Almatec E 10 User manual

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2
CONTENTS

    Page

Introduction.......................................................................................3 
Generaldescriptionofthemachine,appropriateuseandresidualdangers………………………... 3
Storage.......................................................................................3
Codesystem.......................................................................................4
Operationinexplosionproofareas …………………………………………………………………………….……. 5
Technicaldata.......................................................................................5
Performancecharts.......................................................................................6
Installation
Recommendedinstallation  .......................................................................................8
Productports.......................................................................................8
Startupoperations.......................................................................................9
Torquevalues.......................................................................................10
Safetyinstructions.......................................................................................10
Usingassubmersiblepump  .......................................................................................11
Additionaltemperaturehints .......................................................................................12
Providingspareparts.......................................................................................12
Maintennance
Requiredtools.......................................................................................13
Disassembly.......................................................................................13
Assembly.......................................................................................15
Troubleshooting.......................................................................................16
Sparepartlists
CodeEEE–ETZ.......................................................................................18
CodeTEE–TTZ.......................................................................................19
CodeFEE–FTZ.......................................................................................20
CodeUEE–UTZ.......................................................................................21
Explodedviews
E08/E10.......................................................................................22
E15/E25/E40/E50.......................................................................................23
Optionalequipment
Strokecounting(codeC).......................................................................................24
Diaphragmmonitoring(D)  .......................................................................................25
Specialdiaphragms(L+P)………………………………………………………………………………….. 26
ANSIconnections(W)………………………………………………………………………………….. 26
Flangeconnections(F).......................................................................................27
Pumpsforfoodcontact(H)  .......................................................................................27
Damperpreparation(TV)  .......................................................................................27
Drainingsystem(R).......................................................................................28
FKMhousinggaskets(V).......................................................................................29
Externalcontrol(Z).......................................................................................29
Moreoptions……..................................................................................29
Dimensionsdrawing.......................................................................................30
PulsationdampeET/ET‐F.......................................................................................31


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E‐Series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E‐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(59°F)and25°C(77°F)witharelativehumiditybelow65%
‐Preventionofdirectthermalinfluences(sun,heating)




4
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E‐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toclarifytheALMATECpumpcode:

E  15 T T T ‐  R

Optionalequipment(separatemanualforcodeBS, 
separatesparepartslistsforcodesOG,ZandX):
BS Barrierchambersystem
C Strokecounting
D Diaphragmmonitoring
F FlangeconnectionPN10
H Pumpforfoodcontact(EC1935/2004)
L ConductivePTFE/EPDMcompounddiaphragm
OGPumpwithoutinnerthreads
P DiaphragmmadeofmodifiedPTFE
R Drainingsystem
TV Pumppreparedforpulsationdamper
V FKMhousinggasketswithPTFEdiaphragms
W ANSIproductports
Z Externalcontrolled
X Customizedsolutions

TypeandmaterialE Ballvalves,EPDM
ofproductvalves:N  Ballvalves,NBR
T Ballvalves.PTFE
S Ballvalves,stainlesssteel
Z Cylindervalves,PTFE

Diaphragmmaterial: E EPDM
N NBR
T PTFE/EPDMcompound

Housingmaterial:E PE
F PEconductive
T PTFE
U PTFEconductive

  Size,portdimension

ALMATECair‐operateddiaphragmpump,E‐Series

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.

5
OPERATIONINEXPLOSION‐PROOFAREASANDFORFLAMMABLELIQUIDS(REG.‐NO.PTB:03ATEXD004)

Forflammableliquidsaswellasforapplicationsinexplosion‐proofareas,onlypumps
withhousingsandfittingsinconductiveplasticmaterialsmaybeused.AODDpumpsof
theE‐SerieswiththehousingcodesF(PEconductive)andU(PTFEconductive)meetthis
requirement.Thepumphastobegrounded.Aconnectiontogroundthepumpis
includedinthecenterhousing[4].Allotherhousingpartsareconnectedtothecenter
housing;thereforeitisnotnecessarytogroundsingleparts.
ALMATECE‐SeriespumpsmadeofelectricallyconductivePE/PTFE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ATEXmarkingaccording
to94/9/EGpleaseseetheattachedconformitydeclarationandtheaccordingpumplabel.

TECHNICALDATAE08E10E15E25E40E50
Dimensions,mm(in.):  length
width
height
88(3.5)
128(5.0)
129(5.1)
110(4.3)
147(5.8)
169(6.7)
166(6.5)
189(7.4)
240(9.4)
220(8.7)
255(10.0)
320(12.6)
304(12.0)
353(13.9)
432(17.0)
399(15.7)
430(16.9)
552(21.7)
NominalportsizeNPT
AirconnectionBSP
1/4“
R1/8
3/8“
R1/8
1/2“
R1/4
1“
R1/4
11/2“
R1/2
2“
R1/2
Weight,kg(lb):PE
PTFE
‐
2(4)
‐
5(11)
7(15)
12(26)
15(33)
29(64)
34(75)
69(152)
66(146)
131(289)
Max.particlesizeofsolids mm(in.)
forpumpswithballvalves2(0.08)3(0.12)4(0.16)6(0.24)9(0.35)11(0.43)
Suctionliftdry,mWC(ft): cylindervalves
        ballvalves
Suctionliftwet,mWC(ft)
1(3.3)
0,4(1.3)
9(29.5)
2(6.6)
1(3.3)
9(29.5)
3(9.8)
2(6.6)
9,5(31.2)
4(13.1)
3(9.8)
9,5(31.2)
5(16.4)
4(13.1)
9,5(31.2)
5(16.4)
4(13.1)
9,5(31.2)
Max.drivingandoperatingpressure,bar(psig)7(100)7(100)7(100)7(100)7(100)7(100)
Max.operatingtemperature,°C(F): PE
         PTFE*
‐
100(212)
‐
100(212
70(158)
120(248)
70(158)
120(248)
70(158)
120(248)
70(158)
120(248)
Theoreticaldisplacementvolume
persinglestroke(l)0,00750,02150,10,340,982,6
SoundpowerlevelLWA[dB(A)]:**
drivingpressure3bar
drivingpressure5bar
drivingpressure7bar

77,5‐84,0
80,0‐86,5
80,2‐87,0

79,5‐81,0
79,5‐85,0
79,5‐86,0

77,0‐89,0
75,0‐94,0
74,0‐96,0

74,0‐84,2
68,6‐87,8
70,0‐91,0

82,2‐86,6
72,2‐95,5
68,5‐94,4

66,6‐84,9
73,5‐91,5
67,3‐96,0
SoundpressurelevelLpf,1m[dB(A)]:***
drivingpressure3bar
drivingpressure5bar
drivingpressure7bar

64,1‐70,3
66,2‐73,1
66,8‐73,8

65,9‐67,5
65,7‐70,8
65,7‐72,1

63,2‐74,9
60,9‐80,1
60,3‐82,0

61,7‐71,9
56,3‐75,5
57,7‐78,8

69,5‐73,9
59,5‐82,8
55,8‐81,7

53,4‐71,7
60,3‐78,3
54,1‐82,8
*  PTFEpumpswithNBRequipment80°C(176°F)
** determinedinsoundpowerlevelmeasurementsaccordingtoENISO3744respectivelyENISO9614inlaboratoryandpractise
conditions
***soundpressurelevelsasaveragelocation‐independentvaluescalculatednorm‐conformousfromthelocationofthesound
powerlevelslistedabove

ThesetechnicaldatarefertoALMATECE‐Seriespumpswithoutoptionalequipment.


6
PERFORMANCE CHARTS
Thedatarefertowater(20°C/68°F),underusingofdifferentvariations(e.g.ballvalvemodel,damper
preparationetc.),acompressorAtlasCopcoVSG30andcalibratedmeasuringequipment.Thespecified
performancedataarewarrantedbyALMATECinaccordancewithDINENISO9906.





















































7











































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
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
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

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



8
INSTALLATION

Recommendedinstallation



Productports

Theproductportsareintegratedintothecenterhousing[4].Differentportconfigurationscanbeobtained
(withoutusingofascrewedpulsationdamperonly).ThestandardconfigurationoftheE‐Seriesatdeliveryis
withthesuctioninlethorizontallyatthebottomandthedischargeoutlethorizontallyatthetop(figure8.1).
Furtherpossibleconfigurations:
Suctioninletverticallyatthebottom,thedischargeoutlethorizontallyatthetop(figure8.2)
Toobtainthisconfiguration,theplugofthecenterhousing[13]hastoberemovedandsetinthe
standardinlet.
Suctioninlethorizontallyatthebottom,thedischargeoutletverticallyatthetop(figure8.3)
Unscrewthehousingbolts[19],takeoffthesidehousings[1]andturnthecenterhousing[4].
Remountthepumpandadjusttheplug[13]accordingly.






 







fig. 8.1 fig. 8.2 fig. 8.3

9
Startupoperations

UV‐radiationcandamagethehousingpartsofpumpsmadeofPE(materialcodeEandF).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aswellastheairinlet[23]inthecenter
housing[4].Theairinletislocatedbelowthebilingualstickerwithsafetyinstructions.Theconnectionsof
ALMATECair‐operateddiaphragmpumpsmadeofplastichaveslightlytaperedthreads.Usethreadsealonly
sparingly,otherwisetheconnectionscouldbedamaged.

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connectioninthecenterhousing[4].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[23]islocatedinthemiddleofthecenterhousing[4].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[24]directlybehindtheair
inlet[23](notincludedinE08andE10)preventstheentryofbulkparticles.

TheintegratedaircontrolsystemPERSWINGP®[26]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(‐4°F).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/20inch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(122°F)toavoidexpansionandsticking
effectsontheairside.Thismaximum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E‐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.
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

10
Torquevalues

Immediatelybeforeputtingthepumpintooperationaswellasaftersomehoursofpumping,
thehousingbolts[19]havetobefixedaccordingtothetorquedataofthefollowingschedules,
astheelementsofconstruction"settle".Thevalvestopsdischargevalve[9]andtheplugs
[11/13]havetobefixedtoo.Asaremindertheairinlet[23]iscoveredbyacorresponding
stickeratdeliverycondition.Fixingallthesepartsisnecessaryaswellafterperiodsof
stoppage,at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).Thefollowingschedulesshowthetorquevaluesofthepumphousing
bolts,ofthedamperhousingbolts(whenusingapulsationdamperoftheET‐Series)andofthe
optionalflangeconnection(optionalequipmentcodesF3/F4/F5).
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Safetyinstructions
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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.
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.
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.
PumpsizeE08E10E15E25E40E50
Torquevaluesforhousingbolts‐Nm(ftlbs):
PEpumps
PTFEpumps

‐
2(1.5)

‐
4,5(3.3)

8,5(6.3)
6,5(4.8)

14(10.3)
11(8.1)

18(13.3)
15(11.1)

23(17)
19(14)
DampersizeET10ET15ET25ET40ET50
Torquevaluesfordamperhousingbolts
Nm(ftlbs):  PEdamper
PTFEdamper

‐
2(1.5)

3(2.2)
3(2.2)

6(4.4)
6(4.4)

10(7.4)
10(7.4)

11(8.1)
11(8.1)
PumpsizeE15E25E40E50
Torquevaluesforflangeconnections‐Nm(ftlbs):4(3)5(3.7)12(8.9) 15(11.1)