Almatec BIOCOR Series User manual

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2

CONTENTS
Page

Introduction…………………………………..…………………………………………….3

Generaldescriptionofthemachine,appropriateuseandresidualdangers…………….……….3

Storage.......................................................................................3

Codesystem.......................................................................................4

Operationinexplosion‐proofareas.......................................................................................5

Technicaldata.......................................................................................5

Performancecharts.......................................................................................6

Installation.......................................................................................7
Recommendedinstallation .......................................................................................7
Start‐upoperations  .......................................................................................7
Torquevalues.......................................................................................8
Safetyinstructions.......................................................................................8
Additionaltemperaturehints.......................................................................................10

Usageofthevalveliftingmagnets.......................................................................................11

CIPandSIPcleaning,EHEDGconformity................................................................................11

Maintenance........................................................................................12
Requiredtools.......................................................................................12
Disassembly.......................................................................................12
Hintsforassembly.......................................................................................14

Troubleshooting.......................................................................................16

Sparepartlist.......................................................................................18

Explodedview.......................................................................................19

Dimensions.......................................................................................20

Optionalequipment…………………………………………….…………………………………….21
Strokecounting(codeC2,C3,C4)  ………………………..………………………………………….21
Pneumaticstrokecounting(codeC9,C10)……………………………………………………..…………….21
Diaphragmmonitoring(codeD1,D3) ………………………………………………..………………….22
DiaphragmsmadeofmodifiedPTFE(codeP)………………………………………………..………………….22

3
INTRODUCTION

ALMATECair‐operateddiaphragmpumpsareconstructedaccordingtothestateoftheartandtheyare
reliable.Imminentdangerbyoperatingerrorormisusecanleadtodamagesofpropertiesand/orpersons.
Thepumpsaretobeappliedfortheintendeduseandinasafety‐relatedproperconditiononly.

EachpersonworkingontheALMATECair‐operateddiaphragmpumpsconcerninginstallation,start‐up,
handlingormaintenancehastoreadthismanualcompletelyandinanattentivewayandhastofollowall
mentionedproceduresandsafetynotes.


GENERALDESCRIPTIONOFTHEMACHINE,APPROPIATEUSEANDRESIDUALDANGERS

TheALMATECBIOCORpumpsareoscillatingpositivedisplacementpumpsand
arebasedonthefunctionalprincipleofdoublediaphragmpumps.Thebasic
configurationconsistsoftwoexternalsidehousingswithacenterhousing
betweenthem.Eachofthesidehousingscontainsaproductchamberwhichis
sealedagainstthecenterhousingbyadiaphragm.Thetwodiaphragmsare
interconnectedbyapistonrod.Directedbyanaircontrolsystem,the
diaphragmsarealternatelyloadedwithcompressedairsothattheymove
backandforth.Inthefirstfigure,thecompressedairhasforcedtheleft‐hand
diaphragmtowardstheproductchamberanddisplacedtheliquidfromthat
chamberthroughtheopenvalveatthetoptothedischargeport.Liquidis
simultaneouslydrawninbytheright‐handdiaphragm,thusrefillingthe
secondproductchamber.Whentheendofthestrokeisreached,itreverses
automaticallyandthecycleisrepeatedintheoppositedirection.Inthe
secondfigure,liquidisdrawninbytheleft‐handdiaphragmanddisplacedby
theright‐handdiaphragm.

TheappropriateuseofanAlmatecair‐operateddiaphragmpumpoftheBIOCORseriesreferstotheliquid
transporttakingintoaccounttheoperationparametermentionedinthismanualandincomplianceofthe
giventermsforcommissioning,operation,assembly,disassemblyandmaintenance.

Evenifallnecessarysafetymeasuresdescribedinthismanualhavebeenmet,aresidualdangerexistsby
leakagesormechanicaldamages.Atsealingareasorconnectionsliquidcanbereleaseduncontrollably
then.


STORAGE

IngeneraltheALMATECpumpisdeliveredoperationalandpackaged.Iftheunitisnotinstalledrightaway,
properstorageconditionsareimportantforatroublefreeoperationlater.Thepumphastobeprotected
fromwetness,coldness,dirtying,UV‐radiationandmechanicalinfluences.Thefollowingstorageconditions
arerecommended:
‐Steadyventilated,dustandvibrationfreestorageroom
‐Ambienttemperaturebetween15°Cand25°Cwitharelativehumiditybelow65%
‐Preventionofdirectthermalinfluences(sun,heating)




4
CODESYSTEM

TheALMATECMaschinenbauGmbHiscertifiedasamodern,quality‐orientatedenterpriseaccordingto
DINENISO9001:2008and14001:2004.Beforereleasefordispatch,anypumpoftheBIOCORserieshasto
undergoanextendedfinalcontrol.Theperformancedataregisteredduringthisarearchivedinourrecords
andcanbereadbackatanytime.

AsageneralruleinthecountriesoftheEUonlysuchmachinesareallowedtotakeintooperation,which
aredeterminedtomeettheregulationsoftheEUmachinerydirective,theharmonizedstandards,
Europeanstandardsandtherespectivenationalstandards.Hencetheoperatorhastoverifywhetherthe
ALMATECpumpmanufacturedanddeliveredproperlyaccordingtothecustomer’sordermeetsthe
mentionedrequirements.

Thereforemakesure,beforeputtingthepumpintooperation,thatthepumpandtheusedmaterialsof
constructionaresuitablefortheprovidedapplicationandtheinstallationsite.Tocheckthis,theexact
pumpcodeisrequired.Thiscode,theserialnumberandtheyearofconstructionarenotedonthe
identificationplatesonthepumpitself.

Exampleforapumpcode:
B 32 BN - T - 1 - C










Thenumberinbrackets,whichisaddedtoeverypartmentionedinthefollowingexplanations,referstoits
positioninthesparepartlistandtheexplodedview.

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
OPERATIONINEXPLOSION‐PROOFAREASANDFORFLAMMABLELIQUIDS

Forinflammableliquidsaswellasforapplicationsinexplosion‐proofareas,BIOCORpumpshavetobe
groundedtooneoftheM6tappingholeslocatedintheframe[7].Allotherhousingpartsareconnectedin
aconductiveway,thereforeitisnotnecessarytogroundsingleparts.

GroundedBIOCORpumpsaresuitabletobeusedinexplosionareasofthecategory2and3(„zone1“resp.
„zone2“),atmosphereG/D,whichareliabletothe2014/34/EU.Conductivediaphragms(liquidside)are
applicablewithoutrestrictionsfortransferringliquidsofanyexplosion‐group.

Whenusingnon‐conductivediaphragmmaterials,thefollowingexemplaryprotectionmeasureshavetobe
respected:
‐Thepumpisalwaysusedforthetransferofexclusivelyfluidswhichareconductiveorsolubleinwateror
‐Dry‐runningisavoidedbyactionstepswithinthefacilityand/oritscontrolor
‐ Thesystemisinertisatedincaseofdryrunningbynitrogen,water,carbondioxideetc.whenthefluid
transferends.

Pipingsystemsandproductconnectionshavetobegroundedseparately.Toavoidignitionhazardsthe
formationofdustdepositsonthepumpsmustbeprevented.Inexplosionproofareasrepairworkingonly
aftercarefulinspectionofthepracticabilityandonlywithappropriatetools.Forthemarkingaccordingto
2014/34/EUpleaseseetheattachedconformitydeclarationandtheaccordingpumplabel.

CIPandSIPcleaningprocesses(seepage11),whichbrieflyexceedingthemax.surfacetemperatureT80°C,
havetobecheckedconcerningitsATEXpermissibilitybytheoperator.


TECHNICALDATA

B20B32B40
Dimensionsseepage
20
seepage
20
seepage
20
Nominalportsize(pleaseseepage20)
Airconnection(BSP)
‐
1/4"
‐
1/4"
‐
1/2“
Weightkg(lbs)12(27)26(57)67(147)
Max.particlesizeofsolidsmm(“)3(0.12)5(0.20)9(0.35)
Suctionlift,drymWC(‘)
Suctionlift,wetmWC(‘)
2(6.6)
9(29.5)
2,5(8.2)
9(29.5)
3(9.8)
9(29.5)
Max.drivingandoperatingpressurebar(psig)7(100)7(100)7(100)
Max.operatingtemperature°C(°F)80(176)80(176)80(176)
Theoreticaldisplacementvolumepersinglestroke
(l)0.110.310.9
Soundpressurelevelacc.toDIN45635,part24,
dependingontheoperatingdata[dB(A)]: 
drivingpressure3bar
  drivingpressure5bar
drivingpressure7bar


68‐71
73‐75
74‐78


69‐71
71‐75
73‐76


76‐78
77‐80
78‐82

6
PERFORM
A

Thedatar
e
9906.
A
NCECHAR
T
e
fertowate
r
T
S
r
(20°C),wit
h
h
outusingo
f
f
apulsationdampener
a
a
ndinaccor
d
d
ancewith
D
D
INENISO

7
INSTALLATION


Recommendedinstallation



Start‐upoperations

Ingeneral,thepumphastobeconnectedloadfree.Neglectingthiscausesleakageandmaybeeven
damages.Toavoidvibrations,pulsationdampersandcompensatorsarerecommended.Beforeconnecting
thepump,taketheyellowblindplugsoutofthesuctionanddischargeconnections[4,6]aswellastheair
inlet[23].Theairinletislocatedbelowthebilingualstickerwithsafetyinstructions.

Theoperatorisresponsibleforanadequatelystabilityandanappropriatefixationofthepipingaccording
tothestateoftheart.Tofacilitatetheinstallationandmaintenanceshutoffvalvesshouldbeinstalled
rightbeforeandafterthepump.Thenominalwidthoftheconnectionpipeshastobechosenin
accordancetotheconnectionsofthepump.Asmallerpipingcancausecavitation(suctionline)aswellasa
lossofperformance(suctionanddischargeline).Incasethepipeistoobig,thedrysuctioncapacityofthe
pumpcandecrease.Connectthesuctionlinetothelowermanifold[4].Hosepipesshouldbesuitably
armoured.Asuctionlinecontinuouslyrisingwillpreventtheformationofairlocksinthelinewhichwould
affectthesuctionlift.Thedischargelinehastobeconnectedtotheuppermanifold[4].

Theairinlet[23]islocatedinthemiddleofthecenterblock[20].Whendelivereditiscoveredbya
bilingualstickerwithsafetyinstructions,whichcanbeeasilyremoved.Beforeinstallation,makesurethat
theairsupplypipeisfreeofsolids.Tosupplythepumpwithdrivingairsufficiently,thepipediameter
shouldmatchthesizeoftheairinlet.Takecarethatnodirtorparticlescanintrudeintothepumpduring
theconnection,asthesecanaccumulateinsidethepumpandcancausemalfunctions.Anairfilter[22]
directlybehindtheairinlet[23]preventstheentryofbulkparticles.

TheintegratedaircontrolsystemPERSWINGP®[22]isaprecision‐controlthatrequiresoil‐free,dryand
cleancompressedairforoptimalfunction.Ifhumidityisexpected,awaterseparatororairdryerhastobe

8
fittedtoprotectthepumpfromblockingbyice.Theidealconditionisthedewpointofairat‐20°C.In
humidsurroundings,icingfromtheoutsidemayoccurdespitethedrivingairisdried.Ifso,aprolonged
waste‐air‐exhaust(ca.500mmbypipeorhose)canbehelpful.Wheninstallingthepumpintoboardsor
cabinets,ithastobeensuredthatcoldairdoesnotgetcaughtbehindthemuffler.Inapplicationswitha
tendencytofreezingatthewasteairexhaust,goodexperiencesinpractisehavebeenachievedbypre‐
heatingthedrivingairtoincreasethedistancetothedewpointoftheair.Doingso,ithastobeconsidered
thatthedrivingairtemperaturegenerallymaynotexceed50°Ctoavoidexpansionandstickingeffectson
theairside.Thismax.airtemperatureisawellvalidwhenusingacompressorproducingwarmairwhichis
e.g.oftentruefortruckcompressors.

Thepressureofthedrivingairshouldbelimitedtotheamountrequiredtomeettheperformanceneeded.
Excessivepressureincreasesboththeairconsumptionandthewearofthepump.Thepumpisregulated
bytuningtheflowrateoftheair.Foraproperoperationatthelowerperformancerangetheregulationvia
aneedlevalveisrecommended.Anemptypumphastobedrivenslowly(e.g.viaaneedle‐valve).The
pumpstartsautomatically.PumpsoftheBIOCORseriesareself‐primingwhendry,thusitisnotnecessary
tofillthesuctionlineofthepump.Duringslowoperationofthepumpthedrysuctionliftisbetterthan
duringhighstrokefrequency.Thesuctionliftcapacityofaliquid‐filledpump,however,ismuchhigher.The
pumpisappropriateforrunningdryduringslowoperation.Dryrunningathighstrokefrequencycauses
prematurewear.Thepumpscanbriefly(uptomax.onehour)beoperatedagainstacloseddischargeline.
Throttlingonthesuctionsidemaydamagethepump.Whenthepumpoperationhasbeenstoppedbya
closeddischarge,thepressureequilibriumofthediaphragmsmustbeensured.Thiscanbeachievedby
keepingthepumpconnectedtotheairsupplypressure;forlongerstoppage,thepumpmustbereleased
fromthepressurewithinthesystemonbothfluidsideandairsupplyside.
Torquevalues
Beforeputtingthepumpintooperationaswellasaftersomehoursofoperation,the
housingbolts[8,9]havetobefixedaccordingtothetorquedataofthefollowingschedule,
astheelementsofconstruction"settle".Fixingtheboltsisnecessaryaswellafterlonger
periodsofstoppage,atextremetemperaturevariations,aftertransportanddismantling
thepump.Incaseoftemperaturevaryingbetweenextremesorhightemperature
differencebetweentheliquidandthesurrounding,thehousingboltsshouldbecontrolled
morefrequently(intervalproposalsareavailableonrequest).
PumpsizeB20B32B40
Torquevaluesforhousingbolts(Nm) 152720


Safetyinstructions

Installation,operation,andmaintenancebyqualifiedstaffonly.
Beforestart‐upofthepumpanyoneshouldacquaintoneselfwiththeexplanationsofthe
chaptertroubleshooting(seepages16/17).Onlybythisthedefectquicklycanberealized
andeliminatedincaseoftrouble.Problemswhichcannotbesolvedorwithanunknown
reasonshouldbepassedontothemanufacturer.
Beforeanymaintenanceandserviceproceduresarisingonthepumporontheoptional
equipments,thecompleteinstallationhastobeturnedoffandprotectedagainst
accidentalturnon.Thisispossiblebyalockableemergencystopfortheairsupplyofthe
pump.Additionaladangersignagainstrestartshouldbeattached.
Pressuretestsoftheplantapumpisincludedinmayonlybecarriedoutwiththepump
disconnectedfromthepressureonbothportsorbyusingthepressurethepump
developswhileoperating.Theloadofapressureintheplantmaydamagethepump.

9
AODDpumpsmustnotbeoperatedwithapositivesuctionpressure.
Dependingontheconditionsofoperation,theliquidconveyedmightescapefromthe
pumpthroughthemufflerincaseofadiaphragmrupture(inthiscasemufflerhastobe
replaced).Forfurthersafetyrequirementstheoptionalequipmentdiaphragmmonitoring
andbarrierchambersystemarerecommended.
Incaseofadiaphragmrupture,itmightbepossibleforthefluidpumpedtointrudeinto
theairsideofthepump.Inveryadverseconditions‐e.g.pressurewithinthefluidsystem
duringstoppedairsupply‐thefluidmightaswellfinditswayintotheairsupplylines.To
protectotherdeviceslikepulsationdampersorevenpneumaticvalves,itis
recommendedtoprotecttheairsupplylineaccordingly,e.g.viaanon‐returnvalve.This
wouldaswellavoidpollutingtheairsupplyline.
Thestateofthemufflerhastobeinspectedregularly,asablockedmufflercanbeforced
outofthepump.Ifthishappens,damagesofpropertiesand/orpersonscannotbe
excluded.
Iftheproducttendstosettle,thepumphastobeflushedregularly.Forlargersolidsa
filterhastobeinstalledinthesuctionline.
Incaseofdeliveryofhotliquidsthewettedpumpmustnotstandstillforalongertime,
becauseitcouldleadtotemporaryleaksinthevalveareaandtoablockadeoftheair
controlsystem.
Therelevanteffectivesecurityadviseshavetoberespected.
Poolsofliquidwhichappearinthenearouterareaofthepumphavetobeinspectedon
dangerpotential,ifnecessarysafetymeasuresaretobetaken.
Chemicalandbiologicalreactionsintheproductchamberofthepump(mixtureof
differentsubstances)andthefreezingoftheliquidhavetobeavoided.
Beforestartingtodisassemblethepump,takecarethatthepumphasbeenemptiedand
rinsed.Bothportspipingaretobeclosedanddrainedifapplicable.Furtherthepumphas
tobecutofffromanyenergyontheairandproductside.Ifthepumpisbeingdeported
fromtheplant,areferenceaboutthedeliveredliquidhastobeattached.Atemplateis
availableontheAlmatecwebsite.
Pleaserespecttherelevantadditionalsecurityadvices,ifthepumphasbeenusedfor
aggressive,dangerousortoxicliquids(e.g.suitableprotectiveequipmentaccordingto
thesafetydatasheetoftheliquid).Incaseofadiaphragmrupture,itispossiblethat
residuesoftheliquidremainbehindthediaphragms,intheareaoftheaircontrolsystem
andatthemuffler,despiteofseveralflushingprocesses.Hence,appropriatesafety
equipmentaccordingtothesafetydatasheetoftheliquidisindispensable.
Beforeputtingthepumpbackintooperation,thetightnessofthepumphastobe
checked.
PumpsoftheBIOCORseriesmustnotbesubmerged.
Air‐operateddiaphragmpumpscanleadtobruiseswhenlifting,sinkingorassembling
them.Appropriateaccessoriesandsafetyequipmentsaretobeused.Bigandheavy
moduleshavetofixedandsecuredtoliftinggearswhentransporting/replacingthem.
Especiallywhendelivercriticalliquids,wearparts,likediaphragms,shouldbereplaced
withinapreventivemaintenance.
Theuseofnon‐originalALMATECsparepartsandstructuralchangesleadtothelapseof
thewarrantyimmediately.Whenoperatingsuchapump,damagesofpropertiesand/or
personscannotbeexcluded.
Theoperationofthepumpwithnitrogenasdrivinggasispossible.Inclosedrooms
sufficientventilationmustbeprovided.
Possibleelectricalconnections(e.g.whenusingoptionalequipmentwithcontrollers)may
beexecutedbyaqualifiedpersononly.Theregulationsoftherespectivemanufacturers
aretobefollowed.
Atanyworkarisingithastobemadesurethatnoexplosiveatmospherecanappear.
Appropriatesafetyequipmentisrecommended.

10
Procedureforpumpreturn:Accordingtotherequirementsofour14001‐certification,
everyunitwhichissendtoALMATECfordiagnosisormaintenancereasonshastobe
accompaniedbyafilledoutdecontamination‐sheet.Otherwiseaprocessingisnot
possible.Thedecontamination‐sheetisenclosedtothismanual.Pleasepayattentionto
thefurthersafetyregulations.


Additionaltemperaturehints

Thetemperatureandpressurelimitationslistedonpage5aresolelybasedonmechanicaltemperature
limitsofthehousingmaterialused.Dependingonthefluidpumped,themaximumsafeoperating
temperatureofthehousingmaterialcanbereducedsignificantly.

Ageneralaspectoflowertemperaturesis,thatbelow0°Ccold‐brittlingoftheelastomersusedwithinthe
pumpscanresultsinacceleratedwear.ALMATECpumpscanthereforebeoperatedsafelyaswellwithin
low‐temperatureinstallations:However,withliquidsbelow0°Cacceleratedwearofinternalpartshasto
beaccepted.Moreover,freezing,boggingorcrystallisationofthefluidpumpedmustbeavoided,
especiallywithinthepump.

Pleaseconsider,thatviscosityandspecificgravityofmostfluidschangewithtemperature(mostoften
increasingatlowertemperature).Dependingontheapplication,thisfactmaynotonlyresultinresultina
reducedflowrate,thepumpmayevenbeunabletoprimethethickerand/or“heavier“fluidanymore.

Incaseofvaryingapplicationtemperatures,thehousingbolttensionhastobecontrolledverythoroughly,
asvariationslikethesecanchangetheeffectivetensionofthehousingboltsviathedifferentthermal
expansioncharacteristicsofsingle.