Almatec E 10 Operating And Installation Instructions
E-series, air-operated double diaphragm pumps made of plastic
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- Installation and operation manual (48 pages)
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OPER R ATIN N G AND INST T ALLA
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G&W Industrial Sales
915 Emerson Avenue
Parkersburg, WV 26104
304-422-4755
mail@gwindustrial.com
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Summary of Contents for Almatec E 10
- Page 1 OPER R ATIN N G AND INST T ALLA ATION N INST TRUCT TIONS Air‐O Operat ted Do ouble Diap phrag gm Pum mps ade o f Plas E‐Se eries s E 08 ‐ ‐ E 5 50 G&W Industrial Sales 915 Emerson Avenue Parkersburg, WV 26104 304-422-4755...
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Page 2: Table Of Contents
CONTENTS Page Introduction ... -
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 ... -
Page 4: Codesystem
EU machinery directive, the harmonized standards, European standards and the respective national standards. Hence the operator has to verify whether the ALMATEC pump manufactured and delivered properly according to the customer’s order meets the mentioned ... -
Page 5: Operation In Explosion Proof Areas
[4]. All other housing parts are connected to the center housing; therefore it is not necessary to ground single parts. ALMATEC E‐Series pumps made of electrically conductive PE/PTFE are suitable to be used in explosion areas of the category 2 and 3, atmosphere G/D, which are liable to the 94/9/EG. Conductive diaphragms (liquid side) are applicable without restrictions for ... -
Page 6: Performance Charts
PERFORMANCE CHARTS The data refer to water (20°C/68°F), under using of different variations (e.g. ball valve model, damper preparation etc.), a compressor Atlas Copco VSG30 and calibrated measuring equipment. The specified performance data are warranted by ALMATEC in accordance with DIN EN ISO 9906. ... - Page 7 ...
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Page 8: Installation
INSTALLATION Recommended installation Product ports The product ports are integrated into the center housing [4]. Different port configurations can be obtained (without using of a screwed pulsation damper only). The standard configuration of the E‐Series at delivery is with the suction inlet horizontally at the bottom and the discharge outlet horizontally at the top (figure 8.1). Further possible configurations: Suction inlet vertically at the bottom, the discharge outlet horizontally at the top (figure 8.2) To obtain this configuration, the plug of the center housing [13] has to be removed and set in the standard inlet. Suction inlet horizontally at the bottom, the discharge outlet vertically at the top (figure 8.3) Unscrew the housing bolts [19], take off the side housings [1] and turn the center housing [4]. Remount the pump and adjust the plug [13] accordingly. fig. 8.1 fig. 8.2 fig. 8.3 ... -
Page 9: Startup Operations
[23] in the center housing [4]. The air inlet is located below the bilingual sticker with safety instructions. The connections of ALMATEC air‐operated diaphragm pumps made of plastic have slightly tapered threads. Use threadseal only sparingly, otherwise the connections could be damaged. ... -
Page 10: Torque Values
Torque values Immediately before putting the pump into operation as well as after some hours of pumping, the housing bolts [19] have to be fixed according to the torque data of the following schedules, as the elements of construction "settle". The valve stops discharge valve [9] and the plugs [11/13] have to be fixed too. As a reminder the air inlet [23] is covered by a corresponding sticker at delivery condition. Fixing all these parts is necessary as well after periods of stoppage, at temperature variations, after transport and dismantling the pump. In case of temperature varying between extremes or high temperature difference between the liquid and the surrounding, the housing bolts should be controlled more frequently (interval proposals are available on request). The following schedules show the torque values of the pump housing bolts, of the damper housing bolts (when using a pulsation damper of the ET‐Series) and of the optional flange connection (optional equipment codes F3/F4/F5). Pump size E 08 E 10 E 15 E 25 E 40 E 50 Torque values for housing bolts ‐ Nm (ft lbs): PE pumps ‐ ‐ 8,5 (6.3) 14 (10.3) 18 (13.3) 23 (17) ... -
Page 11: Using As Submersible Pump
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. 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. The pump is tested with water before shipment. Water residues inside the pump cannot be precluded. If the liquid, which is wanted to be conveyed, potentially interacts with water, please consult Almatec. 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 ... -
Page 12: Additional Temperature Hints
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 and PTFE keeps mechanically stable as well for an extended temperature range. 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 ... -
Page 13: Required Tools
MAINTENANCE Required tools The general design of the ALMATEC E‐Series is simple. We recommend to take the explosion view in hand to identify the parts by item number that is mentioned in the following. Two tools are delivered along with each pump. The plastic one of these is designed for the mounting of the air‐valve [26], the other one for the mounting of valve seat [16]. Further special tools are not required. Pump size E 08 E 10 E 15 E 25 E 40 E 50 Item Description Tool ... - Page 14 fig. 14.6 fig. 14.7 fig. 14.8 A video of th he disassemb bly of an E‐Se eries pump is s available o n our websit te. (http://www w.psgdover.co om/en/psgtv v/videos‐by‐b brand/psgtv v‐almatec/ite em/5292‐alm matec‐e‐serie es‐ disassembly‐ ‐english). ...
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Page 15: Assembly
Be fore putting g the pump back into o peration, th e tightness of t the pump ha as to be chec cked. A video of th he assembly of an E‐Serie es pump is av vailable on o our website. (http://www w.psgdover.co om/en/psgtv v/videos‐by‐b brand/psgtv v‐almatec/ite em/5293‐alm matec‐e‐serie es‐assembly‐ ‐ english) ... -
Page 16: Troubleshooting
TROUBLESHOOTING Malfunction Possible Reason Solutions/Remarks pump does not operate air supply line blocked/closed 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 check 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 insufficient discharge pressure insufficient pressure/amount of ... - 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, 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 check valve blocked clean/replace valve insufficient suction capacity after connections tighten incompletely ...
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Page 18: Spare Part Lists
SPARE PART LISTS Pump code EEE – ETZ, material housing parts: Polyethylene (PE) Size E 15 E.. E 25 E.. E 40 E.. E 50 E.. Item Pc. Description Material Part‐No. Part‐No. Part‐No. Part‐No. 1 2 Side housing PE 7 15 010 51 7 25 010 51 7 40 010 51 7 50 010 51 2 2 Tension disc 1.4301 7 15 008 22 7 25 008 22 7 40 008 22 7 50 008 22 3 2 Cover PE 7 15 009 51 ... -
Page 19: Code Tee - Ttz
Pump code TEE – TTZ, material housing parts: PTFE Size E 08 T.. E 10 T.. E 15 T.. E 25 T.. E 40 T.. E 50 T.. Item Pc. Description Material Part‐No. Part‐No. Part‐No. Part‐No. Part‐No. Part‐No. 1 2 Side housing PTFE 7 08 010 60 7 10 010 60 7 15 010 60 7 25 010 60 7 40 010 60 7 50 010 60 2 2 Tension disc 1.4301 7 08 008 22 7 10 008 22 7 15 008 22 7 25 008 22 7 40 008 22 7 50 008 22 3 ... -
Page 20: Code Fee - Ftz
Pump code FEE – FTZ, material housing parts: PE conductive Size E 15 F.. E 25 F.. E 40 F.. E 50 F.. Item Pc. Description Material Part‐No. Part‐No. Part‐No. Part‐No. 1 2 Side housing PE conductive 7 15 010 55 7 25 010 55 7 40 010 55 7 50 010 55 2 2 Tension disc 1.4301 7 15 008 22 7 25 008 22 7 40 008 22 7 50 008 22 3 2 Cover PE conductive 7 15 009 55 7 25 009 55 7 40 009 55 7 50 009 55 4 ... -
Page 21: Code Uee - Utz
Pump code UEE – UTZ, material housing parts: PTFE conductive Size E 08 U.. E 10 U.. E 15 U.. E 25 U.. E 40 U.. E 50 U.. Item Pc. Description Material Part‐No. Part‐No. Part‐No. Part‐No. Part‐No. Part‐No. 1 2 Side housing PTFE cond. 7 08 010 65 7 10 010 65 7 15 010 65 7 25 010 65 7 40 010 65 7 50 010 65 2 2 Tension disc 1.4301 7 08 008 22 7 10 008 22 7 15 008 22 7 25 008 22 7 40 008 22 7 50 008 22 3 ... -
Page 22: Exploded Views
EXPLODED VIEWS Pump sizes E 08 / E 10 ... -
Page 23: E 15 / E 25 / E 40 / E 50
Exploded view pump sizes E 15 / E 25 / E 40 / E 50 ... -
Page 24: Optional Equipment
OPTIONAL E QUIPMENT For special r requirement s ALMATEC air‐operated d double dia aphragm pum mps of the E E‐Series can be furnishe d with several optional eq uipment. Th e pump cod e informs w hich of these e are include ed in the pum mp. The cod e is noted on t the identifica ation plate o on the pump . For the bar rrier chambe er system (op ption code B BS) a separat e manual is av vailable. In th he spare part t lists all not ... -
Page 25: Diaphragm Monitoring (D)
The pneum matic stroke c counting syst tem requires s a minimum m air pressure e of 1.5 bar f for optimal fun nction! The air inlet for the pne umatic strok ke counting system mus t not be con nfused with t the actual a ir inlet of th e pump. There efore, you wi ill find some advises ada pted to the p pump type a nd the pump p size. A = Air inlet f for the pump p, B = Air inle et for the pn neumatic stro oke counting g system Spare part list Stroke Countin ng ... -
Page 26: Special Diaphragms (L+P)
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. E 08 E 10 E 15 E 25 E 40 E 50 ... -
Page 27: Flange Connections (F)
2 Flange‐O O‐ring, center h housing ANSI NBR 9 23 588 8 71 9 40 613 3 71 9 62 634 71 ‐ Pumps for fo ood contact (EG VO EC 1 1935/2004) ( option code e H) ALMATEC pu umps of the E‐series we re not desig gn with regar rd to an effe ective cleani ng; however r they will b e frequently u sed in the fo ood industry y. Pumps wit th the optio n code H are e equipped w with wetted parts, whic h ... -
Page 28: Draining System (R)
Draining system (option code R 1, R 2, R 3, R 4, R 5, R 6) A pump equipped with the unique ALMATEC draining system can be emptied along with an inclining discharge line while being installed within the plant. The system is not appropriate to flush the pump with another liquid, nor from suction nozzle nor from discharge connection. It consists of a bypass‐system in the side housings [1], which can be activated by manual valves (code R 1/R 2/R 5) or pneumatically (code R 3/R 4/R 6). Open the manual valves (code R 1/R 2/R 5) by approx. 10 mm by turning to the left (Attention: As there is no blocking of the ... -
Page 29: Fkm Housing Gaskets (V)
Pumps with PTFE diaphr ragms and FK KM housing gaskets (op tion code V) ) FKM gaskets s offer wide espread chem mical resista ance to cove er the major r part of app plications re equiring PTF E diaphragms (check com patibility) an nd combine this with h igh ... -
Page 30: Dimensions Drawing
DIMENSIONS ... -
Page 31: Pulsation Dampe Et/Et-F
An ALMATEC ET‐damper can easily be attached to an E‐Series pump at any time without changes of the piping, provided that the pump is configurated with product ports both horizontally. Make sure that the plug, center housing (item 13 in the exploded view of the pump) is in the right position. For pumps delivered ... - Page 32 without dam mpers, this p plug can be f found at the e bottom sid de of the pu ump general ly. Therefor e, the cente er housing has to be turned d 180°, to ge et the plug to o the top of t the pump. T ake the plug g out, insert the flange‐O O‐ ring [10] and d ...
- Page 33 Damper size ET 10 ET 15 ET 25 ET 40 ET 50 Torque values for damper housing bolts Nm (ft lbs): PE damper ‐ 3 (2.2) 6 (4.4) 10 (7.4) 11 (8.1) PTFE damper 2 (1.5) 3 (2.2) 6 (4.4) 10 (7.4) 11 (8.1) Hints for disassembly of an ET pulsation damper Pull out the cover [5]. Unscrew housing bolts [6] carefully. After that, all parts can be removed. Screw the diaphragm [2] off the actuator shaft [7]. A re‐assembly of used piston rings [8] is impossible; they have to be ...
- Page 34 Dimensions pulsation damper ET mm (inch) A B C D ET 10 NPT 3/8” 85 (3.3) 11 (0.4) 79 (3.1) ET 15 NPT 1/2” 120 (4.7) 12 (0.5) 89 (3.5) ET 25 NPT 1” 170 (6.7) 14 (0.6) 133 (5.2) ET 40 NPT 1‐1/2” 220 (8.7) 16 (0.6) 162 (6.4) ET 50 NPT 2” 285 (11.2) 18 (0.7) 222 (8.7) Exploded view pulsation damper ET...
- Page 35 Additional hints for pulsation damper series ET‐F (flange version) Beside the screwed pulsation damper as standard flange versions (series ET‐F) are available also. In general, pump and damper are dispatched completely mounted. Still, they can be packed in separate boxes, especially for the bigger sizes. If so, use the attached nuts, set screws, washers and discs [11‐14] to flange the damper to the pump. Pump size ET 15 ET 25 ET 40 ET 50 Torque values for flange connections 12 15 4 (3) 5 (3.7) Nm (ft lbs): (8.9) (11.1) Spare part list Flange Damper ET‐F ET 15 ‐ F ET 25 ‐ F ET 40 ‐ F ET 50 ‐ F Item Pc. Description Material Part‐No. Part‐No. Part‐No. Part‐No. Damper housing DIN, code E.. PE ...
- Page 36 115 (4.5) 85 (3.3) 14 (0.6) 176 (6.9) ET 40 ‐ F 220 (8.7) 150 (5.9) 110 (4.3) 18 (0.7) 215 (8.5) ET 50 ‐ F 285 (11.2) 165 (6.5) 125 (4.9) 18 (0.7) 280 (11.0) Exploded view pulsation damper ET‐F (flange version) G&W Industrial Sales 915 Emerson Avenue Parkersburg, WV 26104 304-422-4755 mail@gwindustrial.com Subject to change without notice, 2016/01 (replaces 2013/05) 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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