endangereddevicesandobjects:Creditcards,EC
cards,hearingaids,datamedia,televisions,
monitors,computers,videotapes,mechanical
clocks,andloudspeakers.Collidingofthemagnetsis
tobeavoided,duetotheirbrittlenessthesecan
break.
Procedure:Pumphastorunslowly;takethemagnetsoutoftheboxseparatelyandputthemindividually
onthepump(positionsseearrowsinfigure11.1ontheright).Thepumprunsdryafterafewstrokesand
canbeturnedoff.Pullthemagnetsindividuallyoffthepumpandputthemwiththemagnetpartfirstback
intothebox.
CIPANDSIPCLEANING,EHEDGCONFORMITY
Basicconditionforthedeliveryofhygienicperfectandhigh‐qualityliquidsisaclean
pump.ThedesignofthepumppermitstheCIPaswellastheSIPcleaning.Despitethe
generalrestrictionoftemperatureof80°Cabriefoperating(max.30minutes)to
130°Cforpurificationprocessesispermitted,inthesecasesthepumpmustrunslowly
(e.g.sterilizationwithsteam).Ifacleaningliquidisused,thisshouldbesuckedbythe
pumpitselfwithoutexternalpressureinthesystem.Forexplosionproofareasplease
seetheexplanationsonpage5.
DuetothemissingvalveliftingmagnetsthepumpsizeB40aswellasthematerial
combinationsW1‐W5areEHEDGcompliantonlywhenthepumpisdrainedmanually
(slowoperationofthepumpwithoutliquidinawaythatthepumpcanseepempty).
B
B
figure 11.1
12
MAINTENANCE
Requiredtools
ThegeneraldesignoftheALMATECBIOCORpumpsissimple.Aplastictooldesignedforthemountingof
theair‐valve[22]isdeliveredalongwitheverypump.
ToollistPumpsizeBIOCOR20 BIOCOR32BIOCOR40
PosDescriptionKindofToolToolSizeToolSizeToolSize
3Pipebend,suctionside(unionnut)Hookwrench,lug
[DIN1810,Form
A]
40‐42+
45‐50
45‐50+
68‐75
64+
85‐92
5Pipebend,dischargeside(unionnut)Hookwrench,lug
[DIN1810,Form
A]
40‐42+
45‐50
45‐50+
68‐75
64+
85‐92
8Housingbolt,cpl.,short Open‐end/Box
Wrench/Socket
Spanner
10mm 13mm‐
9Housingbolt,cpl.,long Open‐end/Box
Wrench/Socket
Spanner
10mm 13mm13mm
12Nut,DIN1587Open‐end/Box
Wrench/Socket
Spanner
10mm 10mm10mm
14Setscrew,shaft,DIN913HexagonalKey5mm6mm8mm
22PERSWINGP®aircontrolsystem,cpl.ALMATEC‐Tool 11590154
23AirinletOpen‐endWrench19mm27mm27mm
Disassembly
Whendismantlingapumpthementionedproceduresandsafetynotesonthepages7‐10havetobe
consideredgenerally.Pleasefindthepartnumberforanypartinthesparepartlist.
Firstunscrewthemuffler[25]outofthecenterblock[20].Loosenthefourunionnutsofthesuctionand
dischargeports[4,6]withahookwrench(figure13.1),butdonotunscrewcomplete.Loosenthetwo
unionnuts,whichconnectthetwopipebendsdischargeside[5]withthepumphousings[1],totakeoff
thewholedischargesideofthepump.RemoveO‐ringspumphousing[2].Laythepumponitsbackand
unscrewthenutsofthehousingbolts[8,9]ononesideusingasocketwrenchandtakeofftheframe[4].
Loosenthetwounionnuts,whichconnectthetwopipebendssuctionside[3]withthepumphousings[1],
totakeoffthewholesuctionsideofthepump.RemoveO‐ringspumphousing[2]followedbythepump
housing[1]itself.Sothecompletedischargeside,onepumphousing[1],oneframe[7]andthecomplete
suctionsidearedismantled(figure13.2).Turnofftheunionnutsatthesuctionanddischargesides,sothat
thepipebends[3,5]andthesuctionanddischargeports[4,6]areseparated.Removevalvestops[17],O‐
ringsvalvestop[19]andvalveballs[16].
13
Workcarefullytoensurethatthesealingsurfacesincontacttothediaphragmsarenotdamaged.Screw
onediaphragm[15]left‐turningofftheshaft[13].Carefullypulloutthehousingbolts[8,9],sothesecond
pumphousing[1]andthesecondframe[7]arealsodismantled.Taketheotherdiaphragm[15]alongwith
theshaft[13]outofthecenterblock[20].Unscrewthesetscrewsshaft[14]offthediaphragms[15]
(figure13.3).RemovepistonringsandO‐ringsoftheshaftpistonrings[21]fromtheirgroovescarefully
(figure13.4);donotdamagetheedgesinthecenterblock[20].Are‐assemblyofthesamepistonringsis
impossible,theyhavetobereplaced.Unscrewtheairinlet[23]andtheairfilter[24]outofthecenter
block[20].ToremovethePERSWINGP®aircontrolsystem[22],screwoffbothendcapsusingtheplastic
mountingtoolsuppliedwiththepump(figure13.5).Takeoutmainandpilotpiston.Pushouttheairvalve
housingwiththemountingtoolturnedaround(figure13.6).
figure 13.1
figure 13.2
figure 13.3
figure 13.4 figure 13.5 figure 13.6
14
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m
Spraythe
t
valvestop
[
tobeavoi
d
sideinth
e
fig
u
s
sembly
e
mblyofthe
h
ints.
t
allationof
t
c
k[20].Turn
o
mtheinsid
e
randpusht
o
neverinse
a
gaincompl
e
edgeofthe
mphousing
necessary,
ontotheh
o
s
ideofthep
u
o
uslyflatter
.
4
).
s
econddiap
c
kwardsifn
Installthe
o
mpressthe
m
e[7](don
o
t
hreadsoft
h
[
17]intoth
e
d
ed).Onthe
e
pipebend
u
re 14.1
figure 14.2
componen
t
t
hePERSWI
N
thecenter
b
e
ofcenter
b
hehousingi
rtthehousi
n
e
telyandst
a
airvalveho
Toass
e
theml
i
inthe
groove
Screw
Screw
o
intot
h
diaphr
a
bolts[
housin
g
s[1]havet
o
smoothen
t
o
usingbolts
u
mphousin
g
.
Pushthedi
hragm[15]
ecessary)a
n
secondpu
m
pumphou
s
o
tforgetth
e
h
eports[4,
6
e
suction[4]
suctionsid
e
[5].Toins
t
t
sisprincipa
N
G
P
®[22]ai
b
lock[20]an
b
lock[20].
M
ntothecen
t
n
gviolently
a
rtagain.In
s
usingandsc
e
mbleane
w
i
kekidneys
w
centerblo
c
ssmoothly
u
thesetscr
e
o
nediaphra
g
ecenterbl
o
a
gm(turns
l
8,9](figure
g
bolts[8,9]
o
beabsolu
t
t
hehousing
[
8,9](figure
g
[1].Theh
o
scsontoth
e
i
ntothesha
n
dcarefully
m
phousing
[
s
ings[1]an
d
e
disc)andti
g
6
]andthep
a
nddischar
g
e
placethe
b
t
alltheval
v
llycarriedo
i
rcontrolsy
s
dinsertone
M
oisturethe
t
erblock[2
0
withaham
m
s
ertthemai
n
c
rewinthes
e
w
pistonrin
w
ithlocking
c
k[20](fig
u
u
singsome
r
e
wsshaft[1
4
g
m[15]wit
h
o
ck[20],a
d
l
ightlyback
w
14.2),pay
(B20/B32o
n
t
elycleana
n
surfacesc
a
14.3),paya
t
o
leatthesu
c
e
lowerandl
ft[13],adju
pushtheh
o
[
1],payatt
e
d
thecenter
g
htentheh
o
umphousin
g
eports[6]
a
b
allvalves[
1
v
estops[1
7
figure 14.3
utvice‐vers
a
s
tem,firsts
c
ofthesixO
‐
fourO‐ring
s
0
]usingthe
m
m
er.Incase
n
pistonand
e
condendc
a
g
ofthesh
a
ringpliers
a
u
re14.1);c
o
r
oundtool.
4
]intothe
d
h
setscrews
justthebo
r
w
ardsifne
c
attentiont
o
n
ly).Thesea
n
dundamag
a
refullywit
h
t
tentiontot
c
tionsideh
a
ongerhousi
stwiththe
o
usingbolts
e
ntiontoth
e
block[20]
b
o
usingbolts
g[1]withT
e
a
swellasin
t
1
6]inthes
u
7
]insertth
e
a
tothedis
m
c
rewinone
‐
ringsair‐val
[29]ofthe
m
ountingto
o
thehousing
thepilotpis
a
p.
a
ftpistonri
n
ndinsertth
e
o
mpletelyp
r
d
iaphragms
haft[14]int
o
r
esinthec
e
essary)and
o
thetwo
d
lingsurface
s
e
d;meres
m
h
finesand
p
herightdir
e
snearlyari
g
n
gbolts[9]
a
b
oresinthe
[8,9]compl
e
flowdirec
t
b
yusingas
c
[
8,9]onlylo
o
e
flon‐Spray.
t
othepipe
b
u
ctionport[
4
pinofthe
m
antling.He
endcapflu
s
l
vehousing
[
air‐valveho
o
l.Takecar
e
g
cocksorh
a
s
ton.Laythe
n
g[21],car
e
eringsinto
resstheri
n
[15]andti
g
o
theshaft[
enterblock
fixitwith
t
differentle
n
s
ofthediap
m
allscratch
e
p
aper).Pus
h
e
ctionofthe
g
htangle,t
h
a
ndinstallt
h
e
centerblo
c
l
etethroug
h
tionagain.
crewclamp
.
o
se.
Carefullyin
b
ends[3,5](
b
4
]andont
h
valvestop
figure 14.4
rearesome
s
hlyintothe
[
29]intothe
u
singwitha
e
thatitslips
rdlygetsin,
sixthO‐ring
e
fullyshape
thegrooves
n
gsintothe
g
htenthem.
13],insertit
[20]tothe
t
hehousing
n
gthofthe
hragms[15]
e
scancause
h
thepump
suctionand
h
edischarge
h
eframe[7]
c
k[20](turn
h
thecenter
Ifnecessary
Mountthe
sertO‐rings
b
ucklinghas
h
edischarge
[17]inthe
appropriat
e
Screwthe
discharge
p
InsertO‐ri
n
suctionan
d
thepump
h
thentightl
y
housingb
o
values(se
e
centerblo
improves
e
unionnuts
Beforeput
t
e
notchof
s
unionnuts
o
p
orts[6]loo
s
n
gspumph
d
discharge
s
h
ousings[1]
y
alleight
u
o
lts[8,9]cr
o
e
page8)un
ck[20].An
e
alingbutc
a
againwith
a
t
ingthepu
m
s
uction[4]
o
o
fthepipe
b
s
ebyhand
ousing[2].
s
ideswitht
h
loosely.Fir
s
u
nionnuts
w
o
sswiseeve
n
tilthepum
p
yfurthert
a
ndeformt
h
a
hookwren
c
m
pbackinto
o
rdischarge
b
ends[3,5]
o
Screwthe
c
h
ecorrespo
n
s
tlightlyscr
e
w
ithahoo
k
n
lyaccordin
g
p
housings[
ighteningo
f
h
ehousing!
c
h.
operation,t
h
port[6](fi
g
o
nthesucti
c
ompletep
r
ndingunion
e
whousing
b
k
wrench.N
o
gtothegi
v
1]aresitua
t
fthebolts
Finallyscre
w
h
etightness
g
ure15.1).
on[4]and
r
e‐installed
nutsonto
b
olts[8,9],
o
wfixthe
v
entorque
t
edonthe
doesnot
w
alleight
ofthepum
p
p
hastobec
c
hecked.
figure 15.1
15
16
TROUBLESHOOTING
MalfunctionPossibleReasonSolutions/Remarks
pumpdoesnotoperatenoairsupply
airsupplylineblocked/closed
mufflerblocked
workingchambersblocked
aircontrolsystemdefective
dischargelineblocked/closed
openairsupply
clean/openairsupply
clean/replacemuffler
removeblockage
replaceairvalvesystem
clean/openline
pumpoperatesunsteadilypistonringsworn
aircontrolsystemworn
diaphragmrupture
aircontrolsystemsoiled
ballvalveblocked
icing
replacepistonrings
replaceaircontrolsystem
replacediaphragm,cleanpump
clean/replaceaircontrolsystem
cleaning,removalofbulkparticles
improveairprocessing
airwithinliquidsuctionlineleaky
containerwithliquidempty
diaphragmrupture
cavitation
sealsuctionline
fill/newcontainer
replacediaphragm
adaptsuctionlift,possiblyinstall
suctionpressurisedairchamber
insufficientdischargepressureinsufficientpressure/amountofdriving
air
airsupplylineleaky
aircontrolsystemleaky
ballvalveworn
moreairconsumingcomponents
increaseairsupply
check/repairairsupply
replaceaircontrolsystem
check/replaceballvalve
increasepressure/amountofair
outputdecreasesaircontrolsystemsoiled
icing
airpressuredrop
suctionline/inletstrainersoiled
dischargeline/outletstrainersoiled
mufflerblocked
ballvalveworn
changeinviscosity
moreairconsumingcomponents
clean/replaceaircontrolsystem
improveairprocessing:dryer/filter
ensuresufficientsupplyofair
cleaning
cleaning
replacethemuffler
replacevalve
changeback/adjustpump
increasepressure/amountofair
pumpstopsitselficingoftheaircontrolsystem
airpressuretolow
airpressuredrop
dischargelineblocked
airfilterblocked
valveclosed
aircontrolsystemdefective
wear/leakingofaircontrolsystem
diaphragmrupture
ballvalveblocked/worn
improveairprocessing:dryer/heater
etc.
increaseairpressure
ensuresufficientairsupply
cleandischargeline
cleanairfilter
openvalve
replaceaircontrolsystem
replaceaircontrolsystem
replacediaphragm,cleanpump
clean/replaceballvalve
17
MalfunctionPossibleReasonSolutions/Remarks
pumpsoperates,howeversuction
capacityinsufficient
pumpoperatestoofast
operationbeyondphysicallimits
cavitation
operationbeyondpumpcapacity
aircushionwithinsuction/discharge
line
drysuctionagainstdischargepressure
valvefilterwithinsuctionlineclosed
valvefilterwithindischargelineclosed
containerwithliquidempty
vacuuminsidethecontainer
wearofthecheckvalves
suctionlineleaky
suctionlineblocked
airpressurecushionatdischarge
ballvalveblocked
startmoreslowly
adjustinstallation
checkinstallation,checktemperature,
cooldown
adjustinstallationresp.installbigger
pump
bleedtheline
wetpump,startwithoutpressure
openvalve/cleanfilter
openvalve/cleanfilter
fill/newcontainer
bleedcontainer
replacevalves
sealsuctionline
cleansuctionline
bleeddischargeline
clean/replacevalve
insufficientsuctioncapacityafter
pumprepair
connectionstightenincompletelytighten/sealconnections,
cleansealingarea
diaphragmoverstrainedpressurewithintheplant/system
inadmissiblevacuum
icing
ensurethatpressureisonly
developedbythepumpitself,check
plant/valves,
replacediaphragms
checksuctionline,openvalve
improveairprocessing
leakingbetweenhousingpartshousingboltsloosened
diaphragmsattackedchemically
diaphragmsoverstrained
tensioninstallation/pipework
disassemblethepump,cleansealing
area,tightenhousingboltsaccording
tothetorquevalues
replacediaphragms
replacediaphragms
loosen,eliminatetension,
useofacompensator
mufflergreydrivingairtoohumid,icingimprovequalityofdrivingair
mufflerblacksoiled,oilyairimprovequalityofdrivingair,
installsensitivefilterinsuctionline
pumpisconnectedtoairbutdoes
notoperate
aircontrolsystemblocked
bulkparticles/dirt
chemicalinfluence(O‐ringsswollen)
valveclosedindischargeline
clean/replaceaircontrolsystem
cleanpump,replacenecessaryparts,
improveairquality
check,replacedamagedparts
openvalve
liquidleavesthepumpviathe
muffler
diaphragmrupturereplacediaphragms,
cleanpump
18
SPAREPARTLIST
Allpartsinitalicsarenotproductwetted.B20B32B40
ItemPc.DescriptionMaterialPartnumberPartnumberPartnumber
12PumphousingSS316L520140405321404054014040
24O‐ring,pumphousing*EPDM(FDA)917557739236687393559473
4O‐ring,pumphousing*PTFE917557609236686093559460
4O‐ring,pumphousing*FKM917557949236689493559494
32Pipebend,suctionsideSS316L520138405321384054013840
41Suctionport,codeA(DIN11864)SS316L520441405324414054044140
1Suctionport,codeN1(Naue)SS316L520041405320414054004140
1Suctionport,codeN2(Neumo)SS316L520141405321414054014140
1Suctionport,CodeN2X(NeumoConnectS)SS316L520541405325414054054140
1Suctionport,codeM(DIN11851)SS316L520241405322414054024140
1Suctionport,codeT(Tri‐Clamp)SS316L520341405323414054034140
52Pipebend,dischargesideSS316L520139405321394054013940
61Dischargeport,codeA(DIN11864)SS316L520442405324424054044240
1Dischargeport,codeN1(Naue)SS316L520042405320424054004240
1Dischargeport,codeN2(Neumo)SS316L520142405321424054014240
1Dischargeport,CodeN2X(NeumoConnectS)SS316L520542405325424054054240
1Dischargeport,codeM(DIN11851)SS316L520242405322424054024240
1Dischargeport,codeT(Tri‐Clamp)SS316L520342405323424054034240
72Frame1.4404520143235321432354014323
82Housingbolt,cpl.,short1.43015201542253215422‐
94**Housingbolt,cpl.,long1.4301520156225321562254015622
104ShockabsorberEPDM115022781150227814002278
10a4Shockabsorber1.4301******115022221150222214002222
114**Disc,DIN125PTFE906151609061516090815160
124Nut,DIN15871.4305906106229061062290610622
131Shaft1.4301520145225321452254014522
142Setscrew,shaft,DIN9131.4305910220229122212291622222
152Diaphragm*PTFE115031671250316714003167
2Diaphragm*EPDM(FDA)115031731250317314003173
164Valveball*EPDMmetalcore(FDA)***11503282***12503282***‐
4Valveball*PTFEmetalcore***11503289***12503289***14003269
174ValvestopSS316L520044405320444054004440
184Setscrew,DIN71.4301902401229024012290240122
198O‐ring,valvestop*EPDM(FDA)923668739375287395852573
8O‐ring,valvestop*PTFE923668609375286095852560
8O‐ring,valvestop*FKM923668949375289495852594
201CenterblockPEconductive520053565320535654005356
212Shaftpistonring,cpl.PTFE115041641250416414004164
221PERSWINGP®aircontrolsystem,cpl.PETP520101845201018454010184
231AirinletPETP115047841150478414004784
241AirfilterPE115043511150435114004351
251MufflerPE115244511152445114024451
296O‐ring,airvalvehousing****NBR935504719355047194651571
304Valveliftingmagnet*****1.4301/NdFeB5200462253204622‐
* dependsonthematerialcombination(1‐5resp.W1–W5)**B40:8pieces
***B40:Valveballswithoutmetalcore;materialcombinationsW1‐W4valveballswithoutmetalcore:partnumberending73insteadof82
(forEPDMvalveballs)and69insteadof89(forPTFEvalveballs)
****includedinitem22*****notforB40andmaterialcombinationsW1–W5******formaterialcombinationW1‐W5only
Pleaseseepage4forexplanationofthepumpcode.Whenorderingpleasestatetheserialnumberofthepump.Forspecialconstructionsofthe
Biocorpump(forexampleX01ascodeending)pleaseseeseparatesparepartlist.
19
EXPLODEDVIEW
20
DIMENSIONS
mmABCDE F G H J KLM
B20244381150189123 216 216 25 6.5 6R1/4“ 105
B32284484200246173 256 261 25 17.5‐ R1/4“ 105
B40462681270335228 419 401 40 6‐ R1/2“ ‐
inchABCDE F G H J KLM
B209.615.05.97.44.8 8.5 8.5 1.0 0.260.24R1/4“ 4.1
B3211.219.17.99.76.8 10.1 10.3 1.0 0.69‐ R1/4“ 4.1
B4018.226.810.613.29.0 16.5 15.8 1.6 0.24‐ R1/2“ ‐
PortsCodeA
(DIN11864)
CodeM
(DIN11851)CodeN1CodeN2CodeT
B20Rd44x1/6“
(DN20)
Rd44x1/6“
(DN20)
M36x2
(DN20)
M36x2
(DN20)
1“
Tri‐Clamp
B32Rd58x1/6“
(DN32)
Rd58x1/6“
(DN32)
M52x2
(DN32)
M52x2
(DN32)
11/2“
Tri‐Clamp
B40Rd65x1/6“
(DN40)
Rd65x1/6“
(DN40)
M56x2
(DN40)
M56x2
(DN40)
2“
Tri‐Clamp
CodeN2X:Dimensionsonrequest!
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