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

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

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.

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

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.

Technical data B 20 B 32 B 40

Dimensions (mm) see page

see page

Nominal port size (please see page 18)

Air connection BSP

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.

Kennlinie Biocor 40

7 bar

6 bar

5 bar

4 bar

3 bar

2 bar

0,5 Nm

/min

0,6 Nm

/min

1 Nm

/min

1,2

/min 1,4 Nm

/min

0,8 Nm

/min

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Fördermenge [m

/h]

WS]Förderhöhe [m

(mWC)Total head

Pump capacity (m³/h)

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.

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.

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.

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.

Usage of the valve lifting magnets (sizes B 20 and B 32 with material combination 1 - 4 only)Usage of the valve lifting magnets (sizes B 20 and B 32 with material combination 1 - 4 only)

Valve lifting magnets are attached to B 20 and B 32 BIOCOR pump.

These can be mounted at the position location of the four ball valves

from the outside to the pump housing. The ball valves are raised up

magnetically out of their seats and the pump is drained entirely

without having to be dismounted.

Valve lifting magnets are attached to B 20 and B 32 BIOCOR pump.

These can be mounted at the position location of the four ball valves

from the outside to the pump housing. The ball valves are raised up

magnetically out of their seats and the pump is drained entirely

without having to be dismounted.

Abb. 5.1bb. 5.1

The used magnets are strong NdFeB magnets.

Therefore an appropriate safety distance (500 mm)

must absolutely be kept to all devices and objects,

which can be damaged by magnetism or impaired in

their function. This applies in particular to persons

with cardiac pacemakers; the manufacturer data of

the implant are to be considered. Further endange

devices and objects: Credit cards, EC cards, hearing

aids, data media, televisions, monitors, computers,

video tapes, mechanical clocks, and loudspeakers.

Colliding of the magnets is to be avoided, due to their

brittleness these

The used magnets are strong NdFeB magnets.

Therefore an appropriate safety distance (500 mm)

must absolutely be kept to all devices and objects,

which can be damaged by magnetism or impaired in

their function. This applies in particular to persons

with cardiac pacemakers; the manufacturer data of

the implant are to be considered. Further endange

devices and objects: Credit cards, EC cards, hearing

aids, data media, televisions, monitors, computers,

video tapes, mechanical clocks, and loudspeakers.

Colliding of the magnets is to be avoided, due to their

brittleness these

red

can break.

red

can break.

Procedure: Pump has to run slowly; take the magnets out of the box

separately and put them individually on the pump (positions see

arrows in image on the right). The pump runs dry after a few strokes

and can be turned off. Pull the magnets individually off the pump and put them with the magnet part first

back into the box.

Procedure: Pump has to run slowly; take the magnets out of the box

separately and put them individually on the pump (positions see

arrows in image on the right). The pump runs dry after a few strokes

and can be turned off. Pull the magnets individually off the pump and put them with the magnet part first

back into the box.

CIP and SIP cleaningCIP and SIP cleaning

Basic condition for the delivery of hygienic perfect and high-quality liquids is a clean

pump. The construction of the EHEDG certified BIOCOR pumps permits the CIP as

well as the SIP cleaning. Despite the general restriction of temperature of 80°C a brief

operating (max. 30 minutes) to 130°C for purification processes is permitted, in these

cases the pump must run slowly (e.g. sterilization with steam). If a cleaning liquid is

used, this should be sucked by the pump itself without external pressure in the system.

For explosion proof areas please see the explanations on page 4.

Basic condition for the delivery of hygienic perfect and high-quality liquids is a clean

pump. The construction of the EHEDG certified BIOCOR pumps permits the CIP as

well as the SIP cleaning. Despite the general restriction of temperature of 80°C a brief

operating (max. 30 minutes) to 130°C for purification processes is permitted, in these

cases the pump must run slowly (e.g. sterilization with steam). If a cleaning liquid is

used, this should be sucked by the pump itself without external pressure in the system.

For explosion proof areas please see the explanations on page 4.

DisassemblyDisassembly

When dismantling a pump the mentioned procedures and safety notes on the pages 7-9 have to be

considered generally. The general design of the ALMATEC BIOCOR pumps is simple. A plastic tool

designed for the mounting of the air-valve [22] is delivered along with every pump. Further special tools are

not required. Please find the part number for any part in the spare part list.

When dismantling a pump the mentioned procedures and safety notes on the pages 7-9 have to be

considered generally. The general design of the ALMATEC BIOCOR pumps is simple. A plastic tool

designed for the mounting of the air-valve [22] is delivered along with every pump. Further special tools are

not required. Please find the part number for any part in the spare part list.

First unscrew the muffler [25] out of the center block [20]. Loosen the four union nuts of the suction and

discharge ports [4,6] with a hook wrench (figure 12.1), but do not unscrew complete. Loosen the two union

nuts, which connect the two pipe bends discharge side [5] with the pump housings [1], to take off the whole

discharge side of the pump. Remove O-rings pump housing [2]. Lay the pump on its back and unscrew the

nuts of the housing bolts [8,9] on one side using a socket wrench and take off the frame [4]. Loosen the two

union nuts, which connect the two pipe bends suction side [3] with the pump housings [1], to take off the

whole suction side of the pump. Remove O-rings pump housing [2] followed by the pump housing [1] itself.

So the complete discharge side, one pump housing [1], one frame [7] and the complete suction side are

dismantled (figure 12.2). Turn off the union nuts at the suction and discharge sides, so that the pipe bends

[3,5] and the suction and discharge ports [4,6] are separated. Remove valve stops [17], O-rings valve stop

[19] and valve balls [16].