Dover Almatec Biocor Series User manual

Operating and Installation Instructions
ALMATEC Series
B I O C O R
B 20 / B 32
ought to be studied before
installing the pump
CONTENTS PAGE
Introduction ....................................................................................... 2
Operation in explosion-proof areas ....................................................................................... 3
Technical data ....................................................................................... 3
Performance curves ....................................................................................... 3
Installation and operation ....................................................................................... 4
3-A approval ………………………………………………………………. 6
Usage of the magnetic ball lifters ....................................................................................... 6
CIP and SIP cleaning ....................................................................................... 6
Disassembly ....................................................................................... 7
Hints for assembly ....................................................................................... 8
Troubleshooting ....................................................................................... 10
Spare part list ....................................................................................... 12
Exploded view ....................................................................................... 13
Dimensions ....................................................................................... 14
Accessories ………………………………………………………………. 15

2
Introduction
The ALMATEC Maschinenbau GmbH is certified as a modern, quality-orientated enterprise according to
DIN EN ISO 9001:2000. Before release for dispatch, any BIOCOR pump 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. The item number, the serial number and the year of construction of the pump are noted on the
identification plates on the pump itself.
Before putting any pump into operation, make sure, that the materials of construction are resistant to the
chemical to be pumped. To check this, the exact pump code is required.
Example for a pump code:
B 32 BN - T - 1 - C
The number in brackets, which is added to every part mentioned in the following explanations, refers to its
position in the spare part list and the exploded view.
Operation in explosion-proof areas and for inflammable liquids (Reg.-No. PTB: 03 ATEX D004)
For inflammable liquids as well as for applications in explosion-proof areas, BIOCOR pumps have to be
grounded to one of the M6 tapping holes located in the frame [7]. All other housing parts are connected in a
conductive way, therefore it is not necessary to ground single parts.
Grounded BIOCOR pumps of are electro-statically suitable to be used within any explosive areas. As well
following electrostatic reasons, conductive diaphragms (liquid side) are suitable 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 conductive and 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. The “X” in the
following marking stands for the max. operating temperature, which is 80°C for the BIOCOR series.
BIOCOR Series Size, port dimension
Material combinations:
1 = Diaphragms/valve balls
PTFE, O-rings EPDM (FDA)
2 = Diaphragms/valve balls/
O-ringsPTFE
3 = Diaphragms/valve balls/
O-rings EPDM (FDA)
4 = Diaphragms/valve balls
PTFE
,
O-rin
g
s FKM
Suction/discharge ports suitable
for:
A = Aseptic DIN 11864
N1 = Sanitary thread Naue
N2 = Sanitary thread Neumo
N2X= Neumo Connect S
M = Sanitary thread DIN 11851
T = Tri-Clamp
Optional equipment:
B = Barrier chamber
C = Stroke counting
D = Diaphragm monitoring
Marking Ex according to 94/9/EG
II 2G TX
Housing material:
BN= SS316L (1.4435)
Baseler Norm II
electrolytic
polishing

3
Technical data B 20 B 32
Dimensions (mm): length
width
height
see
page
12
see
page
12
Nominal port size (please see page 12)
Air connection
-
R 1/4“
-
R 1/4“
Weight (kg) 12 26
Max. particle size of solids (mm) 3 5
Suction lift, dry (mWC)
Suction lift, wet (mWC)
2
9
2.5
9
Max. driving and operating pressure (bar) 7 7
Max. operating temperature (°C) 80 80
Theoretical displacement volume
per single stroke (l) 0,11 0,31
Sound pressure level acc. to DIN 45635, part 24,
depending on the operating data [dB (A)]:
driving pressure 3 bar
driving pressure 5 bar
driving pressure 7 bar
68-71
73-75
74-78
69-71
71-75
73-76
Performance curves
The data refer to water (20°C), without using of a pulsation dampener.

4
Recommended installation
Installation and operation
In general, the pump has to be connected load free. Neglecting this causes leakage and maybe even
damages. To avoid vibrations, pulsation dampers and compensators are recommended. Before connecting
the pump, take the yellow blind plugs out of the suction and discharge connections [4,6] as well as the air
inlet [23].
To facilitate the installation and maintenance shut off valves should be installed right before and after the
pump. The nominal width of the connection pipes has to be chosen in accordance to the connections of the
pump. A smaller piping can cause cavitation (suction line) as well as a loss of performance (suction and
discharge line). In case the pipe is too big, the dry suction capacity of the pump can decrease. Connect the
suction line to the lower manifold [4]. Hosepipes should be suitably armoured. A suction line continuously
rising will prevent the formation of air locks in the line which would affect the suction lift. The discharge line
has to be connected to the upper manifold [4].
The air inlet [23] is located in the middle of the center block [20]. Before installation, make sure that the air
supply pipe is free of solids. To supply the pump with driving air sufficiently, the pipe diameter should match
the size of the air inlet. Take care that no dirt or particles can intrude into the pump during the connection,
as these can accumulate inside the pump and can cause malfunctions. An air filter [22] directly behind the
air inlet [23] prevents the entry of bulk particles.
The integrated air control system PERSWING P®[22] is a precision-control that requires oil-free, dry and
clean compressed air for optimal function. If humidity is expected, a water separator or air dryer has to be
fitted to protect the pump from blocking by ice. The ideal condition is the dewpoint of air at -20°C. In humid
surroundings, icing from the outside may occur despite the driving air is dried. If so, a prolonged waste-air-
exhaust (ca. 500 mm by pipe or hose) can be helpful. When installing the pump into boards or cabinets, it
has to be ensured that cold air does not get caught behind the muffler.
The pressure of the driving air has to 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. An empty pump has to be driven slowly (e.g. via a needle-valve). The
pump starts automatically. Pumps of the BIOCOR series are self-priming when dry, thus it is not necessary
to fill the suction line of the pump. The suction lift capacity of a liquid-filled pump, however, is much higher.
The pump is appropriate for running dry during slow operation. Dry running at high stroke frequency causes

5
premature wear.The maximum permissible stroke frequencies can be found in the following table. 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.
Pump size B 20 B 32
Max. number of strokes/min. during
nominal performance 280 200
•Before putting the pump into operation as well as after some hours of operation, the
housing bolts [8,9] have to be fixed according to the torque data of the following
schedule, as the elements of construction "settle". Fixing the bolts is necessary as well
after longer periods of stoppage, at extreme temperature variations, after transport and
dismantling the pump.
Pump size B 20 B 32
Torque values for housing bolts (Nm) 15 27
•Installation, operation, and maintenance by qualified staff only.
•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.
•Pneumatic diaphragm 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 (muffler has to be renewed).
For further safety requirements the optional equipment diaphragm monitoring and
barrier chamber system are recommended.
•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.
•The relevant effective security advises have to be respected.
•Pumps of the BIOCOR series must not be submerged.
•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.
•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 a
sufficient ventilation must be provided.
•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.

6
Abb. 5.1
figure 6.1
3-A approval
BIOCOR pumps with the material combination 2 or 4 equipped with the option
D (diaphragm monitoring, see page 14) are 3-A approved. Please pay attention
to the following additional hints:
•The pump has to be installed with a minimum distance of 100 mm
between the floor and the suction port and 50 mm between the floor
and the frame.
•The function of the leak detection sensor can be tested easily by
approaching the sensor to any kind of liquid. The operating signal of
the sensor has to be used for fail save to assure a well operating
sensor at any time. If the leak detection sensor triggers an alarm, the
air supply to the pump has to be stopped immediately.
Usage of the valve lifting magnets
Valve lifting magnets are attached to every BIOCOR pump. These
can be mounted at the position location of the four ball valves from
the outside to the pump housing. The ball valves are raised up
magnetically out of their seats and the pump is drained entirely
without having to be dismounted.
The used magnets are strong NdFeB magnets.
Therefore an appropriate safety distance (500 mm)
must absolutely be kept to all devices and objects,
which can be damaged by magnetism or impaired in
their function. This applies in particular to persons
with cardiac pacemakers; the manufacturer data of
the implant are to be considered. Further endangered
devices and objects: Credit cards, EC cards, hearing
aids, data media, televisions, monitors, computers,
video tapes, mechanical clocks, and loudspeakers.
Colliding of the magnets is to be avoided, due to their
brittleness these can break.
Procedure: Pump has to run slowly; take the magnets out of the box
separately and put them individually on the pump (positions see
arrows in figure 6.1). The pump runs dry after a few strokes and can
be turned off. Pull the magnets individually off the pump and put them with the magnet part first back into
the box.
CIP and SIP cleaning
Basic condition for the delivery of hygienic perfect and high-quality liquids is a clean
pump. The construction of the EHEDG certified BIOCOR pumps permits the CIP as
well as the SIP cleaning. Despite the general restriction of temperature of 80°C a brief
operating (max. 30 minutes) to 130°C for purification processes is permitted, in these
cases the pump must run slowly (e.g. sterilization with steam). If a cleaning liquid is
used, this should be sucked by the pump itself without external pressure in the
system.
B
B

7
Disassembly
The general design of the ALMATEC BIOCOR pumps is simple. A plastic tool designed for the mounting of
the air-valve [22] is delivered along with every pump. Further special tools are not required. Please find the
part number for any part in the spare part list.
•Before starting to disassemble the pump, take care that the pump has been emptied
and rinsed. Further the pump has to be cut off from any energy on the air and product
side. If the pump is being removed from the plant, a reference sheet 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.
•Before putting the pump back into operation, the tightness of the pump has to be
checked.
First unscrew the muffler [25] out of the center block [20]. Loosen the four union nuts of the suction and
discharge ports [4,6] with a hook wrench (figure 7.1), but do not unscrew complete. Loosen the two union
nuts, which connect the two pipe bends discharge side [5] with the pump housings [1], to take off the whole
discharge side of the pump. Remove O-rings pump housing [2]. Lay the pump on its back and unscrew the
nuts of the housing bolts [8,9] on one side using a socket wrench and take off the frame [4]. Loosen the two
union nuts, which connect the two pipe bends suction side [3] with the pump housings [1], to take off the
whole suction side of the pump. Remove O-rings pump housing [2] followed by the pump housing [1] itself.
So the complete discharge side, one pump housing [1], one frame [7] and the complete suction side are
dismantled (figure 7.2). Turn off the union nuts at the suction and discharge sides, so that the pipe bends
[3,5] and the suction and discharge ports [4,6] are separated. Remove valve stops [17], O-rings valve stop
[19] and valve balls [16].
Work carefully to ensure that the sealing surfaces in contact to the diaphragms are not damaged. Screw one
diaphragm [15] left-turning off the shaft [13]. Carefully pull out the housing bolts [8,9], so the second pump
housing [1] and the second frame [7] are also dismantled. Take the other diaphragm [15] along with the
shaft [13] out of the center block [20]. Unscrew the set screws shaft [14] off the diaphragms [15] (figure 7.3).
Remove piston rings and O-rings of the shaft piston rings [21] from their grooves carefully (figure 8.1); do
not damage the edges in the center block [20]. A re-assembly of the same piston rings is impossible, they
have to be replaced. Unscrew the air inlet [23] and the air filter [24] out of the center block [20]. To remove
the PERSWING P®air control system [22], screw off both end caps using the plastic mounting tool supplied
with the pump (figure 8.2). Take out main and pilot piston. Push out the air valve housing with the mounting
tool turned around (figure 8.3).
figure 7.1
figure 7.2
figure 7.3

8
Hints for assembly
The re-assembly of the components is principally carried out vice-versa to the dismantling. Here are some
additional hints.
For the installation of the PERSWING P®[22] air control system, first screw in one end cap flushly into the
center block [20]. Turn the center block [20] and insert one of the six O-rings air-valve housing [29] into the
end cap from the inside of center block [20]. Moisture the four O-rings [29] of the air-valve housing with a bit
of water and push the housing into the center block [20] 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 [29]
on the edge of the air valve housing and screw in the second end cap.
To assemble a new piston ring of the shaft piston ring [21], carefully shape
them like kidneys with locking ring pliers and insert the rings into the grooves in
the center block [20] (figure 8.4); completely press the rings into the grooves
smoothly using some round tool.
Screw the set screws shaft [14] into the diaphragms [15] and tighten them.
Screw one diaphragm [15] with set screw shaft [14] into the shaft [13], insert it
into the center block [20], adjust the bores in the center block [20] to the
diaphragm (turn slightly backwards if necessary) and fix it with the housing
bolts [8,9] (figure 8.5), pay attention to the two different length of the housing
bolts [8,9]. The sealing surfaces of the diaphragms [15] and the pump 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). Push the pump
housing [1] onto the housing bolts [8,9] (figure 8.6), pay attention to the right direction of the suction and
discharge side of the pump housing [1]. The hole at the suction side has nearly a right angle, the discharge
one is obviously flatter. Push the discs onto the lower and longer housing bolts [9] and install the frame [7]
(figure 8.7).
.
figure 8.1 figure 8.2 figure 8.3
figure 8.4
figure 8.5 figure 8.6 figure 8.7

9
Screw the second diaphragm [15] into the shaft [13], adjust with the bores in the center block [20] (turn
slightly backwards if necessary) and carefully push the housing bolts [8,9] complete through the center block
[20]. Install the second pump housing [1], pay attention to the flow direction again. If necessary carefully
compress the pump housings [1] and the center block [20] by using a screw clamp. Mount the second frame
[7] (do not forget the disc) and tighten the housing bolts [8,9] only
loose.
Spray the threads of the ports [4,6] and the pump housing [1] with
Teflon-Spray. Carefully insert O-rings valve stop [17] into the suction
[4] and discharge ports [6] as well as into the pipe bends [3,5] (buckling
has to be avoided). On the suction side place the ball valves [16] in the
suction port [4] and on the discharge side in the pipe bend [5]. To
install the valve stops [17] insert the pin of the valve stop [17] in the
appropriate notch of suction [4] or discharge port [6] (figure 9.1). Screw
the union nuts of the pipe bends [3,5] on the suction [4] and discharge
ports [6] loose by hand
Insert O-rings pump housing [2]. Screw the complete pre-installed suction and discharge sides with the
corresponding union nuts onto the pump housings [1] loosely. First lightly screw housing bolts [8,9], then
tightly all eight union nuts with a hook wrench. Now fix the housing bolts [8,9] crosswise evenly according to
the given torque values (see page 4) until the pump housings [1] are situated on the center block [20]. Any
further tightening of the bolts does not improve sealing but can deform the housing! Finally screw all eight
union nuts again with a hook wrench.
Before putting the pump back into operation, the tightness of the pump has to be checked.
Notes
figure 9.1

10
Troubleshooting
Malfunction Possible Reason Solutions/Remarks
pump does not operate no air supply
air supply line blocked/closed
muffler blocked
working chambers blocked
air control system defective
discharge line blocked/closed
open air supply
clean/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
ball 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
ball valve worn
more air consuming components
increase air supply
check/repair air supply
replace air control system
check/replace ball 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
ball 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
ball 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 ball valve

11
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
ball valve blocked
start more slowly
adjust installation
check installation, check
temperature, 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 tighten/seal connections,
clean sealing area
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
diaphragms attacked chemically
diaphragms overstrained
tension installation/pipework
disassemble the pump, clean
sealing area, tighten housing bolts
according to the torque values
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

12
Spare part list B 20 B 32
Item Pc. Description Material Part number Part number
1 2 Pump housing SS 316 L (1.4435) 5 20 140 40 5 32 140 40
2 4 O-ring, pump housing* EPDM (FDA) 9 17 557 73 9 23 668 73
4 O-ring, pump housing* PTFE 9 17 557 60 9 23 668 60
4 O-ring, pump housing* FKM 9 17 557 94 9 23 668 94
3 2 Pipe bend, suction side SS 316 L (1.4435) 5 20 138 40 5 32 138 40
4 1 Suction port, code A (DIN 11864) SS 316 L (1.4435) 5 20 441 40 5 32 441 40
1 Suction port, code N1 (Naue) SS 316 L (1.4435) 5 20 041 40 5 32 041 40
1 Suction port, code N2 (Neumo) SS 316 L (1.4435) 5 20 141 40 5 32 141 40
1 Suction port, code N2X (Neumo Connect S) SS 316 L (1.4435) 5 20 541 40 5 32 541 40
1 Suction port, code M (DIN 11851) SS 316 L (1.4435) 5 20 241 40 5 32 241 40
1 Suction port, code T (Tri-Clamp) SS 316 L (1.4435) 5 20 341 40 5 32 341 40
5 2 Pipe bend, discharge side SS 316 L (1.4435) 5 20 139 40 5 32 139 40
6 1 Discharge port, code A (DIN 11864) SS 316 L (1.4435) 5 20 442 40 5 32 442 40
1 Discharge port, code N1 (Naue) SS 316 L (1.4435) 5 20 042 40 5 32 042 40
1 Discharge port, code N2 (Neumo) SS 316 L (1.4435) 5 20 142 40 5 32 142 40
1 Discharge port, code N2X (NeumoConnectS) SS 316 L (1.4435) 5 20 542 40 5 32 542 40
1 Discharge port, code M (DIN 11851)) SS 316 L (1.4435) 5 20 242 40 5 32 242 40
1 Discharge port, code T (Tri-Clamp) SS 316 L (1.4435) 5 20 342 40 5 32 342 40
7 2 Frame SS 316 L (1.4404) 5 20 143 23 5 32 143 23
8 2 Housing bolt, cpl., short 1.4301 5 20 154 22 5 32 154 22
9 4 Housing bolt, cpl., long 1.4301 5 20 156 22 5 32 156 22
10 4 Shock absorber EPDM 1 15 022 78 1 15 022 78
11 4 Disc, DIN 125 PTFE 9 06 151 60 9 06 151 60
12 4 Nut, DIN 1587 1.4305 9 06 106 22 9 06 106 22
13 1 Shaft 1.4301 5 20 145 22 5 32 145 22
14 2 Set screw, shaft, DIN 913 1.4305 9 10 220 22 9 12 221 22
15 2 Diaphragm* PTFE 1 15 031 67 1 25 031 67
2 Diaphragm* EPDM (FDA) 1 15 031 73 1 25 031 73
16 4 Valve ball* EPDM with metal core (FDA) 1 15 032 82 1 25 032 82
Valve ball* PTFE with metal core 1 15 032 89 1 25 032 89
17 4 Valve stop SS 316 L (1.4435) 5 20 044 40 5 32 044 40
18 4 Set screw, DIN 7 1.4301 9 02 401 22 9 02 401 22
19 8 O-ring, valve stop* EPDM (FDA) 9 23 668 73 9 37 528 73
8 O-ring, valve stop* PTFE 9 23 668 60 9 37 528 60
8 O-ring, valve stop* FKM 9 23 668 94 9 37 528 94
20 1 Center block PE conductive 5 20 053 56 5 32 053 56
21 2 Shaft piston ring, cpl. PTFE 1 15 041 64 1 25 041 64
22 1 PERSWING P® air control system, cpl. PETP 5 20 101 84 5 20 101 84
23 1 Air inlet PETP 1 15 047 84 1 15 047 84
24 1 Air filter PE 1 15 043 51 1 15 043 51
25 1 Muffler PE 1 15 244 51 1 15 244 51
29 6 O-ring, air valve housing** NBR 9 35 504 71 9 35 504 71
30 4 Valve lifting magnet 1.4301/NdFeB 5 20 046 22 5 32 046 22
* depends on the material combination (1,2,3 or 4)
** included in item 22
Please see page 2 for explanation of the pump code. When ordering please state the serial number of the
pump. For special constructions of the Biocor pump (for example X01 as code ending) please see separate
spare part list.

13
Exploded view

14
Dimensions (in mm)
A B* C D E F G H J* K L
B 20 244 381 150 189 123 216 216 25 6,5 6 R 1/4“
B 32 284 484 200 246 173 256 261 25 17,5 - R 1/4“
Code A
(DIN 11864)
Code M
(DIN 11851) Code N1 Code N2 Code T
B 20 Rd 44 x 1/6“
(DN 20)
Rd 44 x 1/6“
(DN 20)
M 36 x 2
(DN 20)
M 36 x 2
(DN 20)
1“
Tri-Clamp
B 32 Rd 58 x 1/6“
(DN 32)
Rd 58 x 1/6“
(DN 32)
M 52 x 2
(DN 32)
M 52 x 2
(DN 32)
1 1/2“
Tri-Clamp
*Code N2X (Neumo Connect S):
B 20: DN 20; the measure of "B" changes to 433 mm, suction port protrudes 20 mm over the
shock absorbers (measure of "J" is dropped)!
B 32: DN 32; the measure of "B" changes to 546 mm, suction port protrudes 14 mm over the
shock absorbers (measure of "J" is dropped)!

15
Optional equipment
For special requirements ALMATEC pneumatic double diaphragm pump of the series BIOCOR can be
furnished with several optional equipments. The pump code informs, which of these are included in the
pump (see page 2).
Stroke counting (option code C)
A sensor integrated in the center block [20] of the pump to monitor the movement of a diaphragm [15]
without direct contact.
The stroke counting system is available in four 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
•C 9 / C 10 Stroke counting pneumatical (please see additional information on a separate sheet)
In case only the sensor is included (code C 2), it has to be connected to an existing controller. 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.
Size B 20 B 32
Code Item Piece Description Material Part number Part number
C 2 20 1 Center block for sensor PA 5 20 153 56 5 32 153 56
Center block, conductive for sensor PE conductive 1 15 340 56 1 25 340 56
50 1 Stroke sensor, Namur diverse 1 00 072 99 1 00 072 99
C 3 as C 2, but additional:
- 1 Clamp amplifier diverse 1 00 171 99 1 00 171 99
- 1 Stroke counter diverse 1 00 071 99 1 00 071 99
C 4 as C 2, but additional:
- 1 Controller diverse 1 00 370 99 1 00 370 99
- 1 Stroke Counter diverse 1 00 071 99 1 00 071 99
Diaphragm monitoring system (option code D)
A capacitive diaphragm sensor is mounted in the muffler [25] 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. 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 (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.
Size B 20 B 32
Code Item Piece Description Material Part number Part number
D 1 51 1 Diaphragm sensor, Namur diverse 1 00 773 99 1 00 773 99
D 3 51 1 Diaphragm sensor, Namur diverse 1 00 773 99 1 00 773 99
- 1 Controller diverse 1 00 370 99 1 00 370 99

16
Barrier system (option code B)
To comply with high safety standards, the barrier system replaces the standard diaphragm [15] by a tandem
arrangement of two diaphragms [15,46] and a barrier chamber [40] of transparent PMMA filled with a non-
conductive liquid (De-ionised water) in between. To ensure the correct operation of the pump, the barrier
chambers [40] have to be filled completely. In case a diaphragm breaks, the conductivity of the barrier liquid
rises which is registered by the conductivity sensors [43]. The minimum conductivity of 22 µS covers a wide
range of media. Otherwise, a conductive barrier liquid can be filled into the chamber, so that the liquid
emerging in case of a diaphragm rupture causes a decrease in conductivity to be registered. After using for
some time the De-ionised water can be pollute with germs. In this case the water needs to be replaced.
The barrier system is available in three variations:
•B 1 Barrier system with sensors, standard
•B 3 Barrier system complete with sensors and controller
•B 4 Barrier system complete with sensors and controller for explosion proof zone
The sensors can either be connected to an existing controller (code B 1) or to the controller included (code
B 3 / B 4). 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.
Size B 20 B 32
Code Item Piece Description Material Part number Part number
B 1 13 1 Shaft 1.4301 5 20 245 22 5 32 245 22
14 2 Set screw, shaft, barrier chamber 1.4305 9 10 223 22 9 12 224 22
20 1 Center block PE conductive 1 15 240 55 1 25 240 55
22 1 PERSWING P® air controll system, cpl. PETP 2 15 001 84 2 15 001 84
40 2 Separation chamber ring PMMA 5 20 176 58 5 32 176 58
43 4 Conductivity sensor PTFE-L 1 10 074 65 1 10 074 65
44 8 O-ring, separation chamber EPDM 9 03 509 72 9 03 509 72
45 4 Plug PA 1 10 077 53 1 10 077 53
46 2 Inner diaphragm EPDM 1 15 131 72 1 25 131 72
47 2 Spacer PETP 5 20 178 84 -
B 3 as B 1, but additional:
- 1 Conductivity controller diverse 1 00 075 99 1 00 075 99
B 4 as B 1, but additional:
- 1 Conductivity controller Ex diverse 1 00 175 99 1 00 175 99
Subject to change without notice, 2008/09 (replaces 2008/08)
ALMATEC Maschinenbau GmbH
Carl-Friedrich-Gauss-Str. 5 · 47475 Kamp-Lintfort · Germany
Telephone ++49.2842.9610 · Telefax ++49.2842.96140
http://www.almatec.de · e-mail: [email protected]