Almatec BIOCOR Series User manual

Operating and Installation Instructions
BIOCOR Series
B 20 / B 32 / B 40
Ought to be studied before installing the pump
Original Instruction

2
CONTENTS PAGE
Introduction ………………………………………………………………. 3
General description of the machine, appropriate use and residual dangers …………………. 3
Storage ....................................................................................... 3
Codesystem ....................................................................................... 3
Operation in explosion-proof areas ....................................................................................... 4
Technical data ....................................................................................... 5
Performance curves ....................................................................................... 5
Recommended installation ....................................................................................... 7
Installation and operation ....................................................................................... 7
Torque values ....................................................................................... 8
Safety hints ....................................................................................... 8
Additional temperature hints ....................................................................................... 9
3-A license ………………………………………………………………. 10
Usage of the magnetic ball lifters ....................................................................................... 11
CIP and SIP cleaning ....................................................................................... 11
Disassembly ....................................................................................... 11
Hints for assembly ....................................................................................... 12
Troubleshooting ....................................................................................... 14
Spare part list ....................................................................................... 16
Exploded view ....................................................................................... 17
Dimensions ....................................................................................... 18
Optional equipment ………………………………………………………………. 19

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, appropriate 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)
Codesystem
The ALMATEC Maschinenbau GmbH is certified as a modern, quality-orientated enterprise according to
DIN EN ISO 9001:2008 and 14001:2005. 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 customers order meets the mentioned
requirements.

4
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
BIOCOR Series Size, port dimension
Material combinations:
1 = Diaphragms/valve balls
PTFE, O-rings EPDM (FDA)
2 = Diaphragms/valve balls/
O-ringsPTFE
3 = Diaphragms/valve balls/
O-rings EPDM (FDA)
4 = Diaphragms/valve balls
PTFE, O-rings FKM
W1-W4= as above, but with
valve balls without metal
core and without ma
g
nets
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:
B = Barrier chamber
C = Stroke counting
D = Diaphragm monitoring
Housing material:
BN= SS316L (1.4435)
Baseler Norm II
electrolytic
polishing
* Not available on models marked with 3-A symbol.
** For models supplied marked with 3-A symbol, gaskets from SKS components shall be used in
combination with suitable rubber materials.
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.
Operation in explosion-proof areas and for inflammable liquids (Reg.-No. PTB: 03 ATEX D004)
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, atmosphere
G/D, which are liable to the 94/9/EG. 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
94/9/EG please see the attached conformity declaration. For the ATEX marking according to 94/9/EG
please see the attached conformity declaration and the according pump label.
CIP and SIP cleaning processes, which briefly exceeding the max. surface temperature T80°C, have to be
checked concerning its ATEX permissibility by the operator.

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Technical data B 20 B 32 B 40
Dimensions (mm) see page
18
see page
18
see page
18
Nominal port size (please see page 18)
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
Performance curves
The data refer to water (20°C), without using of a pulsation dampener.

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Kennlinie Biocor 40
7 bar
6 bar
5 bar
4 bar
3 bar
2 bar
0,5 Nm
3
/min
0,6 Nm
3
/min
1 Nm
3
/min
1,2
Nm
3
/min 1,4 Nm
3
/min
0,8 Nm
3
/min
0
10
20
30
40
50
60
70
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Fördermenge [m
3
/h]
WS]Förderhöhe [m
(mWC)Total head
Pump capacity (m³/h)

7
Recommended installation
Installation and operation
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 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]. 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
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.

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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. 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 hints
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 14/15). 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.
Pump 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.

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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.
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.
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.

10
3-A license
BIOCOR pump sizes B20 and B32 with the material combination 2 or 4
equipped with the option D (diaphragm monitoring, see page 18) are licensed
to display the 3-A symbol. Please pay attention to the following additional hints:
Maintenance interval
ALMATEC suggest following minimum maintenance intervals and
processes for the diaphragms and leak detection sensor:
By using the pump 24 hours a day/7 days a week the diaphragms and
leak detection sensor has to be checked every 3 months. By using the
pump in other operating conditions the diaphragms and leak detection
sensor has to be checked every 6 months.
Maintenance process diaphragms
Disassemble the pump as described on page 11. Make an optical check of the condition of the whole
pump, especially the condition of the diaphragms (general condition, surface of the product wetted
PTFE side, non product wetted EPDM side). For comparison, please use the following pictures:
←image left:
Good condition
image right →:
Bad condition
If the diaphragms are in bad conditions, they have to be replaced by new diaphragms.
Maintenance process leak detection sensor
Unscrew the muffler with the leak detection sensor from the center block of the pump. Stick the sensor
into a cup filled with water and check, that the control unit gets a signal from the sensor. If the sensor
does not fail, clean the sensor with a smooth cloth and screw the muffler back into the center block. For
screwing depth see pictures below.
If the sensor fails (no signal to the control unit), the sensor has to be removed from the muffler and to
be replaced by a new sensor. Therefore remove the failed sensor from the muffler. Check the new
sensor again (as described above). If the sensor gives a signal to the control unit, clean the sensor with
a smooth cloth and screw sensor back into the muffler. Screw the muffler back into the center block.