Almatec CXM Series User manual

OPERATING AND INSTALLATION INSTRUCTIONS
Air-Operated Diaphragm Pumps
made of conductive Polyethylene
CXM
Series
Special Pump CXM 20 FES-X02
Original Instruction
Read carefully before pump installation

2
CONTENTS
Page
Introduction ....................................................................................... 3
General description of the machine, appropriate use
and residual dangers ………………………………………………………………………………….. 3
Storage and long-term usage ....................................................................................... 3
Code system ....................................................................................... 4
Operation in explosion proof areas ....................................................................................... 5
Special Operations Conditions ………………………………………………………………………………… 5
Atex Marking for Gases and Dusts in Accordance to 2014/34/EU ……………………………………………….. 6
Technical data ....................................................................................... 7
Performance charts ....................................................................................... 7
Dimensions ....................................................................................... 8
Installation ....................................................................................... 9
Recommended installation ....................................................................................... 9
Start-up operation ....................................................................................... 12
Torque values ....................................................................................... 10
Safety instructions ………………………………………………………………………………….. 10
Using as submersible pump ....................................................................................... 12
Additional temperature hints ....................................................................................... 12
Disassembly and assembly advises ....................................................................................... 13
Trouble shooting ....................................................................................... 14
Spare part list ....................................................................................... 16
Exploded views ....................................................................................... 17

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 CXM 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 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 AND LONG-TERM USAGE
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 must 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)
Plastic materials are subject to aging processes depending on material, surrounding conditions and application
parameters. Chemical contact and/or increased temperature can amend material characteristics on the long run,
especially mechanical capabilities. For safety reasons, we do therefore recommend as part of every maintenance (resp.
in case of no maintenance till then after two years and then every six month): A careful visual check of all pump parts
for visible damages, a tactile check of all sealing surface (e.g. by moving a finger along the surface after cleaning), a
shape-check of the housing parts (e.g. by laying a drawer on plain surfaces) and a movability check of all threads. Any
eventually damaged part needs to be replaced!

4
CODE SYSTEM
PSG Germany GmbH is certified as a modern, quality-orientated enterprise according to DIN EN ISO 9001 and 14001.
Before release for dispatch, any pump must undergo an extended final control.
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 must 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 to clarify the ALMATEC CXM pump code:
CXM 50 F E S -X02
Special design: without tension discs but with customized housing bolts
Type and material of valves: S Valve balls, SS
Material of diaphragms and o-rings: E EPDM
Housing material: F Conductive Polyethylene
Pump size, capacity in l/min
ALMATEC air-operated double diaphragm pump, CXM series

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OPERATION IN EXPLOSION-PROOF AREAS AND FOR FLAMMABLE LIQUIDS
X= CAUTION! = Special operating conditions apply!
For pumping flammable liquids or in Ex-areas, only pumps with housing parts and internals made of
conductive plastic may be used. Air-operated diaphragm pumps of the CXM series with housing code F (PE
conductive) meet this requirement. They must generally be grounded via a connection on the right
sidehousing [1]. The ground connection must have a minimum cross-section of 6 mm2. All other housing
parts are conductive and connected to each other.
ALMATEC air-operated diaphragm pumps made of electrically conductive PE/PTFE are suitable for use in
potentially explosive atmospheres of category 2 and 3 ("Zone 1" and "Zone 2" respectively), atmosphere
G/D, which are subject to the scope of EU Directive 2014/34/EU. Conductive diaphragms (material code
68, 70, 72) can be used without restriction for pumping liquids in all explosion groups. If non-conductive
diaphragm materials are used (material code 67, 98), explosion group IIB applies within the pump for
pump size CXM 10 up to including CXM 135 (regardless of the installation site).
Pipelines and product connections must be grounded separately. To avoid ignition hazards, the formation
of dust deposits on the units must be prevented. Repairs in hazardous areas may only be carried out after
careful examination of the feasibility and only with appropriate tools and by trained specialist personnel.
The ATEX marking according to Directive 2014/34/EU can be found in the enclosed Declaration of Conformity
and the corresponding sticker on the pump or damper.
The interfaces for electrical accessories have been considered and do not represent a new potential ignition
source.
The type of protection "c = design safety" was applied in accordance with guideline EN ISO 80079-37.
SPECIAL CONDITIONS
CXM 20 FES-X02
Permissible ambient temperature (°C) [F]
-10 –50 [14 –122]
Permissible temperature of driving air (°C) [F]
0 –50 [32 –122]
Maximum driving/operating pressure (bar) [psi]
7 [101]
Maximum driving/operating temperature (X):
PE(°C) [F]:
70 [158]

6
ATEX MARKING FOR GASES AND DUSTS IN ACCORDANCE TO 2014/34/EU
In order to enable the optimum and flexible design of an ATEX pump to the customer-specific application,
a differentiation is made in the marking between the installation location of the pump (hazardous area
outside the pump) and the inside of the pump (hazardous area inside the pump).
Equipment category G (gases, mists, vapors)
Installation site: Category G
Inside the pump: Category G
Conductive ALMATEC air-operated diaphragm pumps may generally be used in explosion group IIC at the
installation site (potentially explosive area outside the pump), since the solid housings are made of
dissipative materials and the entire pump is grounded.
ATTENTION! Inside the pump, the permitted explosion group varies depending on the diaphragm material
used:
When using non-conductive diaphragms, explosion group IIB applies inside the pump:
II 2/2 G Ex h IIB/IIC T6…T4 Gb/Gb X (inside the pump/installation site)
When using conductive diaphragms, explosion group IIC applies inside the pump:
II 2/2 G Ex h IIC/IIC T6…T4 Gb/Gb X (inside the pump/installation site)
Equipment category D (dusts)
Installation site: Category D
Inside the pump: Category G
Conductive ALMATEC air-operated diaphragm pumps may generally be used in dust group IIIC at the
installation site (potentially explosive area outside the pump; equipment category D).
ATTENTION! Inside the pump (equipment category G), the approved explosion group varies depending on
the diaphragm material used:
When using non-conductive diaphragms, explosion group IIB applies inside the pump:
II 2/2 D Ex h IIB/IIIC T 70°C…130°C Gb/Db X (inside the pump/installation site)
When using conductive diaphragms, explosion group IIC applies inside the pump:
II 2/2 D Ex h IIC/IIIC T 70°C…130°C Gb/Db X (inside the pump/installation site)

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TECHNICAL DATA
NPT port connections
CXM 20
FES-X02
Dimensions, mm (in.): length
width
height
124 (4.9)
151 (5.9)
123 (4.8)
Nominal port size NPT
Air connection BSP
1/2“
1/4”
Weight, kg (lb)
1.8 (3.8)
Max. particle size of solids mm (in.)
for pumps with ball valves
2 (0.08)
Suction lift dry, mWC (ft):
Suction lift wet, mWC (ft)
1 (3.3)
8 (26.3)
Maximum driving/operating pressure (bar) [psi]
7 [101]
Maximum driving/operating temperature (X): PE(°C) [F]:
70 [158]
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
68-70
71-73
72-75
PERFORMANCE CHARTS
The data refer to water (20°C/68°F), under using of a compressor Atlas Copco VSG30 and calibrated measuring
equipment. The specified performance data are warranted by ALMATEC in accordance with DIN EN ISO 9906.

8
DIMENSIONS in mm

9
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 blind plugs
out of all connections. The connections of ALMATEC CXM pumps have slightly tapered threads. Use threadseal only
sparingly, otherwise the connections could be damaged.
Port positions CXM pumps with NPT product connections (pump sizes 10/20/50/130)
On delivery, the liquid connections of all CXM pumps are situated as follows:
Suction port “face side horizontal”, discharge port “upper side vertical” (see illustration)
By turning the center block by 180° by its longitudinal axis –after unscrewing and taking out the housing
bolts –the configuration can be changed to:
Suction port “underside vertical”, discharge port “face side horizontal”
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. Seal the suction line diligently; 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 air inlet is located at the front of the pump in the middle of the center housing [2]. 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. The integrated air control system PERSWING P®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

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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 CXM
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
Size
CXM 20 FES-X02
Torque values for housing bolts (Nm)
4
Safety instructions
•Installation, operation, and maintenance by qualified staff only.
•Before putting the pump into operation as well as after some hours of pumping, the housing bolts
[9] have to be fixed according to the torque data. 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).
•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.
•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 for the 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.