Page 1
S 50 ® Keep the operating manual for future use! Manufacturer: Record the exact type and serial number here. sera GmbH (can be read off the type plate on the pump) sera-Straße 1 34376 Immenhausen Type Germany Tel.: +49 5673 999-00 Fax: +49 5673 999-01 Serial No.
1. General 1.1 General user information Before commissioning and during operation of the sera dosing pump the respective regulations valid at the place of installation are to be observed. The sera dosing pump is delivered ready for installation. Carefully read these instructions and especially the safety instructions herein contained before installation and initial start-up of the pump.
■ reduce repair cost and downtime. ■ The sera quality management and quality assurance system for pumps, systems, valves and fittings and compressors is certified according to ISO 9001:2008. The sera product meets the valid safety and accident prevention regulations.
Chapter 2.8 of these operating instructions. 2.8 Intended use The sera product is only to be deployed according to the intended purpose stated in the product description and the acceptance test certificate. If the product is to be used for other applications, then the suitability of the product for the new operating conditions...
DANGER! Personal protective equipment must be provided by the owner! NOTE! NOTE! 2.11 Utilities/Lubricants The sera stepper motor pump is lubricated for life. TA 508 Rev. 00 en 11/2015 Subject to technical modifications! www.sera-web.com...
Admissible current load of the digital outputs exceeded. ■ No sera sensors for flow rate / flow or fill level ► damage to the electronics. ■ Electronics opened in order to connect the mains cable directly to the power supply ► electric shock or dam- ■...
Disregard of the maintenance intervals specified in the operating manual. ■ Use of incorrect spare parts/oils (e.g. not sera original spare parts, wear parts, wrong viscosity). ■ Improper mounting of spare and wear parts (e.g. incorrect tightening torque for pump body).
Wrong or no protective clothing at all. ■ Poorly ventilated room. ■ 2.12.9 Disposal Improper disposal of the pumped medium, utilities and materials. ■ No marking of hazardous media. ■ Falsche Entsorgung der Elektronik. ■ TA 508 Rev. 00 en 11/2015 www.sera-web.com Subject to technical modifications!
3. Transport and storage 3.1 General sera products are checked for perfect condition and function previous to shipment. Check for transport damage immediately after arrival of goods. If damage is found, this is to be reported immediately to the responsible carrier and the manufacturer.
(litre/hour) iSTEP (example) 4.1.2 Type plate Each sera dosing pump is factory provided with a type plate. The following information can be found on this type plate. Designation Pump type Nominal flow rate Delivery volume of the pump at rated pressure with media similar to water.
Medium state ► from 50 l/h, max. 5% solids, grain size 30 µm. 4.4 Noise measurement According to DIN 45635 the measured sound pressure level of the diaphragm pumps is below 70 dB (A). TA 508 Rev. 00 en 11/2015 Subject to technical modifications! www.sera-web.com...
A constant flow rate is achieved that enables gentle dosing with low pulsation. Standard Operation 100% Flow rate Flow rate Flow rate Slow Mode for viscous media Flow rate Flow rate Pressure stroke Suction stroke Time TA 508 Rev. 00 en 11/2015 www.sera-web.com Subject to technical modifications!
4.7 Functional description 4.7.1 General sera dosing pumps are run-dry safe oscillating displacement pumps that are characterised by high tightness of the dosing head. The fluid is conveyed by a deformable diaphragm. The stepper motor pumps consist of the following (main) components: Drive housing ■...
Factory setting 50%, approx. 10 µS/cm. The diaphragm monitoring device MBE-02 (1) is mounted in the base ring (2) and permanently connected to the electronics in the drive housing (3). TA 508 Rev. 00 en 11/2015 Subject to technical modifications! www.sera-web.com...
A connection for flow monitoring or flow rate measurement and an "empty" signal with pre-alarm and dry run alarm are available as standard. The removable control element with graphical display can be attached to the corresponding side on the housing depending on the operating side. TA 508 Rev. 00 en 11/2015 www.sera-web.com Subject to technical modifications!
The interface module provides level input and Profibus or Profinet connectivity. 4.7.9 Suction lances connection (accessories) In order to connect the stepped motor pump to a sera suction lance, an 8-pole cable connector with M12 thread is needed (accessory part number: 90042494 or 90022885).
Nominal frequency [1/min] Stroke length [mm] Max. liquid temperature [°C] Min. liquid temperature [°C] Max. operating temperature [°C] Min. operating temperature [°C] Max. storage temperature [°C] Min. storage temperature [°C] TA 508 Rev. 00 en 11/2015 www.sera-web.com Subject to technical modifications!
Page 21
Signal output Impedance at 0/4-20 mA [Ω] analog output Weight Plastic [kg] Steel [kg] Dimension Diaphragm diameter [mm] Sound pressure Max. sound pressure [dB(A)] LP(A)<65dB(A) +/-5dB(A) at max. burden TA 508 Rev. 00 en 11/2015 Subject to technical modifications! www.sera-web.com...
All pipes and containers connected to the pump must comply with the regulations and must be cleaned, tension-free ■ and intact. The pump must be adequately fastened at the installation site. WARNING! TA 508 Rev. 00 en 11/2015 www.sera-web.com Subject to technical modifications!
Page 25
WARNING! Install the return line of overpressure protection and/or ventilation valve sloping downward into the associated tank. WARNING! The pump is only designed for operation outside Ex-zones! DANGER! TA 508 Rev. 00 en 11/2015 Subject to technical modifications! www.sera-web.com...
Page 26
The following fittings can be used on the suction side: SUCTION SIDE Suction aid Line strainer Siphon vessel Suction lance Multifunction device Dosing set Foot valve Shut-off valve 2.10 TA 508 Rev. 00 en 11/2015 www.sera-web.com Subject to technical modifications!
Page 27
Vent valve device (option) Flow monitor Flow meter Injection fitting Pulsation damper Diaphragm pressure- Diaphragm relief valve keeping valve Multifunction valve 2.10 Dosing set 2.11 Dosing valve 2.12 Shut-off valve TA 508 Rev. 00 en 11/2015 Subject to technical modifications! www.sera-web.com...
Page 28
If air can be drawn in due to falling liquid level in the suction tank and at the same time delivered to a pressurised line or against a pressure-sustaining valve ► install vent valve in the pressure line. TA 508 Rev. 00 en 11/2015 www.sera-web.com Subject to technical modifications!
Page 29
Install an injection fitting that routes into a main line to prevent the backflow of the pumped medium in the dosing line. Unwanted mixing in the dosing line occurs if any possible backflow from the main line is not prevented. DANGER! TA 508 Rev. 00 en 11/2015 Subject to technical modifications! www.sera-web.com...
Page 30
CAUTION! If the permissible operating pressure is exceeded and the pump is not equipped with overpressure protection, the pump will be damaged. ATTENTION! TA 508 Rev. 00 en 11/2015 www.sera-web.com Subject to technical modifications!
Page 31
(suction side). Dosing valve 2.11 Installation of the dosing valve prevents the liquid from the system to be treated being able to penetrate into the dosing line. TA 508 Rev. 00 en 11/2015 Subject to technical modifications! www.sera-web.com...
7. Electrical connections 7.1 Mains power connection The sera stepped motor pump is supplied ready for connection with a 2m long power cable, SCHUKO plug in the standard version and optionally with the customer-specific mains power connection. The variable mains power connection enables worldwide use of the stepped motor pump.
8-pole For firmware updates and for the data transfer between USB port pumps (see chapter 10.10.7 "Data transfer"). Seal unused control ports with protective caps. DANGER! 7.2.1 External control TA 508 Rev. 00 en 11/2015 Subject to technical modifications! www.sera-web.com...
Page 34
Collective signal Pump active Ready to Run Collective fault (blue) Analogue output Analogue input Flow meter Remaining batch Stroke frequency (yellow) 24 V external 24 V external (red) Ground Ground TA 508 Rev. 00 en 11/2015 www.sera-web.com Subject to technical modifications!
Pre-alarm and dry running are set to normally open floating contacts at the factory. The sockets of the connections are A-coded and the assignations of the functions are symbolically labelled. TA 508 Rev. 00 en 11/2015 Subject to technical modifications! www.sera-web.com...
Unforeseen start-up of the pump can occur. DANGER! Before connecting the power, ensure that all seals and the hydraulic connection lines are correctly installed and that unused connections are sealed with protective caps. DANGER! TA 508 Rev. 00 en 11/2015 www.sera-web.com Subject to technical modifications!
Stepper motor pump ® iSTEP Operating Instructions 10. Operation 10.1 Controls Manual control iSTEP case with graphical display "BACK" Graphical display LED (status) "START/STOP" "START/STOP" Click wheel TA 508 Rev. 00 en 11/2015 Subject to technical modifications! www.sera-web.com...
Turning the click wheel to the right (clockwise) (2) increases the value and to the left (anticlockwise) (3) reduces the value. Tapping (1) confirms the desired value and the cursor is free again. 10.3 Start-up (initial commissioning) sera Settings sera Settings Select your language...
Flow rate too low – Warning message Flow rate too low – Shutdown Optional diaphragm rupture monitoring Diaphragm rupture Vent valve Venting Analogue operation mA signal < 3.5 mA mA signal > 20.5 mA TA 508 Rev. 00 en 11/2015 Subject to technical modifications! www.sera-web.com...
0.0 % freq. Start 0.0 % freq. Start 10.6.4 Batch 2 Batch 3 TIMER TIMER No Timer chosen! No Timer chosen! PARAMETER chapter Timer 1 10.6.5 Timer ..Timer 10 TA 508 Rev. 00 en 11/2015 www.sera-web.com Subject to technical modifications!
Page 41
Time Password Batch 1 Manual 10.10 Maintenance 0.0 % freq. Start Data Transfer Factory Reset CALIBRATION TIMER Active No Timer chosen! chapter Strokes 0200 Frequency 080% 10.11 Start Calibration TA 508 Rev. 00 en 11/2015 Subject to technical modifications! www.sera-web.com...
(only with a calibrated pump). Batch 1 Manual SEE CHAPTER 10.6.4 0.0 % freq. Start TIMER It is possible to select between ten different timer settings. TIMER SEE CHAPTER 10.6.5 No Timer chosen! TA 508 Rev. 00 en 11/2015 www.sera-web.com Subject to technical modifications!
In this mode, a reduction of the received pulses Mode Division; Multipl. is performed. This means that the pump will only perform a stroke after an adjustable number of Factor .../... pulses (reduction factor) has been received. TA 508 Rev. 00 en 11/2015 Subject to technical modifications! www.sera-web.com...
Page 44
If the number of received pulses exceeds the number that can be handled by the pump, then the pulses will be buffered and the strokes will be performed later. TA 508 Rev. 00 en 11/2015 www.sera-web.com Subject to technical modifications!
A signal with a control current of 4 mA corresponds to 0% stroke frequency; a signal with 20 mA corresponds to 100% stroke frequency. In this range, the stroke frequency behaves proportionally to the control current (see fol- lowing figure). TA 508 Rev. 00 en 11/2015 Subject to technical modifications! www.sera-web.com...
Page 46
If the control current is >15 mA, the stroke frequency of the pump is 80%. PARAMETER 1 0 0 Signal Adjustment Analog I1 05,0 mA Frequency f1 000 % Analog I2 15,0 mA Frequency f2 080 % Current [mA] TA 508 Rev. 00 en 11/2015 www.sera-web.com Subject to technical modifications!
In-/Outputs Batch 2 Extras Batch 3 0.0 % freq. Start Batch 1 PARAMETER Control Manual Impulse; Recipe; Analog Batch 1 Quantity 100N Batch 2 Flow R. 0,0% Batch 3 TA 508 Rev. 00 en 11/2015 Subject to technical modifications! www.sera-web.com...
Page 48
(Example: manual batch, 200 strokes (quantity N) at 50% stroke frequency) Batch 1 BATCH CHARGE Control Manual Batch 1 Manual V: 200N Quantity 200N Stroke Freq. 50,0% 50,0 % freq. Start TA 508 Rev. 00 en 11/2015 www.sera-web.com Subject to technical modifications!
Page 49
Tapping the Back button cancels the batch. NOTE! Signals for "remaining batch" and "batch ended" can be evaluated using ap- propriately configured outputs (see chapter 10.8.3 "Outputs 1 and 2"). NOTE! TA 508 Rev. 00 en 11/2015 Subject to technical modifications! www.sera-web.com...
Page 50
The batch can be cancelled using the START/STOP buttons on the pump or by an external signal ("External Stop"). Another input must be configured accordingly for "External stop" (see chapter 10.8). NOTE! TA 508 Rev. 00 en 11/2015 www.sera-web.com Subject to technical modifications!
Page 51
Incoming signals during the batch dosing are not buffered. The repetition of any batch (or the start of another batch) NOTE! cannot be performed until after completion of the running batch. TA 508 Rev. 00 en 11/2015 Subject to technical modifications! www.sera-web.com...
Page 52
■ is performed by interruption of the input signal ■ Signals for "remaining batch" and "batch ended" can be evaluated using ap- propriately configured outputs (see chapter 10.8.3). NOTE! TA 508 Rev. 00 en 11/2015 www.sera-web.com Subject to technical modifications!
TIMER Next: Timer 1 Tu 10:00 Tu 10:30 Q: 50,0% freq. Any possible overlapping of specified time periods is prevented (an appropriate message is shown on the display). NOTE! TA 508 Rev. 00 en 11/2015 Subject to technical modifications! www.sera-web.com...
Signal Cycle time 40 min Dosing monitoring Calibration Sensor Active Function Warning Strokes Faulty strokes Speed Alarm limit Option Level Normally open Pre-alarm contact Normally open Dry run contact TA 508 Rev. 00 en 11/2015 www.sera-web.com Subject to technical modifications!
Configuration of the input for the batch recipe selection operating mode Batch Start Function for starting the batch externally Contact Normally open contact Configuration of the contact type (NC or NO). Normally closed contact TA 508 Rev. 00 en 11/2015 www.sera-web.com Subject to technical modifications!
Function for specification of the batch speed (20 mA corresponds to the value set under Batch parameters) Contact Normally open contact Configuration of the contact type (NC or NO). Normally closed contact TA 508 Rev. 00 en 11/2015 Subject to technical modifications! www.sera-web.com...
(see chapter 13 "Troubleshooting and fault clearance") for fault descriptions / causes Batch Finished Signal of the end of batch for batch operating mode. Contact Normally open contact Configuration of the contact type (NC or NO). Normally closed contact TA 508 Rev. 00 en 11/2015 www.sera-web.com Subject to technical modifications!
Due to the reduced suction stroke speed, the maximum configurable deliv- Manual ery quantity reduces (see "Technical data"). 41.2 % freq. The Slow mode symbol (arrow) is shown on the Home display. TA 508 Rev. 00 en 11/2015 Subject to technical modifications! www.sera-web.com...
Speed Limit Dosing Monitor 10.9.3 Dosing monitor The connection of a sera flow monitor to the dosing pump ena- EXTRAS bles monitoring of the flow rate of the dosing pump. The connection of a sera flow meter to the dosing pump pro-...
The sensitivity is set to 50% at the factory. This corresponds to a minimum conductivity of the dosing medium of approx. 10 µS/cm. The minimum conductivity at 100% sensitivity is 4 µS/cm. NOTE! TA 508 Rev. 00 en 11/2015 Subject to technical modifications! www.sera-web.com...
Stepper motor pump ® iSTEP Operating Instructions 10.9.5 Level The connection of a sera suction lance enables the monitoring EXTRAS of the fill level of the dosing tank: Diaph. Monitor The following items can be adjusted: Level De-Aeration Pre-alarm ■...
Input of the venting time in seconds. During each venting process, the vent valve will be opened for this time. The factory setting is 10 sec. (value range: 5 – 300 sec.). TA 508 Rev. 00 en 11/2015 Subject to technical modifications! www.sera-web.com...
Page 64
Possible pin assignment for external control of the automatic ventilation device with a PLC Programmable Logic Control (PLC) Venting 24V DC (output) External Stop 24V DC (output) 24V DC Collective fault Input Stroke signal 0V (Ground) TA 508 Rev. 00 en 11/2015 www.sera-web.com Subject to technical modifications!
■ 30 min ■ SD-Card ■ 10 h ■ 24 h ■ Contrast 0-100% ■ Volume unit Display of the units in the metric system or US gallons ■ TA 508 Rev. 00 en 11/2015 Subject to technical modifications! www.sera-web.com...
PW1-Mode sages (Level 02, see "Menu guidance"). This password can be activated PW2-Mode and deactivated (when leaving the factory, it is activated). Password 1 9990 Password 2 9021 TA 508 Rev. 00 en 11/2015 www.sera-web.com Subject to technical modifications!
Disconnect power Pump rinsed ? Chapter and change 11.1.2 diaphragm! Diaphragm change finished? The counters for diaphragm operating hours and diaphragm service life are reset after successful diaphragm replacement. TA 508 Rev. 00 en 11/2015 Subject to technical modifications! www.sera-web.com...
Display Pumpe 10.10.8 Factory settings Restore pump to factory settings SYSTEM (see parameters table for factory settings). Data Transfer YES must be set and acknowledged for this. Factory Reset TA 508 Rev. 00 en 11/2015 www.sera-web.com Subject to technical modifications!
0200 Strokes 0200 calibration has been MANUAL MANUAL Frequency 080% Frequency 080% NOTE! performed. Q:20,000 l/h 100.0 % freq. Start Cal. Start Cal. This value can now be changed! TA 508 Rev. 00 en 11/2015 Subject to technical modifications! www.sera-web.com...
Page 70
After calibration of the pump, the total dosing volume is also indicated in litres. TIMER operating mode After calibration of the dosing pump, the delivery rate is entered directly as setpoint in l/h instead of via the stroke frequency adjustment. TA 508 Rev. 00 en 11/2015 www.sera-web.com Subject to technical modifications!
Operat. Hours SW-Version vCprot10 HW-Version vHC02.001 sera Code 19570 Serial-No. 10.13 Messages The messages menu function can be reached using a message icon from the operating mode window. All messages that occur during operation are displayed here in plain text and with date and time of the occurrence.
WARNING! Repairs on the stroke drive may only be performed by sera. The pump should only be opened by sera or after previous consultation with sera. WARNING! Before starting all maintenance work, ensure that the required wear and/or spare parts are available.
TIGHTENING TORQUES OF THE FIXING SCREWS Pump body Pump body ...FRP Pump body PVC Pump body 1.4571 iSTEP S 15 ® iSTEP S 30 ® iSTEP S 40 ® iSTEP S 50 ® TA 508 Rev. 00 en 11/2015 Subject to technical modifications! www.sera-web.com...
Replacement of the wear parts must only be performed on depressurised systems that are disconnected from the power supply. WARNING! Remove cover plate (1) of the pump body (GRP design). ■ TA 508 Rev. 00 en 11/2015 www.sera-web.com Subject to technical modifications!
Page 75
Connect the suction and pressure lines as well as the electrical connection of the dosing pump. The dosing pump is operational again after executing the instructions on the graphical display (see chapter 10.10.6 "Maintenance"). TA 508 Rev. 00 en 11/2015 Subject to technical modifications! www.sera-web.com...
Depending on their use and period of use, wear parts must be replaced at regular intervals in order to ensure reliable functioning of the dosing pump. sera recommends replacement of wear parts after 3000 operating hours or at least once per year. In the event of premature diaphragm rupture caused by harsh operating conditions, switch off the dosing pump and replace the drive diaphragm (in accordance with "Diaphragm replacement"...
Screws, complete Flat seal Pump body Push rod adapter Compression spring Automatic ventilation device kit (option) Pos. consisting of Automatic ventilation device (incl. O-ring) Pos. consisting of Diaphragm rupture electrode TA 508 Rev. 00 en 11/2015 Subject to technical modifications! www.sera-web.com...
Operating Instructions 13. Fault analysis and fault correction sera products are sophisticated technical products which are only shipped after having been thoroughly tested and checked at our factory. Should there be any faults, these can be detected and rectified easily and quickly based on the error messages in the display and the instructions in the tables.
Page 79
Remove pump and check for possible damage - increase █ █ █ █ Pumped medium frozen in pipe. temperature of the pumped medium. █ █ Pump valves dry. Moisten pump body and valves. Open vent valve TA 508 Rev. 00 en 11/2015 Subject to technical modifications! www.sera-web.com...
Materials coming into contact Check whether the pumped me- █ █ with the medium not suitable dium matches the design data and for the pumped medium. select other materials if necessary. TA 508 Rev. 00 en 11/2015 www.sera-web.com Subject to technical modifications!
Page 81
Power supply failed / switched █ Restore power supply. off. █ █ █ No mains power connection. Connect mains power supply. Moisten pump body and valves. █ Pump valves dry. Open vent valve TA 508 Rev. 00 en 11/2015 Subject to technical modifications! www.sera-web.com...
Drain off lubricants and dispose of according to regulations! ■ Dismount materials and send them to a suitable waste disposal company! ■ The consignor is responsible for leaking lubricants or fluids! WARNING! TA 508 Rev. 00 en 11/2015 www.sera-web.com Subject to technical modifications!
The clearance certificate is part of the inspection-/repair order. sera reserves the right to refuse acceptance of the order for other reasons. Please make a copy and leave the original with the operating instructions! (can also be downloaded from: www.sera-web.com)
Page 84
Certificate) have been correctly and completely and that the returned parts were carefully cleaned. The parts are sent free of residues of dangerous amount. Place, Date Department Signature (and company stamp) www.sera-web.com TA 508 Rev. 00 en 11/2015 www.sera-web.com Subject to technical modifications!
Page 85
Stepper motor pump ® iSTEP Operating Instructions NOTES TA 508 Rev. 00 en 11/2015 Subject to technical modifications! www.sera-web.com...
Need help?
Do you have a question about the iSTEP S 20 and is the answer not in the manual?
Questions and answers