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Sera 409.2 Series Operating Instructions Manual

Piston diaphragm pump
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* a v a i l a b l e u n t i l 3 1 . 1 2 . 2 0 1 6

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Summary of Contents for Sera 409.2 Series

  • Page 1 * a v a i l a b l e u n t i l 3 1 . 1 2 . 2 0 1 6...

  • Page 2: Table Of Contents

    4.7.8 Stroke frequency transmitter (option) ..................19 4.7.9 Diaphragm rupture monitoring ....................20 5. Technical Data ............................22 5.1 Output data ........................... 22 5.2 Motor data ............................ 23 5.3 Dimensions ........................... 24 TA 435 Rev. 11 en 03/2016 www.sera-web.com Subject to technical modifications!
  • Page 3 13. Fault analysis and corrective action...................... 54 14. Shut-down ..............................56 15. Disposal..............................56 15.1 Dismantling and transport ......................56 15.2 Complete disposal ........................56 16. Clearance Certificate ..........................57 17. Appendix ..............................59 TA 435 Rev. 11 en 03/2016 Subject to technical modifications! www.sera-web.com...

  • Page 4: General

    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.

  • Page 5: Quality Instructions

    ■ The sera quality management and quality assurance system for pumps, systems, valves and fittings and compres- sors is certified according to ISO 9001:2008. The sera product meets the valid safety and accident prevention regulations.

  • Page 6: Safety Instructions For Owner / Operator

    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...

  • Page 7: Operating Conditions

    NOTE! NOTE! 2.11 Utilities/Lubricants If not agreed otherwise in the contract conditions, the sera dosing pump will always be supplied with the necessary utilities. (For type and quantitiy of utilities/lubricants, see Chapter 11.1 „Working materials“). TA 435 Rev. 11 en 03/2016 Subject to technical modifications! www.sera-web.com...

  • Page 8: Foreseeable Misuse

    Suction height too high, pump capacity too low ► process error. ■ Arbitrary modification of the pump (valves, internal fuse, …). ■ Setting of the hydraulic compensating valve misadjusted. ■ TA 435 Rev. 11 en 03/2016 www.sera-web.com Subject to technical modifications!

  • Page 9: Maintenance/Repair

    ■ the assembly pump, electronics opened). Prescribed maintenance schedules ignored. ■ Use of wrong spare parts/oils (e.g. no sera original spare parts, wrong viscosity). ■ Improper mounting of spare and wearing parts (e.g. wrong tightening torque for pump body). ■...

  • Page 10: Transport And Storage

    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.

  • Page 11: Product Description

    (motor driven pumps) (motor driven pumps) Revision index max. Nominal capacity (litre/hour (each pump head)) Displacer (type of construction) Double diaphragm (without) Single diap hragm Multy-layer diaphragm Piston Diaphragm (Example) TA 435 Rev. 11 en 03/2016 Subject to technical modifications! www.sera-web.com...

  • Page 12: Type Plate

    Piston diaphragm pump 409.2 Operating instructions 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. Type min/max 1/min Hydrfl Designation Pump type Serial number of the pump Minimum/maximum permissible pressure in the pump inlet Minimum/maximum permissible pressure in the inlet cross section which the pump can be used for.

  • Page 13: Assembly Groups Of The Piston Diaphragm Pump

    Suction valve Assembly pump Pump body with diaphragm rupture signal Pressure valve Actuator for explosion-hazardous area option EExeIIT4 - motor option not illustrated Diaphragm rupture electrode pressure switch option TA 435 Rev. 11 en 03/2016 Subject to technical modifications! www.sera-web.com...

  • Page 14: Functional Description

    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. Piston diaphragm pumps consist of the following (main) components: Drive motor ■...
  • Page 15 (connecting rod does no longer hit the adjusting spindle (4)). Insert percent scale again. ■ Use the setscrew to secure the percent scale to the ■ hand wheel. Adjust desired stroke length. ■ TA 435 Rev. 11 en 03/2016 Subject to technical modifications! www.sera-web.com...
  • Page 16 Activation is performed by appropriate control units (see sera - accessories) The set stroke length can be read off on the pump (percent scale) Information on the electrical connection is given inside the cover of the actuator.

  • Page 17: Assembly Pump

    Blow- and hydraulic discharge valve are set to the pressure specified in the order confirmation before shipment. TA 435 Rev. 11 en 03/2016 Subject to technical modifications! www.sera-web.com...

  • Page 18: Pump Body

    Depending on the applied backpressure, movements of the plastic pump body in elastic materials are possible. This does not affect the pumps’s service life or operational reliability. The diaphragm rupture signalization is integrated in the pump body (see fig. „Diaphragm rupture monitoring“). TA 435 Rev. 11 en 03/2016 www.sera-web.com Subject to technical modifications!

  • Page 19: Suction-/Pressure Valve

    ATTENTION! 4.7.8 Stroke frequency transmitter (option) sera dosing pumps are oscillating displacement pumps with an exactly defined stroke volume per each pump stroke. If these dosing pumps should be used for automatic filling pro- cesses or charge dosing, then the single pump strokes must be determined and converted into electrical signals.

  • Page 20: Diaphragm Rupture Monitoring

    Piston diaphragm pump 409.2 Operating instructions 4.7.9 Diaphragm rupture monitoring sera diaphragm pumps are equipped with a diaphragm rupture monitoring. 4.7.9.1 Visual diaphragm rupture monitoring by manometer (only local si- gnalling) Standard execution In case of a rupture of the working diaphragm, the medium under pressure flows through a bore in the pump body to the signalling manometer and causes a pointer deflection.
  • Page 21 ≤ 1bar. For this reason and in order to guarantee a correct dosing function, the pump should always ATTENTION! be operated with a pressure of ≥ 1bar! TA 435 Rev. 11 en 03/2016 Subject to technical modifications! www.sera-web.com...

  • Page 22: Technical Data

    Maximum pressure for pump bodies made of plastics. Standard-design. The nominal data refer to water, 20°C and nominal pressure. With lower counterpressure it can come to be soaked off achievements.. TA 435 Rev. 11 en 03/2016 www.sera-web.com Subject to technical modifications!

  • Page 23: Motor Data

    II2G EExe IIT4 EExdeIIT4-motor 0,37 1.400 1.700 II2G EExde IIT4 (flameproof enclosure) The data can be read off the type plate on the drive motor of the respective diaphragm pump! TA 435 Rev. 11 en 03/2016 Subject to technical modifications! www.sera-web.com...

  • Page 24: Dimensions

    Piston diaphragm pump 409.2 Operating instructions 5.3 Dimensions M8, Ø 6,5 M 1...4 Mounting holes for removing the actuator cover TA 435 Rev. 11 en 03/2016 www.sera-web.com Subject to technical modifications!
  • Page 25 AC motor EExeIIT4 - motor Stroke frequency transmitter MBE Manometer MBE Pressure swtich MBE Pressure swtich (Ex) Stroke me- Amongst others dimensions for see drawing chanism fastening the pump TA 435 Rev. 11 en 03/2016 Subject to technical modifications! www.sera-web.com...

  • Page 26: Assembly / Installation

    Exchange the plug in the compensating valve for the vent screw in the bag. ■ Keep the adjusting key (included in the delivery scope) in close proximity to the pump. ■ TA 435 Rev. 11 en 03/2016 www.sera-web.com Subject to technical modifications!
  • Page 27 Check valve Safety valve Vent valve (ball valve) Diaphragm relief valve Injection fitting Pressure keeping valve Shut-off valve Dosing pump with integrated relief valve Strainer Dosing pump CS 409.2 TA 435 Rev. 11 en 03/2016 Subject to technical modifications! www.sera-web.com...

  • Page 28: Provide For An Overpressure Protection

    If the permissible operating pressure is exceeded and the pump is not equipped with an overpressure protection the pump can get damaged. ATTENTION! The pumped medium may spout out if the pump is damaged. DANGER! TA 435 Rev. 11 en 03/2016 www.sera-web.com Subject to technical modifications!

  • Page 29: Preventing A Backflow Of The Pumped Medium

    When installing a pressure keeping valve, make sure that an uncon- trolled dosing is prevented (by a positive pressure difference (≥ 1 bar) between pressure and suction side). ATTENTION! TA 435 Rev. 11 en 03/2016 Subject to technical modifications! www.sera-web.com...

  • Page 30: How To Ensure Suction Free From Air

    6.5 Install the empty-tank alarm so that the tank is refilled before air is drawn in. The delivery may be interrupted if air enter in the suction line! NOTE! TA 435 Rev. 11 en 03/2016 www.sera-web.com Subject to technical modifications!

  • Page 31: How To Avoid An Emptying Of The Suction Line

    (0.1 – 0.5mm aperture size – depen- ding on nominal width of the valve). Pump and system may not function properly if contami-nates are not collected. ATTENTION! TA 435 Rev. 11 en 03/2016 Subject to technical modifications! www.sera-web.com...

  • Page 32: Suction Via A Siphon Vessel

    Pay attention to accelerating pressure which may be genera- ■ ted in a long suction line. 6.9 In case of easily degassing pumped media Install the pump so that it can be operated with afflux. ■ TA 435 Rev. 11 en 03/2016 www.sera-web.com Subject to technical modifications!

  • Page 33: Dosing Of Suspensions

    6.11 Damping of the pulsation By installing pulsation dampers if: for procedural reasons, a pulsation-poor flow rate is desired, ■ Accelerating forces which arise due to the pipe geometry must be reduced. ■ TA 435 Rev. 11 en 03/2016 Subject to technical modifications! www.sera-web.com...
  • Page 34 Mechanical breakdown of the pump, leakage and valve wobbles as a result of the ■ maximum pressure on the pressure side of the pump being ex-ceeded. Damage to the pipe and in the pipe installed fittings. ■ TA 435 Rev. 11 en 03/2016 www.sera-web.com Subject to technical modifications!

  • Page 35: Electrical Connection / Interfaces

    Piston diaphragm pump 409.2 Operating instructions 7. Electrical connection / Interfaces sera diaphragm pumps are driven either by a three-phase motor or an AC motor. 7.1 Motor connection In case of a three-phase motor The motor connection depends on the voltage indication on the type plate and the applied supply voltage.

  • Page 36: Operation In Explosion-Hazardous Areas

    DANGER! The product supplied by sera meets the requirements of directive 94/9/EC if it is correspondingly marked. This guaran- tees safe operation in explosion-hazardous areas. It is the operator’s task to define the field of application and to check whether the pump is suited for this application.

  • Page 37: Operation

    The maintenance notes listed in Chapter 10 are generally applicable. Exception: The oil level in the stroke mechanism of the pump and the level of the hydraulic fluid of the pump must be checked once a week! CAUTION! TA 435 Rev. 11 en 03/2016 Subject to technical modifications! www.sera-web.com...

  • Page 38: Start-Up

    The set pressure must not exceed the nominal pressure of the pump! ATTENTION! For the start-up of the pump exchange the plug in the compensating valve for the vent screw in the bag. ■ TA 435 Rev. 11 en 03/2016 www.sera-web.com Subject to technical modifications!

  • Page 39: Operation

    The flow capacity of the dosing pump is set via the stroke length control (see chapter „Stroke length adjustment“). When using an electrical actuator please take note of the separate operating in- structions for the actuator! NOTE! TA 435 Rev. 11 en 03/2016 Subject to technical modifications! www.sera-web.com...

  • Page 40: Maintenance

    The following safety instructions apply to all service and are sure to follow. Carry out all maintenance work only on non-pressurized system! WARNING! Repairs on the stroke mechanism may only be performed by sera! WARNING! Before starting maintenance make sure that the wearing parts and the spare parts required are available.

  • Page 41: Working Materials

    Piston diaphragm pump 409.2 Operating instructions 11.1 Working materials Pump type Specification sera use Quantity ARAL CLP VG220 Degol ...409.2-...KM DIN51517-3 0,3 Litres BG220 Pump type Type Quantity (cm ...409.2-7,5 KM ...409.2-10 KM ...409.2-12 KM ...409.2-18 KM ...409.2-30 KM ALAN FOOD 100 ...409.2-45 KM...

  • Page 42: Drive Unit

    Fill oil in threaded hole of the venting screw. ■ For type and quantitiy of the gear oil, please see ■ Chapter “Working materials“. Screw in venting screw (5). ■ TA 435 Rev. 11 en 03/2016 www.sera-web.com Subject to technical modifications!

  • Page 43: Dosing Unit

    11.3.1 Overview of the tightening torques Pump type Torque ...409.2-7,5 KM ...409.2-10 KM ...409.2-12 KM ...409.2-18 KM ...409.2-30 KM 15,0 ...409.2-45 KM ...409.2-70 KM ...409.2-95 KM ...409.2-135 KM ...409.2-190 KM TA 435 Rev. 11 en 03/2016 Subject to technical modifications! www.sera-web.com...

  • Page 44: Changing The Diaphragm

    Check all components of the hydraulic system incl. the ■ compensating valve (3) for damage and soiling if the- se have come into contact with the medium in case of a diaphragm rupture. TA 435 Rev. 11 en 03/2016 www.sera-web.com Subject to technical modifications!
  • Page 45 Screw in vent valve. ■ Reset stroke length to the initial value. ■ Connect suction- and pressure line. ■ Fill in new hydraulic fluid after every diaphragm change. ATTENTION! TA 435 Rev. 11 en 03/2016 Subject to technical modifications! www.sera-web.com...
  • Page 46 (4). Adjust the pressure switch to the desired position. Add the suction and pressure line and connect the pump to the power supply. The multi-layer diaphragm pump is then again ready for operation. TA 435 Rev. 11 en 03/2016 www.sera-web.com Subject to technical modifications!
  • Page 47 Put socket spanner (2) (SW10) on rifle nut (4) and hold ■ in place. Put smaller socket spanner (1) (SW5,5) through bigger ■ socket spanner (2), loosen lock nut (3) and remove so- cket spanner (1). TA 435 Rev. 11 en 03/2016 Subject to technical modifications! www.sera-web.com...
  • Page 48 If the defined values are kept, switch pump off and tigh- ■ ten lock nut while holding the rifle nut in place. TA 435 Rev. 11 en 03/2016 www.sera-web.com Subject to technical modifications!
  • Page 49 If an external discharge valve or a safety valve is installed on the pump pressure side the set pressure of the hydraulic discharge valve should be by 10% higher than the set pressure of the discharge / safety valve. ATTENTION! TA 435 Rev. 11 en 03/2016 Subject to technical modifications! www.sera-web.com...
  • Page 50 Doing this the system must be pressurized. Now turn set screw for another half turn. The hydraulic relief ■ valve is set to operating conditions now. Please take care of safety instructions! ■ TA 435 Rev. 11 en 03/2016 www.sera-web.com Subject to technical modifications!

  • Page 51: Spare And Wearing Parts

    The following parts are regarded as spare parts of the piston diaphragm pump: Pump body ■ Manometer ■ Pressure switch ■ Compensating valve ■ Piston ■ Cylinder and cylinder sleeve ■ TA 435 Rev. 11 en 03/2016 Subject to technical modifications! www.sera-web.com...

  • Page 52: List Of Spare And Wearing Parts

    Piston diaphragm pump 409.2 Operating instructions 12.3 List of spare and wearing parts TA 435 Rev. 11 en 03/2016 www.sera-web.com Subject to technical modifications!
  • Page 53 Sealing washer Pos. consisting of Multi-layer diaphragm set Manometer Hydraulic oil Pos. consisting of Manometer Pressure switch Pos. consisting of Pressure switch Pressure switch Pos. consisting of Pressure switch (Ex-execution) TA 435 Rev. 11 en 03/2016 Subject to technical modifications! www.sera-web.com...

  • Page 54: Fault Analysis And Corrective Action

    13. Fault analysis and corrective action sera - products are proven technical products which are only shipped after an extensive final test in our works. Should any malfunctions occur, these can be located and corrected easily with the help of the following reference guide .
  • Page 55 Air in the hydraulik fluid room or Hydraulik fluid control and anew █ █ █ █ █ not enough or too much hydraulik fill see chap. „Ventilation after fluid. diaphragm replacement“. TA 435 Rev. 11 en 03/2016 Subject to technical modifications! www.sera-web.com...

  • Page 56: Shut-Down

    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 435 Rev. 11 en 03/2016 www.sera-web.com Subject to technical modifications!

  • Page 57: Clearance Certificate

    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 58 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 435 Rev. 11 en 03/2016 www.sera-web.com Subject to technical modifications!

  • Page 59: Appendix

    Page 1 of 3 Data sheets showing similar products: Back mount; model 111.12; see data sheet PM 01.09 Panel mounting series, back mount; model 111.16; see data sheet PM 01.10 TA 435 Rev. 11 en 03/2016 Subject to technical modifications! www.sera-web.com...
  • Page 60 WIKA data sheet PM 02.12 ∙ 03/2015 Page 3 of 3 WIKA Alexander Wiegand SE & Co. KG Alexander-Wiegand-Straße 30 63911 Klingenberg/Germany Tel. +49 9372 132-0 +49 9372 132-406 info@wika.de www.wika.de TA 435 Rev. 11 en 03/2016 www.sera-web.com Subject to technical modifications!
  • Page 61 Crimp ring, glossy finish stainless steel, triangular bezel Filling liquid 1) Option Glycerine Approvals and certificates, see website Page 2 of 3 WIKA data sheet PM 02.12 ∙ 03/2015 TA 435 Rev. 11 en 03/2016 Subject to technical modifications! www.sera-web.com...
  • Page 62 0190 / 0191, 0196, 0197 0184 / 0185, Our preset switches are sealed approx. 130 g with lacquer paint and the set 0194 / 0195 pressure is embossed on the body. TA 435 Rev. 11 en 03/2016 www.sera-web.com Subject to technical modifications!
  • Page 63 Type exceeded. 24 V 42 V 250 V 50 mA Gold contacts Silver contacts Adjustable hysteresis Zinc-plated steel (CrVI-free) Stainless steel 1.4305 DIN–socket device TA 435 Rev. 11 en 03/2016 Subject to technical modifications! www.sera-web.com...
  • Page 64 (24 V on request) also see page 35 0186 / 0187 (Up to max 42 V) 0196 / 0197 Order number: 1-1-70-621-007 1-1-80-652-002 24 VDC: 1-1-84-652-011 1-1-00-420-009 250 VAC: 1-1-84-652-010 TA 435 Rev. 11 en 03/2016 www.sera-web.com Subject to technical modifications!
  • Page 65 26/27. Accessories see page 28 Static pressure, dynamic pressures should be 30 to 50% lower. These values refer to the hydraulic or pneu- matic part of the pressure switch. TA 435 Rev. 11 en 03/2016 Subject to technical modifications! www.sera-web.com...
  • Page 66 Customer specific set point adjustment Code SETP Oxygen application Code 0765 Mounting on 2" pipe Code 0407 Stainless steel tag plate and wire Code 9941 www.baumer.com Data sheet A32.02 Page 1 / 4 TA 435 Rev. 11 en 03/2016 www.sera-web.com Subject to technical modifications!
  • Page 67 For other set points the dead band value can be calculated by linear interpolation between the values at 10% and 90%. www.baumer.com Page 2 / 4 Data sheet A32.02 TA 435 Rev. 11 en 03/2016 Subject to technical modifications! www.sera-web.com...
  • Page 68 Dimensions (mm) 2 fixing holes for M6 screw ATEX certified Cable gland (not mounted) 1/4 NPT female www.baumer.com Data sheet A32.02 Page 3 / 4 TA 435 Rev. 11 en 03/2016 www.sera-web.com Subject to technical modifications!
  • Page 69 Pressure range 0 ... 10 bar over pressure max. 40 bar Option : Oxygen application Option : Mounting on 2" pipe Option : Stainless steel tag plate and wire www.baumer.com Data sheet A32.02 Page 4 / 4 TA 435 Rev. 11 en 03/2016 Subject to technical modifications! www.sera-web.com...
  • Page 70 Piston diaphragm pump 409.2 Operating instructions NOTE TA 435 Rev. 11 en 03/2016 www.sera-web.com Subject to technical modifications!
  • Page 71 Piston diaphragm pump 409.2 Operating instructions NOTE TA 435 Rev. 11 en 03/2016 Subject to technical modifications! www.sera-web.com...

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