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Related Manuals for Almatec Biocor Series
Summary of Contents for Almatec Biocor Series
- Page 1 OPER RATIN N G AND INST T ALLA ATION N INST TRUCT TIONS Air‐O Operat ted Do ouble Diap phrag gm Pum mps de of tainles ss ste el ocor ries B 2 20 B 3 32 B 4 40 Origin nal Inst tructio ...
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Page 2: Table Of Contents
CONTENTS Page Introduction …………………………………..……………………………………………. 3 General description of the machine, appropriate use and residual dangers … ………….………. 3 Storage ... -
Page 3: Introduction
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 BIOCOR pumps are oscillating positive displacement pumps and ... -
Page 4: Code System
CODE SYSTEM The ALMATEC Maschinenbau GmbH is certified as a modern, quality‐orientated enterprise according to DIN EN ISO 9001:2008 and 14001:2004. Before release for dispatch, any pump of the BIOCOR series has to undergo an extended final control. The performance data registered during this are archived in our records and can be read back at any time. As a general rule in the countries of the EU only such machines are allowed to take into operation, which are determined to meet the regulations of the EU machinery directive, the harmonized standards, European standards and the respective national standards. Hence the operator has to verify whether the ALMATEC pump manufactured and delivered properly according to the customer’s order meets the ... -
Page 5: Operation In Explosion-Proof Areas
OPERATION IN EXPLOSION‐PROOF AREAS AND FOR FLAMMABLE LIQUIDS For inflammable liquids as well as for applications in explosion‐proof areas, BIOCOR pumps have to be grounded to one of the M6 tapping holes located in the frame [7]. All other housing parts are connected in a conductive way, therefore it is not necessary to ground single parts. Grounded BIOCOR pumps are suitable to be used in explosion areas of the category 2 and 3 („zone 1“ resp. „zone 2“), atmosphere G/D, which are liable to the 2014/34/EU. 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. ... -
Page 6: Performance Charts
PERFORMA ANCE CHART TS The data re efer to water r (20°C), with h out using of f a pulsation dampener a a nd in accord d ance with D D IN EN ISO 9906. ... -
Page 7: Installation
INSTALLATION Recommended installation Start‐up operations In general, the pump has to be connected load free. Neglecting this causes leakage and maybe even damages. To avoid vibrations, pulsation dampers and compensators are recommended. Before connecting the pump, take the yellow blind plugs out of the suction and discharge connections [4,6] as well as the air inlet [23]. The air inlet is located below the bilingual sticker with safety instructions. 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 ... -
Page 8: Torque Values
fitted to protect the pump from blocking by ice. The ideal condition is the dewpoint of air at ‐20°C. In humid surroundings, icing from the outside may occur despite the driving air is dried. If so, a prolonged waste‐air‐exhaust (ca. 500 mm by pipe or hose) can be helpful. When installing the pump into boards or cabinets, it has to be ensured that cold air does not get caught behind the muffler. In applications with a tendency ... - Page 9 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. A template is available on the Almatec website. Please respect the relevant additional security advices, if the pump has been used for aggressive, dangerous or toxic liquids (e.g. suitable protective equipment according to the safety data sheet of the liquid). In case of a diaphragm rupture, it is possible that residues of the liquid remain behind the diaphragms, in the area of the air control system and at the muffler, despite of several flushing processes. Hence, appropriate safety equipment according to the safety data sheet of the liquid is indispensable. Before putting the pump back into operation, the tightness of the pump has to be checked. Pumps of the BIOCOR series must not be submerged. Air‐operated diaphragm pumps can lead to bruises when lifting, sinking or assembling them. Appropriate accessories and safety equipments are to be used. Big and heavy modules have to fixed and secured to lifting gears when transporting/replacing them. Especially when deliver critical liquids, wear parts, like diaphragms, should be replaced within a preventive maintenance. The use of non‐original ALMATEC spare parts and structural changes lead to the lapse of the warranty immediately. When operating such a pump, damages of properties and/or persons cannot be excluded. The operation of the pump with nitrogen as driving gas is possible. In closed rooms sufficient ventilation must be provided. Possible electrical connections (e.g. when using optional equipment with controllers) may be executed by a qualified person only. The regulations of the respective manufacturers are to be followed. At any work arising it has to be made sure that no explosive atmosphere can appear. Appropriate safety equipment is recommended. ...
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Page 10: Additional Temperature Hints
Procedure for pump return: According to the requirements of our 14001‐certification, every unit which is send to ALMATEC for diagnosis or maintenance reasons has to be accompanied by a filled out decontamination‐sheet. Otherwise a processing is not possible. The decontamination‐sheet is enclosed to this manual. Please pay attention to the further safety regulations. Additional temperature hints The temperature and pressure limitations listed on page 5 are solely based on mechanical temperature limits of the housing material used. Depending on the fluid pumped, the maximum safe operating ... -
Page 11: Usage Of The Valve Lifting Magnets
USAGE OF THE VALVE LIFTING MAGNETS Valve lifting magnets are attached to B 20 and B 32 BIOCOR pumps with the material combinations 1‐5. 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. ... -
Page 12: Maintenance
MAINTENANCE Required tools 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. Tool list Pump size BIOCOR 20 BIOCOR 32 BIOCOR 40 Pos Description Kind of Tool Tool Size Tool Size Tool Size 3 Pipe bend, suction side (union nut) Hook wrench, lug 40‐42 + 45‐50 + 64 + [DIN 1810, Form 45‐50 68‐75 85‐92 A] 5 Pipe bend, discharge side (union nut) Hook wrench, lug 40‐42 + 45‐50 + 64 + [DIN 1810, Form 45‐50 68‐75 85‐92 ... - Page 13 figure 13.1 figure 13.3 figure 13.2 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 ...
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Page 14: Hints For Assembly
Hints for as ssembly The re‐asse embly of the component ts is principa lly carried o ut vice‐versa a to the dism mantling. He re are some additional h hints. ® For the inst tallation of t the PERSWIN NG P [22] ai ir control sys stem, first sc crew in one end cap flus shly into the center bloc ck [20]. Turn the center b block [20] an d insert one of the six O‐ ‐rings air‐val lve housing [ [29] into the end cap fro om the inside e of center b block [20]. M Moisture the four O‐rings [29] of the ... - Page 15 appropriate e notch of s suction [4] o or discharge port [6] (fig gure 15.1). Screw the union nuts o of the pipe b bends [3,5] o on the sucti on [4] and discharge p ports [6] loos se by hand Insert O‐rin ngs pump h ousing [2]. Screw the c complete pr re‐installed suction and d discharge s sides with th he correspon nding union ...
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Page 16: Troubleshooting
TROUBLESHOOTING Malfunction Possible Reason Solutions/Remarks pump does not operate no air supply open air supply air supply line blocked/closed clean/open air supply muffler blocked clean/replace muffler working chambers blocked remove blockage air control system defective replace air valve system discharge line blocked/closed clean/open line pump operates unsteadily piston rings worn replace piston rings air control system worn replace air control system diaphragm rupture replace diaphragm, clean pump air control system soiled clean/replace air control system ball valve blocked cleaning, removal of bulk particles icing improve air processing air within liquid suction line leaky seal suction line container with liquid empty fill/new container diaphragm rupture replace diaphragm cavitation adapt suction lift, possibly install suction pressurised air chamber ... - Page 17 Malfunction Possible Reason Solutions/Remarks pumps operates, however suction pump operates too fast start more slowly capacity insufficient operation beyond physical limits adjust installation cavitation check installation, check temperature, cool down operation beyond pump capacity adjust installation resp. install bigger pump air cushion within suction/discharge bleed the line line dry suction against discharge pressure wet pump, start without pressure valve filter within suction line closed open valve/clean filter valve filter within discharge line closed open valve/clean filter container with liquid empty fill/new container vacuum inside the container bleed container wear of the check valves replace valves suction line leaky seal suction line suction line blocked clean suction line air pressure cushion at discharge bleed discharge line ball valve blocked clean/replace valve ...
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Page 18: Spare Part List
SPARE PART LIST All parts in italics are not product wetted. B 20 B 32 B 40 Item Pc. Description Material Part number Part number Part number 1 2 Pump housing SS 316 L 5 20 140 40 5 32 140 40 5 40 140 40 2 4 O‐ring, pump housing* EPDM (FDA) 9 17 557 73 9 23 668 73 9 35 594 73 4 O‐ring, pump housing* PTFE 9 17 557 60 9 23 668 60 9 35 594 60 4 O‐ring, pump housing* FKM 9 17 557 94 9 23 668 94 9 35 594 94 ... -
Page 19: Exploded View
EXPLODED VIEW ... -
Page 20: Dimensions
DIMENSIONS mm A B C D K L B 20 244 381 150 189 6 R 1/4“ B 32 284 484 200 246 17.5 ‐ R 1/4“ B 40 462 681 270 335 ‐ R 1/2“ ‐ inch A B C D K L B 20 ... -
Page 21: Optional Equipment
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 4). For the barrier chamber system (option code BS) a separate manual is available. Stroke counting (option code C 2, C 3, C 4) 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 ... -
Page 22: Diaphragm Monitoring (Code D1, D3)
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 ... -
Page 23: Diaphragms Made Of Modified Ptfe (Code P)
Diaphragms made of modified PTFE (option code P) For media with increased diffusion tendency as well as for application with priming out of a vacuum PTFE/EPDM compound diaphragms made of modified PTFE are available. Spare parts special diaphragm B 20 B 32 B 40 Code Item Pc. Description Material Part No. Part No. Part No. PTFE mod. P 15 2 ... - Page 24 Subject to change without notice, 2017/01 (replaces 2016/10) 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: info@almatec.de ...
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