Almatec Biocor Diaphragm Pump

The Almatec Biocor air-operated double-diaphragm pump series is specifically designed for sterile applications within the pharmaceutical, biotech, and food industries. The aseptic pumps are EHEDG certified and in compliance with FDA, USP Class VI, and ATEX standards. The B20 and B32 sizes are also available in a 3-A version.

Since the Biocor is sterile by design, it has no horizontal areas. The pump is drained by magnetically lifting the valve balls from the outside. The pump has no drives, no rotating parts, and no shaft seals within the fluid. This specialized design—with the integrated cleaning system—allows for clean-in-place (CIP) and sterilization-in-place (SIP) capabilities.

Models

  • B20
  • B32
  • B40

The Biocor series is available in three pump sizes: B20, B32, and B40.

Working Principle

The Biocor series is based on the functional principle of double diaphragm pumps. The basic configuration consists of two external pump housings with a center block between them. Each pump housing contains a product chamber that is separated from the center block by a diaphragm. Both diaphragms are interconnected by a piston rod. Controlled by an air control system, they are alternately subjected to compressed air so that they move back and forth.


In Fig. 1 the compressed air has forced the left 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 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 Fig. 2 liquid is drawn in by the left-hand diaphragm and displaced by the right-hand diaphragm. The liquid is displaced, and thus conveyed, by the compressed air. The diaphragms merely serve as barriers and are not pressurized, which greatly increases the service life of the diaphragms.

Materials
Wetted Housing PartsElectropolished 316L stainless steel with Ra of ≤ 0.4 μm (15.75 µin)
Frame304 stainless steel
Center BlockConductive polyethylene
Diaphragms, Ball Valves, O-ringsPTFE or EPDM (FDA); other materials on request
Connections

The suction and discharge ports are suitable for Tri-Clamp® or other sanitary threads (Naue, Neumo, DIN 11851, DIN 11864).

Biocor Features
  • Integrated cleaning system with high cleaning results
  • CIP (clean-in-place) and SIP (sterilization-in-place) options
  • Smooth diaphragms without disc and seals
  • Gentle displacement
  • Proof against dry running
  • Self-priming
Gentle Handling

Always a demand for sterile applications, all Biocor pumps have no horizontal areas in the housing parts. Each pump comes with four ball lifting magnets, which can be attached to the pump housing from the outside at the location of the four ball valves. The ball valves are raised up magnetically out of their seats, and the pump is drained entirely without having to be dismounted. There are no mechanical ball lifters with parts and seals in the wetted area. Since there are no rotating parts or shaft seals in the product chamber, the pump provides gentle displacement, making it suitable for applications that require extremely gentle handling.

active Pulsation Dampers

Due to their design, pumps with oscillating action produce a pulsating flow. Although the double-acting design of Almatec pumps and the direct pneumatic drive greatly reduce the pulsation, a pulsation damper must still be installed on the discharge side in order to obtain a virtually uniform flow.

The dampers are self-regulating. As with Almatec pumps, the diaphragm merely serves as a barrier between product and air chamber and is, therefore, always without pressure. If the pressure on the product side drops due to changes in the operating conditions, the pressure on the other side of the diaphragm will decline accordingly. As soon as the pressure on the product side rises, the pressure on the other side will increase as well. This automatic adjustment optimizes the diaphragm setting and ensures a consistently good damping effect.

Diaphragms, Ball Valves, and Air Control System

The surface of the Almatec diaphragms is smooth and not interrupted by any seals. Due to the integrated metal core, they do not require diaphragm discs, which frequently result in leaks. Almatec diaphragms have always been designed from the "PTFE" point of view, which results in Almatec diaphragms having a large diameter and short stroke with low flexural load.

Almatec diaphragms for the Biocor series are available in the materials EPDM (FDA) or PTFE/EPDM composite. The ball valves, which are insensitive against solids, have a metal core for a better suction lift. Additionally, the use of the ball lifting magnets for the complete pump draining is possible.

Almatec's Biocor pumps are equipped with the patented PERSWING P® air control system. This metal-free, pneumatically pilot-operated control system ensures accurate reversal of the main piston and is characterized by low noise levels. The PERSWING P has only two moving parts, which ensures that there is absolutely no dead center in the control system. It does not require maintenance, operates without any lubrication whatsoever, and is made up of no more than four different parts. The complete cartridge can be replaced easily. PERSWING P is a precision control system and, therefore, requires clean, oil-free compressed air to ensure its optimal function.

Optional Equipment

Diaphragm Monitoring (Code D)
While Almatec diaphragms are designed for an optimum service life, the diaphragms remain a wear part. In the event of a diaphragm rupture, a capacitive sensor in the pump muffler detects any liquid and gives a corresponding signal to a controller (can also be supplied), which then triggers an alarm or disconnects the pump via a solenoid valve.

Barrier Chamber System (Code B)
The Almatec barrier chamber system meets further safety requirements. The individual diaphragm is replaced by two diaphragms arranged in tandem with a barrier chamber filled with non-conductive liquid. The barrier chambers must always be completely filled so the driving air pressure can be transmitted. If the diaphragm on the product side ruptures, medium merely enters the barrier chamber, and the neutral barrier liquid flows into the medium. The change in conductivity of the barrier liquid is detected by sensors and signaled to a controller, which triggers an alarm or disconnects the pump. The conductivity limit equals 22 microSiemens.

Stroke Counting (Code C)
A sensor is installed in the center block of the pump to count the strokes. The diaphragm movement is scanned without contact. 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 that can then be processed further. For example, the counter could make the pump shut down via a solenoid valve. Another possibility is the pneumatical stroke counting.

Dimensional Data

B20B32B40
Length (in)9.611.218.2
Width (in)5.97.910.6
Height (in)151926.8
Nominal Port Size*DN 20DN 32DN 40
Air Connection, BSP¼ inch¼ inch½ inch
Weight (lb)2757147

*Depends of the chosen suction and discharge connection.

Technical Data

B20B32B40
Max Particle Size of Solids0.120.200.35
Suction Lift, Dry (ftWc)6.68.29.8
Suction Lift, Wet (ftWc)29.529.529.5
Max Driving and Operating Pressure (psig)100100100
Max Operating Temperature176ºF176ºF176ºF
Max Short-Term Temperature266ºF266ºF266ºF
Max Capacity (gpm)15.43375
Max Discharge Pressure (psig)100100100

Product Literature

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