Almatec E Series User manual

Operating and Installation Instructions
E-Series
Pump Size E 80
Air-Operated Diaphragm Pumps
made of Plastic
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 and long-term usage ....................................................................................... 3
Code system ....................................................................................... 4
Operation in explosion proof areas ………………………………………………………………. 5
Special operating conditions ………………………………………………………………. 5
Technical data ....................................................................................... 7
Performance chart ....................................................................................... 7
Recommended installation ....................................................................................... 8
Installation,
operation and maintenance ....................................................................................... 8
Safety hints ....................................................................................... 9
Using as submersible pump ....................................................................................... 10
Additional temperature hints ....................................................................................... 10
Disassembly ....................................................................................... 11
Assembly ....................................................................................... 12
Troubleshooting ....................................................................................... 13
Spare parts list ....................................................................................... 15
Exploded view ....................................................................................... 16
Optional equipment
Stroke counting ………………………………………………………………. 17
Diaphragm monitoring ………………………………………………………………. 17
Pulsation damper ET 80 ....................................................................................... 18
Dimensions ....................................................................................... 21

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 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 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 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)
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!

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Code system
PSG Germany GmbH is certified as a modern, quality-orientated enterprise acc. to DIN EN ISO 9001 and 14001.
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 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 to clarify the ALMATEC pump code:
E 80 E E E - TV
Optional equipment:
BSOptional equipment
C Stroke counting
D Diaphragm monitoring
TVDamper preparation (TVD without
blind flange)
W ANSI flange
Type and material E Ball valves, EPDM
of product valves: N Ball valves, NBR
T Ball valves. PTFE
Diaphragm material: E EPDM
N NBR
T PTFE/EPDM-compound
Housing material: E PE
F PE-conductive
Size and port dimension
ALMATEC Pneumatic 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 EX-AREAS OR PUMPING 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 E series with housing codes F (PE conductive) and U
(PTFE conductive) meet this requirement. They must generally be grounded
via a connection on the central housing [4]. 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), for explosion
group IIB within the pump following protection measure (minimum one) must be taken for pump size E 80 as
examples:
- exclusive use of water-miscible or conductive pump media or
- Avoidance of dry running through operational measures or
- inerting during dry running with nitrogen, water, carbon dioxide, etc. following the
pumping operation.
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 OPERATING CONDITIONS
E80
Permissible ambient temperature °C (°F)
-10 –50 (14 –122)
Permissible temperature compressed air °C (°F)
0 –50 (32 –122)
Maximum drive and operating pressure bar (psi)
7 (101,5)
Maximum operating temperature °C (°F) (X):
70 (158)

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The ATEX marking for gases and dusts is defined as follows according 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 and performance chart
Technical data
E 80
Dimensions, mm (inch): length
width
height
700 (27.6)
627 (24.7)
844 (33.2)
Nominal port size DIN / ANSI
Air connection BSP
3”
R 3/4“
Weight, kg (lb):
207 (456)
Max. particle size of solids mm (inch)
for pumps with ball valves
15 (0.6)
Suction lift dry, mWC (ft)
Suction lift wet, mWC (ft)
3-4 (9.8-13.1)
9,5 (31.2)
Max. driving and operating pressure, bar (psig)
7 (100)
Max. operating temperature, °C (F)
70 (158)
Theoretical displacement volume
per single stroke (l)
5,1
Sound power level LWA [dB (A)]:**
driving pressure 3 bar
driving pressure 5 bar
driving pressure 7 bar
73,0-74,3
77,3-79,1
77,8-80,9
Sound pressure level Lpf, 1 m [dB (A)]:***
driving pressure 3 bar
driving pressure 5 bar
driving pressure 7 bar
58,7-60,0
63,0-64,8
63,5-66,6
** 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.
Performance data are in accordance with DIN EN ISO 9906. The data refer to water (20°C) without using of a
pulsation damper.

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Recommended installation
Installation, operation and maintenance
UV-radiation can damage the housing parts of pumps made of PE. In general, the pump has to be connected
load free. The flange connections (DIN or ANSI) of the product ports with the suction inlet horizontally at the
bottom and the discharge outlet horizontally at the top are integrated into the center housing [2] (torque value
30 Nm). 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 [19] in the center housing [2].
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 [2]. 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 [19] is located in the middle of the center housing [2]. 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®
[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 (-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 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 E-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

9
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.
Safety hints
•Before putting the pump into operation as well as after some hours of pumping, the housing
bolts [15] have to be fixed according to the torque data of 50 Nm (37 ft lbs), as the elements of
construction "settle". The valve stops discharge valve [6] and the plugs [7] have to be fixed too.
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).
•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 12/13). 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.
•Additional advice for handling sensitive Fluids: With correct material choice, all wetted parts
inside the pump are made from materials appropriate for your fluid - selected types as well for
for food contact. A malfunction, however, might result in a contact of the fluid to components
that are non-wetted during normal operation (e.g. inside the air section). Therefore, we
recommend as usual for pumps, to discard the batch after a malfunction when handling

10
sensitive fluids. Please consider that a conformity for food-contact solely refers to wetted
materials themselves, NOT to a “Hygienic Pump Construction”.
•Before putting the pump back into operation, the tightness of the pump has to be checked.
•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.
Using as submersible pump
Consider the following advises when using an E-Series pump as a submersible pump: When immersing an air-
operated diaphragm pump, it must generally be ensured that the waste air is deducted above the fluid level with
a pipe or similar. The pump must be located vertically upright to guarantee proper function. Minute leakage on
the air inlet or outlet can block the air valve. The pump must be disconnected from the pressure within the system
during standstill. When choosing the pump type, it must be taken into consideration that all external parts - even
those non-wetted during standard operation - like covers, shock absorbers, connections etc. must be resistant
to the fluid pumped. Please consider as well that depending on the material, the pump must be weight down
resp. fixed.
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 (32°F) cold-brittling of the elastomers used within the
pumps can results in accelerated wear. Regarding the housing materials, please note that PE - other than PP -
keeps its mechanical strengths at low temperatures. ALMATEC pumps of the E-Series can therefore be operated
safely as well within low-temperature installations: However, with liquids below 0°C (32°F) 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. Emptying the pump via the drainage system (optional equipment code R)
may be a useful tool to assist this.
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.

11
Disassembly
When dismantling a pump the mentioned procedures and safety notes on the previous pages have to be
considered generally. The general design of the ALMATEC E-Series is simple. Two tools are delivered along
with every pump. The plastic one of these is designed for the mounting of the air-valve [22], the other one for
the mounting of valve seat [10]. Further special tools are not required.
Take the caps out of the side housings [1] to get access to the housing bolts [15]. Unscrew the housing bolts
[15] on one side using a socket wrench and remove the side housing [1]. Work carefully to ensure that the sealing
surfaces in contact to the diaphragms are not damaged. Carefully draw the housing bolts [15] out of the pump.
The center housing [2] and both side housings [1] are removeable now. Remove the sleeve [3] out from the side
housing [1]. Take the O-rings sleeve [11] out of the center housing [2] and both side housings [1] for a possible
renewal.
For further dismantling of the side housings [1], screw out the valve stop, discharge valve [6] with an appropriate
wrench (figure 9.1). Alternatively, you can stick two housing bolts [15] into the holes in the valve stop [6] and
loosen the valve stop with a third housing bolt [15] fixed in between the others. Take out the ball valve [9] and
the O-ring, valve stop, discharge valve [12]. Use the metallic mounting tool to unscrew the valve seat [10] (figure
9.2/9.3).
The plug, side housing [7] can be unscrewed the same way as described for the valve stop [6]. Loosen the bolt,
valve stop [5] with a screw-driver and remove lock bolt [4] and ball valve [9]. Turn the mounting tool and screw
the valve seat [10] into the side housing [1] (figure 9.4). The valve seat [10] and the valve stop, discharge valve
[4] can now be removed from inside the side housing.
Screw one diaphragm [14] left-
turning off the shaft [16] and pull the
other diaphragm [14] out of the
center housing [2] using the
shaft[16]. Take set screws shaft [17]
out of the diaphragms [14] (figure
9.5). Remove both parts of the shaft
piston rings [18] from their grooves
carefully (figure 9.6); do not damage
the edges in the center housing, a
re-assembly of the same piston
rings is impossible, they have to be
replaced.
Unscrew the muffler [21], the air inlet [19] and the air filter [20] out of the center housing [2]. To remove the
PERSWING P®air control system, screw off both end caps using the plastic mounting tool delivered with the
pump (figure 9.7). Take out main and pilot piston. Push out the air valve housing with the mounting tool turned
around (figure 9.8).
figure 9.1
figure 9.2
figure 9.3
figure 9.4
figure 9.5
figure 9.6
figure 9.7
figure 9.8

12
Assembly
The re-assembly of the components is principally carried out vice-versa to the dismantling. Here are some
additional references.
For the installation of the PERSWING P®air control system, first screw in one end cap flushly into the center
housing [2]. Insert one of the six O-rings air-valve housing [24] into the end cap from the inside. Moisture the
four O-rings [24] of the air-valve housing with a bit of water and push the housing into the center housing [2]
using the mounting tool. Take care that it slips in softly. Do never insert the housing violently with a hammer. In
case the housing cocks or hardly gets in, take it out again completely and start again. Insert the main piston and
the pilot piston. Lay the sixth O-ring [24] on the edge of the air valve housing and screw in the second end cap.
To assemble new piston rings [18], carefully shape them like kidneys with
locking ring pliers and insert the rings into the grooves in the center
housing [2] (figure 10.1); completely press the rings into the grooves
smoothly using some round tool.
Screw the set screws [17] into the diaphragms and tighten them. Fix the
diaphragms [14] completely into the shaft [16] with the set screws [17].
Adjust the bores in the center housing [2] to the diaphragm on both sides
(turn slightly backwards if necessary). The sealing surfaces of the
diaphragms and the side housings [1] have to be absolutely clean and
undamaged; mere small scratches can cause leaking (if necessary,
smoothen the housing surfaces carefully with fine sandpaper).
When assembly the housing bolts pay attention to the correct
arrangement of the spring washers. The pump sizes E 80 has 6 spring
washers on both housing bolt sides. Figure 10.2 shows the arrangement.
The arrangement represented in the drawing makes an improvement of
power and way possible. Already used spring washers may not be
installed again.
Cautiously push the O-rings, sleeve [11] into the side housings [1] and the center housing [2] (avoid bending the
rings by all means! If necessary, moisture and softly twist the rings). Shove one diaphragm [14] into the center
housing [2], lay the side housing [1] onto the diaphragm and fix its position with housing bolts [15]. After that,
shove the other diaphragm [14] into the center housing [2] and carefully push the housing bolts [15] completely
through the center housing [2] [slightly turning the bolts helps them to find their way]. Take care, that the
diaphragms [14] are not damaged. Adjust the second side housing [1]. Fix the housing bolts [15] crosswise
evenly according to the given torque values until the side housings [1] are situated on the center housing [2].
Any further tightening of the bolts does not improve sealing but can deform the housing! Before putting the pump
back into operation, the tightness of the pump has to be checked.
Only use original ALMATEC spare parts for repairs and / or preventive maintenance work. If this is not observed,
the CE and ATEX markings, the declaration of conformity (s) and the guarantee claim for the pump will expire.
All work on the pump may only be carried out with the appropriate tools and by trained specialist personnel.

13
Troubleshooting
Malfunction
Possible Reason
Solutions/Remarks
pump does not operate
air supply line blocked/closed
muffler blocked
working chambers blocked
air control system defective
discharge line blocked/closed
open air supply
clean/replace muffler
remove blockage
replace air valve system
clean/open line
pump operates unsteadily
piston rings worn
air control system worn
diaphragm rupture
air control system soiled
check valve blocked
icing
replace piston rings
replace air control system
replace diaphragm, clean pump
clean/replace air control system
cleaning, removal of bulk particles
improve air processing
air within liquid
suction line leaky
container with liquid empty
diaphragm rupture
cavitation
seal suction line
fill/new container
replace diaphragm
adapt suction lift, possibly install
suction pressurised air chamber
insufficient discharge pressure
insufficient pressure/amount of
driving air
air supply line leaky
air control system leaky
check valve worn
more air consuming components
increase air supply
check/repair air supply
replace air control system
check/replace check valve
increase pressure/amount of air
output decreases
air control system soiled
icing
air pressure drop
suction line/inlet strainer soiled
discharge line/outlet strainer soiled
muffler blocked
check valve worn
change in viscosity
more air consuming components
clean/replace air control system
improve air processing: dryer/filter
ensure sufficient supply of air
cleaning
cleaning
replace the muffler
replace valve
change back/adjust pump
increase pressure/amount of air
pump stops itself
icing of the air control system
air pressure to low
air pressure drop
discharge line blocked
air filter blocked
valve closed
air control system defective
wear/leaking of air control system
diaphragm rupture
check valve blocked/worn
improve air processing:
dryer/heater etc.
increase air pressure
ensure sufficient air supply
clean discharge line
clean air filter
open valve
replace air control system
replace air control system
replace diaphragm, clean pump
clean/replace check valve

14
Malfunction
Possible Reason
Solutions/Remarks
pumps operates, however suction
capacity insufficient
pump operates too fast
operation beyond physical limits
cavitation
operation beyond pump capacity
air cushion within
suction/discharge line
dry suction against discharge
pressure
valve filter within suction line
closed
valve filter within discharge line
closed
container with liquid empty
vacuum inside the container
wear of the check valves
suction line leaky
suction line blocked
air pressure cushion at discharge
check valve blocked
start more slowly
adjust installation
check, cool down
adjust installation resp. install
bigger pump
bleed the line
wet pump, start without pressure
open valve/clean filter
open valve/clean filter
fill/new container
bleed container
replace valves
seal suction line
clean suction line
bleed discharge line
clean/replace valve
insufficient suction capacity after
pump repair
connections tighten incompletely
check valves inserted falsely
tighten/seal connections
correct positioning of check valves
diaphragm overstrained
pressure within the plant/system
inadmissible vacuum
icing
ensure that pressure is only
developed by the pump itself,
check plant/valves,
replace diaphragms
check suction line, open valve
improve air processing
leaking between housing parts
housing bolts loosened
O-rings sleeve damaged
diaphragms attacked chemically
diaphragms overstrained
tension installation/pipework
tighten bolts, check pump
replace O-rings
replace diaphragms
replace diaphragms
loosen, eliminate tension,
use of a compensator
muffler grey
driving air too humid, icing
improve quality of driving air
muffler black
soiled, oily air
improve quality of driving air,
install sensitive filter in suction line
pump is connected to air but does
not operate
air control system blocked
bulk particles/dirt
chemical influence (O-rings
swollen)
valve closed in discharge line
clean/replace air control system
clean pump, replace necessary
parts, improve air quality
check, replace damaged parts
open valve

15
Spare part list
Pump size
E 80 E..
E 80 F..
Item
Pc.
Description
Material
Part Number
Part Number
1
2
Side housing
PE/PE conductive
7 80 010 52
7 80 010 56
2
1
Center housing, DIN
Center housing, ANSI
PE/PE conductive
PE/PE conductive
7 80 011 52
7 80 411 52
7 80 011 56
7 80 411 56
2a
16
Thread bushing, center housing, DIN
Thread bushing, center housing, ANSI
1.4305
1.4305
2 40 169 22
3 40 069 22
2 40 169 22
3 40 069 22
2b
2
O-ring, center housing, code .E.
O-ring, center housing, code .T.
EPDM
FEP/FKM
9 99 629 72
9 99 629 59
9 99 629 72
9 99 629 59
2c
1
Muffler cap
PE/PE conductive
2 80 046 52
2 80 046 56
3
4
Sleeve
PE/PE conductive
2 80 012 52
2 80 012 56
4
2
Lock bolt
PE/PE conductive
2 80 113 52
2 80 113 56
5
4
Bolt, valve stop
PE
2 40 014 52
2 40 014 52
6
2
Valve stop, discharge valve
PE/PE conductive
2 80 015 52
2 80 015 56
7
2
Plug, side housing
PE/PE conductive
2 80 017 52
2 80 017 56
7a
2
O-ring, plug side housing, code .E.
O-ring, plug side housing, code .T.
EPDM
FEP/FKM
9 99 635 72
9 99 635 59
9 99 635 72
9 99 635 59
9
4
Ball valve, code ..E
Ball valve, code ..T
Ball valve, code ..N
EPDM
PTFE
NBR
1 80 032 73
15-1080-55
1 80 032 71
1 80 032 73
15-1080-55
1 80 032 71
10
4
Valve seat
PE/PE conductive
2 80 018 52
2 80 018 56
11
8
O-ring, sleeve, code .E.
O-ring, sleeve, code .T.
O-ring, sleeve, code .N.
EPDM
FEP/FKM
NBR
9 99 635 72
9 99 635 59
9 99 635 71
9 99 635 72
9 99 635 59
9 99 635 71
12
2
O-ring, valve stop, discharge valve, code .E.
O-ring, valve stop, discharge valve, code .T.
O-ring, valve stop, discharge valve, code .N.
EPDM
FEP/FKM
NBR
9 99 629 72
9 99 629 59
9 99 629 71
9 99 629 72
9 99 629 59
9 99 629 71
13
4
Shock absorbers
NR
1 80 322 85
1 80 322 85
14
2
Diaphragm, code .E.
Diaphragm, code .T.
Diaphragm, code .N.
EPDM
PTFE
NBR
1 80 031 72
1 80 031 67
1 80 031 71
1 80 031 72
1 80 031 67
1 80 031 71
15
8
Housing bolt, cpl.
1.4301
2 80 020 22
2 80 020 22
16
1
Shaft
1.4301
2 80 030 22
2 80 030 22
17
2
Set screw, shaft
1.4305
9 24 224 22
9 24 224 22
18
2
Shaft piston ring, cpl.
PTFE
1 80 041 64
1 80 041 64
19
1
Air inlet
PETP
1 80 047 84
1 80 047 84
20
1
Air filter
PE
1 40 043 51
1 40 043 51
21
1
Muffler, cpl.
diverse
15-3510-99
15-3510-99
22
1
PERSWING P® air control system, cpl.
PETP
2 80 201 84
2 80 201 84
24
6
O-ring, air valve housing (included in item 22)
NBR
9 66 533 71
9 66 533 71
Optional Equipment Code TV/TVD
Item
Pc.
Description
Material
Part Number
Part Number
Code TV/TVD: Damper preparation
2
1
Center housing, DIN
Center housing, ANSI
PE/PE conductive
7 80 811 52
7 80 911 52
7 80 811 56
7 80 911 56
2a
24
Thread bushing, center housing, DIN
Thread bushing, center housing, ANSI
1.4305
1.4305
2 40 169 22
3 40 069 22
2 40 169 22
3 40 069 22
2b
3
O-ring, center housing, code .E.
O-ring, center housing, code .T.
EPDM
FEP/FKM
9 99 629 72
9 99 629 59
9 99 629 72
9 99 629 59
30*
1
Blind flange
PE/PE conductive
2 80 067 52
2 80 067 56
-
8
Hexagon bolt DIN 933
1.4301
9 16 212 22
9 16 212 22
-
8
Washer DIN 125
1.4301
9 17 151 22
9 17 151 22
-
8
Spring washer DIN 2093
1.4301
9 16 154 22
9 16 154 22
* not for code TVD
More optional equipment on the pages 16-19.
When ordering please state the serial number of the pump.

16
Exploded view

17
Stroke counting (option code C 2, C 3, C 4)
A sensor [50] is installed in the center pump housing [2] to count the strokes. The diaphragm movement is
scanned without contact by this sensor: a safe form of monitoring totally independent of external influences and
the pump's mode of operation. The issued sensor pulses can be output to existing detectors or to a stroke
counter (can also be supplied). When the preset value is reached, the stroke counter outputs a signal which can
then be processed further, for instance in order to shut down the pump via a solenoid valve.
The stroke counting system is available in three variations:
•C 2 Stroke sensor (Namur), also for explosion-proof zone
•C 3 Stroke counting system complete with sensor and stroke counter
•C 4 Stroke counting system complete with sensor, stroke counter and controller for
explosion-proof zone
In case only the sensor is included (code C 2), it has to be connected to an existing controller with Namur inlet.
For applications an explosion-proof device is required for (code C 4) the intrinsically safe controller has to be
installed between the sensor and the counter. The wiring diagram and technical data can be found on the electric
units themselves. For further details, please refer to the data delivered by the manufacturers of the components.
The controllers have to be installed in a suitable cabinet.
Spare part list Stroke Counting
E 80
Code
Item
Pc.
Description
Material
Part-No.
C2
2*
1
Center housing DIN for
sensor, code E..
PE
7 80 111 52
50
1
Stroke sensor, Namur
diverse
1 00 072 99
-
1
O-ring, stroke sensor
NBR
9 25 535 71
C3
as C 2, but additional:
-
1
Clamp amplifier
diverse
1 00 171 99
-
1
Stroke counter
diverse
1 00 071 99
C4
as C 2, but additional:
-
1
Controller
diverse
1 00 370 99
-
1
Stroke counter
diverse
1 00 071 99
* Part-No. for center housings with ANSI connections on request
Diaphragm monitoring (option code D 1, D 3)
Although ALMATEC diaphragms with integrated metal core are designed for an optimum service life, the
diaphragm remains a wear part. If it breaks, liquid can leak into the center housing and possibly emerge through
the muffler. This can be prevented simply and effectively with the ALMATEC diaphragm monitoring.
A capacitive diaphragm sensor is mounted in the muffler adapter [21a] of the pump, which registers any liquid
approaching the sensor, no matter whether the liquid is conductive or not. Hence, a fast reaction to a damage
of a diaphragm becomes possible. However, it has to be considered, that the diaphragm monitoring possibly
cannot prevent that liquid can leave the pump via the muffler. For higher safety requirements the ALMATEC
barrier chamber system (optional equipment code BS) is recommended. In case of humid surrounding air a
false alert may occur despite operating the pump with dried compressed air.
The diaphragm monitoring system is available in two variations:
•D 1 Diaphragm sensor (Namur), also for explosion proof area
•D 3 Diaphragm monitoring system complete with sensor and controller
The diaphragm sensor can either be connected to an existing controller with Namur inlet (code D 1) or to the
controller included (code D 3). The wiring diagram and technical data can be found on the controller itself. For
further details, please refer to the data delivered by the manufacturers of the components. The controllers have
to be installed in a suitable cabinet.
Spare part list diaphragm monitoring
E 80
Code
Item
Pc.
Description
Material
Part-No.
D1
21a
1
Adapter muffler for sensor
PETP
1 80 545 84
51
1
Diaphragm sensor, Namur
diverse
1 00 773 99
D3
21a
1
Adapter muffler for sensor
PETP
1 80 545 84
51
1
Diaphragm Sensor, Namur
diverse
1 00 773 99
-
1
Controller
diverse
1 00 370 99

18
ALMATEC Pulsation Damper ET80-F for E-Series E 80 pump
The pump size E 80 of the E-Series can be equipped with an ALMATEC pulsation damper type ET80-F. The
ALMATEC pulsation dampers series ET represents the latest generation of active pulsation dampers. They are
specially designed to be used along with ALMATEC air-operated double diaphragm pumps of the E-Series.
A general aspect to be considered is, that a pulsation damper decreases the total capacity of the system
depending on the point of operation.
Before putting an ALMATEC pulsation damper into operation, make sure, that the materials of construction are
resistant to the chemical to be pumped. To check this, the exact damper code is required. This code, the serial
number and the year of construction are noted on the identification plates on the damper itself.
Example of the damper type code:
ET 80 E A E - F
flange connection DIN / PN 10 or ANSI (Fw)
Diaphragm material: E EPDM
N NBR
T PTFE/EPDM-compound
Material of damper head: A PA
F PE conductive
Material of damper housing: E PE
F PE conductive
Size, nominal connection size: DN 80
ALMATEC pulsation damper, ET series
Air supply connection: R 1/2“ BSP
Max. operating pressure: 7 bar (100 psig)
Max. operating temperature: 70°C (158°F)
Installation and operation
air connection
pump
discharge line
suction line
air supply
air connection
damper

19
For inflammable liquids as well as for applications in explosion protected areas, only dampeners made of
conductive plastic materials may be used.
In general, pump and dampener are dispatched completely mounted. Still, they can be packed in separate boxes,
especially for the bigger sizes. If so, insert the flange O-ring [30] into the groove of the flange connection of the
center housing and flange-mount the dampener with the attached screws and washers with a torque value of 30
Nm (22 ft lbs).
Before connecting the pump, take the yellow blind plugs out of air inlet which is located on the top of the
dampener head [16]. For correct operation, the dampener absolutely needs an air-supply of its own, which has
to be taken from the air-supply of the pump. Pump and pulsation dampener have to be connected to the same
air pressure. No stop or regulating valve may be placed between pump and dampener. The driving air has to be
oil-free, dry and clean. The dampener requires a minimum counter pressure of at least 1 bar for optimal function.
Together with the pump an empty dampener has to be driven slowly. The dampeners are self-regulating for all
changing operating conditions.
•Before putting the pulsation dampener into operation as well as after some hours of
operating, the housing bolts [10] have to be tightened with a torque data of 30 Nm
(22 ft lbs), as the elements of construction tend to "settle". Fixing the bolts is necessary
as well after longer periods of stoppage, at extreme temperature variations, transport
and after dismantling.
•Pressure tests of the plant a pump and a dampener are included in may only be carried
out with the aggregate (pump and dampener) disconnected from the pressure on both
ports or by using the pressure the aggregate develops while operating. The load of a
pressure in the plant may damage the pump and the pulsation dampener.
•Before starting to disassemble the pump, take care that pump and dampener have been
emptied and rinsed. Further both have to be cut off from any energy on the air and
product side. If pump and dampener 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 and the dampener
have been used for aggressive, dangerous or toxic liquids.
•Before putting the pump and the dampener back into operation, the tightness of both has
to be checked.
•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.
•For further warning instructions, please refer to pages 6-8.
Disassembly instructions
Unscrew housing bolts [10] carefully. After that, all parts can be removed. Screw the diaphragm [14] off the
actuator shaft [13]. A re-assembly of used piston rings [17] is impossible; they have to be replaced including the
O-rings underneath. To assemble new piston rings [17] carefully shape them like kidneys with locking ring pliers
and insert the rings into the grooves; completely press the rings into the grooves smoothly using some round
tool.
Spare part list
ET80-F (DIN)
ET80-Fw
(ANSI)
Item
Pc
Description
Material
Part-No.
Part-No.
1
1
Damper housing, flange, code E..
Damper housing, flange, code F..
PE
PE conductive
7 80 180 52
7 80 180 56
7 80 280 52
7 80 280 56
10
8
Housing bolt, cpl.
SS
2 80 083 22
2 80 083 22
13
1
Actuator shaft
SS
1 80 482 22
1 80 482 22
14
1
Diaphragm, code ..E
Diaphragm, code ..T
EPDM
PTFE
1 50 031 72
1 50 031 67
1 50 031 72
1 50 031 67
16
1
Damper head, code .A.
Damper head, code .F.
PA
PE conductive
2 80 081 53
2 80 081 56
2 80 081 53
2 80 081 56
17
3
Shaft piston ring, cpl.
PTFE
1 50 041 64
1 50 041 64
22
1
Muffler
PE
1 50 644 51
1 50 644 51
28
8
Hexagon bolt
SS
9 16 212 22
9 19 212 22
28a
8
Spring washer
SS
9 16 154 22
9 20 154 22
29
8
Washer
SS
9 17 151 22
9 21 151 22
30
1
Flange-O-ring, center housing, code ..E
Flange-O-ring, center housing, code ..T
Flange-O-ring, center housing, code ..N
EPDM
FEP/FKM
NBR
9 99 629 72
9 99 629 59
9 99 629 71
9 99 629 72
9 99 629 59
9 99 629 71

20
Exploded view damper
Item 10 / 28 / 28a / 29 = 8x