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39

TA 435

Rev.

11 en

03/2016

Subject to technical modifications!

Piston diaphragm pump

409.2

Operating instructions

www.sera-web.com

10.1 General

As soon as the drive motor is supplied with voltage the pumps starts to work.

NOTE!

The (standard) dosing pump is without an I/O switch. Any devices to switch the dosing pumps on or off have to be 

installed by the operator.

10.2 Setting the delivery rate

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!

10. Operation

Содержание 409.2 Series

Страница 1: ...a v a i l a b l eu n t i l 3 1 1 2 2 0 1 6...

Страница 2: ...ion for maintenance and service 7 2 11 Utilities Lubricants 7 2 12 Foreseeable misuse 8 2 12 1 Transport 8 2 12 2 Assembly and installation 8 2 12 3 Start up 8 2 12 4 Operation 8 2 12 5 Maintenance Re...

Страница 3: ...box 35 7 4 Motor protection 35 8 Operation in explosion hazardous areas 36 8 1 Identification 36 8 2 Installation 36 8 3 Potential equalization 36 8 4 Start up 36 8 5 Operation 37 8 5 1 Degassing of t...

Страница 4: ...the note Text and symbol Danger of fatal injury Risk of injury Damage to property in the operating instructions DANGER X X X Identifies an imminent danger that results in fatal or severe injuries if n...

Страница 5: ...sed WARNING The personnel for operation maintenance inspection and installation must be suitably qualified for their tasks The owner must clearly define responsibility and supervision of the personnel...

Страница 6: ...roved any warranty claim becomes null and void CAUTION The sera product is only to be deployed according to the intended purpose stated in the product description and the acceptance test certificate I...

Страница 7: ...issions are to be monitored by corresponding controly systems of the total installation Wear protective clothing gloves breathing mask and a face protecting mask ATTENTION Personal protective equipmen...

Страница 8: ...ff 2 12 2 Assembly and installation 2 12 Foreseeable misuse The following misuse is assigned to the life cycles of the machine Misuse can result in danger to the operating personnel DANGER Tipping beh...

Страница 9: ...em Pumped medium contaminated with oil Poorly ventilated room 2 12 5 Maintenance Repair Wrong rinsing medium material changed reaction with the medium Wrong cleaning agent material changed reaction wi...

Страница 10: ...s installed Proper storage increases the service life of the product and includes prevention of negative influences such as heat moisture dust chemicals etc The following storage specifications are to...

Страница 11: ...roke mechanism with side drive shaft and connected to the drive via a clutch Z twin design X Stroke mechanism with two opposite pump heads combined suction and pressure side Y Stroke mechanism with tw...

Страница 12: ...n max P2 max bar bar n N Hydrfl Q N l h 1 min cm3 1 2 3 4 5 7 6 No Designation 1 Pump type 2 Serial number of the pump 3 Minimum maximum permissible pressure in the pump inlet Minimum maximum permissi...

Страница 13: ...Drive motor 4 Blind plug M design 5 Manual stroke length adjustment 6 Manual stroke length adjustment with position indicator option 7 Stroke length adjustment with actuator option 8 Stroke frequency...

Страница 14: ...g return spring 3 The effective stroke length can be changed by means of an adjustable scale knob 1 which prevents the connecting rod from following the rotary cam up to the rear dead centre during su...

Страница 15: ...ted during operation of the pump The set stroke length can be read off the percent scale the example shows a set stroke length of 65 In delivery state the stroke length adjustment is factory set to 50...

Страница 16: ...ompensated in the clutch 2 In case of dosing pumps with electrical actuator a manual adjustment of the stroke length on the pump is no longer possible Exception actuator with hand wheel The actuator i...

Страница 17: ...may leak out during normal operation there is no need to replenish hydraulic fluid The blow valve always sucks in a greater quantity of hydraulic fluid than is leaking out at the piston during each s...

Страница 18: ...of the protection diaphragm indicates the correct mounting position changing the diaphragm set see Chapter Replacing the diaphragm The direction of the notch 4 does not matter NOTE 1 4 3 2 The hydraul...

Страница 19: ...ith 2 m cable LED green indicates supply voltage LED yellow indicates switching status When switching inductive loads protectors relays etc surge protectors va ristors must be fitted owing to the high...

Страница 20: ...nometer and causes a pointer deflection Switch off the pump immediately Replace the diaphragm Clean the diaphragm rupture monitoring If the pump is operated with a backpres sure that is only slightly...

Страница 21: ...g instructions www sera web com 4 7 9 3 Diaphragm rupture monitoring by pressure switch Ex Area The pressure switch is factory set to a switching pressure of 1bar For this reason and in order to guara...

Страница 22: ...near dosing range between 20 and 100 stroke length 3 Maximum pressure for pump bodies made of plastics 4 Standard design The nominal data refer to water 20 C and nominal pressure With lower counterpre...

Страница 23: ...rating Thermal class ATEX design BG kW min 1 Hz V A IP 50Hz 60Hz Standard 71 0 37 1 400 1 700 50 60 PAY ATTENTION TO THE TYPE PLATE 1 55 F FU operation 71 037 1 400 1 700 50 60 55 F AC motor 71 0 37...

Страница 24: ...en 03 2016 Piston diaphragm pump 409 2 Operating instructions www sera web com 5 3 Dimensions 1 Mounting holes 2 for removing the actuator cover 2 1 min 200 7 80 98 98 80 30 39 M8 6 5 D S G B C A 148...

Страница 25: ...ter operation N2 M3 AC motor N3 M4 EExeIIT4 motor N4 T Stroke frequency transmitter MBE K1 MBE Manometer K2 MBE Pressure swtich K3 MBE Pressure swtich Ex Stroke me chanism Amongst others dimensions fo...

Страница 26: ...p in such a way that there is no vibration and no tension and that it is aligned precisely Install the pump at the optimum possible operating height Mount the pump in such a way that the valves are ve...

Страница 27: ...ake suitable precautions on the supply side collecting tray dia phragm rupture electrode to ensure that the container does not run dry in the event of a diaphragm rupture WARNING Illustrations in this...

Страница 28: ...on line e g foot valve of a suction lance 6 1 Provide for an overpressure protection 2 2 1 4 5 6 5 6 4 1 19 19 10 10 10 10 The hydraulic discharge valve installed in the pump protects the pump from ov...

Страница 29: ...e if a possible backflow from the main line is not prevented DANGER Pay attention to avoid chemical reactions arising from a backflow of the pumped medium DANGER 2 4 5 3 1 10 9 6 3 Eliminating undesir...

Страница 30: ...m 4 1 5 12 3 8 4 7 1 5 2 9 2 If due to a falling fluid level in the tank air may be drawn in and delivered to a pressurised line or against a pressure keeping valve Install a vent valve 8 into the pre...

Страница 31: ...ll a line strainer 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 2 1 4 11 5 10 Install a foot...

Страница 32: ...Suction via a siphon vessel 6 9 In case of easily degassing pumped media Install the pump so that it can be operated with afflux 2 1 7 14 15 5 10 4 10 2 1 10 4 5 For use with high tanks without connec...

Страница 33: ...reasons a pulsation poor flow rate is desired Accelerating forces which arise due to the pipe geometry must be reduced 6 11 Damping of the pulsation Pump head must be cleaned to avoid precipitation e...

Страница 34: ...keeping valve between pump and pulsation damper 2 5 4 1 10 20 16 1 2 10 16 4 5 16 13 Undamped accelerating forces can cause the following malfunctions damage Fluctuations of the delivery rate dosing...

Страница 35: ...ection of rotation The direction of rotation of the drive motor is arbitrary 7 Electrical connection Interfaces sera diaphragm pumps are driven either by a three phase motor or an AC motor Before clos...

Страница 36: ...group temperature class in compliance with direc tive 94 9 EC Ex II2G c IIBT4 or Ex II2G c IICT4 note special specifications in the confirmation of order The intended operating conditions in explosio...

Страница 37: ...ve no explosive potential Formation of an explosive gas mixture must be prevented DANGER Permissible ambient temperature 0 C Ta 40 C The maintenance notes listed in Chapter 10 are generally applicable...

Страница 38: ...ues Check whether all electrical connections are correct Check whether the information of the mains voltage on the type plate with the local circumstances agrees 9 Start Up 9 1 Driving Motor Precondit...

Страница 39: ...work NOTE The standard dosing pump is without an I O switch Any devices to switch the dosing pumps on or off have to be installed by the operator 10 2 Setting the delivery rate The flow capacity of t...

Страница 40: ...h a suitable detergent rinse so that no delivery medium remains in the pump body Otherwise steps out on dismantling pumped The flushed fluid ab sorb contact and disposed of safely This measure must al...

Страница 41: ...ing materials Pump type Specification sera use Quantity LUBRICANT 409 2 KM 0 3 Litres CLP VG220 DIN51517 3 ARAL Degol BG220 Pump type Type Quantity cm3 HYDRAULIC FLUID 409 2 7 5 KM 409 2 10 KM 409 2 1...

Страница 42: ...ith screw plug pay attention to the sealing ring 4 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 T...

Страница 43: ...Operating instructions www sera web com 11 3 Dosing unit 11 3 1 Overview of the tightening torques Pump type Torque Nm TIGHTENING TORQUES OF THE FIXING SCREWS 1 409 2 7 5 KM 15 0 409 2 10 KM 409 2 12...

Страница 44: ...Remove multi layer diaphragm set 1 out of the cylin der 2 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 m...

Страница 45: ...ecure the nut crosswise 1 Fill hydraulic fluid 1 in store tank type and quantity are indicated in Chapter Working materials Set maximum stroke length Fill hydraulic fluid in store tank and make sure n...

Страница 46: ...e vice 1 Apply delivery pressure and have the pump run for a short period 30s Switch off the pump Screw on the signal device Pressure switch is for pump body made of plastic A Adjust the pressure swit...

Страница 47: ...te from these values the compensating valve is to be reset according to the actual operating conditions while adhering to the maximum permissible pres sures Blow valve Set the spring tension of the bl...

Страница 48: ...ise spring tension is increased higher suction height Counterclockwise spring tension is reduced lower suction height or supply Remove socket spanner and screwdriver and switch pump on pump is operate...

Страница 49: ...is pressed together to solid length ATTENTION Turn set screw slowly clockwise until the fluid level lowers again and reaches the level before opening Turn the set screw a turn further to the right Hy...

Страница 50: ...ight resistance at the pressure spring After pump has primed again in unpressurized system set the hydraulic relief valve back to operating conditions This can be done as follows In case there is a ma...

Страница 51: ...ensure a safe function of the piston diaphragm pump We recommend to replace the intermediate diaphragm after 3000 operating hours or at least once a year In case of a premature diaphragm rupture caus...

Страница 52: ...435 Rev 11 en 03 2016 Piston diaphragm pump 409 2 Operating instructions www sera web com 12 3 List of spare and wearing parts 3 6 7 A 10 1 2 11 4 5 12 B A A A B B B 8 9 13 14 15 16 17 18 19 20 21 22...

Страница 53: ...nsisting of 29 O ring 9 Cylinder 30 Insert socket 8 Screw plug 31 O ring 32 Transition piece Cylinder bushing kit Pos consisting of Pump body kit stainless steel 3 Cylinder bushing Pos consisting of 1...

Страница 54: ...Open shut off valves resp check opening status dismount pump and check on poss damages replace damaged parts No liquid in dsing tank Fill supply tank Pump valves leaking Remove and clean pump valves P...

Страница 55: ...echanism drive Leaks at pumphead Contact materials not resistant and unsuitable Check medium against original or der and quote If necessary select different wetted parts Viscosity too high Check visco...

Страница 56: ...utralize and decontaminate Package unit and ship A clearance certificate must be filled in when systems are returned to the manuf acturer see Chapter 16 Acceptance will be rejected if this clearance c...

Страница 57: ...lations for prevention of accidents and the environmental protection regulations such as the Waste Management Act and the German Household Water Act to protect their employees or man and the environme...

Страница 58: ...y arrangements with respect to health or water hazardous media are in the further handling not required required The following safety precautions regarding rinsing residual liquids and waste disposal...

Страница 59: ...atures Reliable and cost effective Design per EN 837 1 Nominal size 40 50 63 80 100 and 160 Scale ranges up to 0 400 bar Mechanical pressure measurement WIKA data sheet PM 01 01 Page 1 of 3 WIKA data...

Страница 60: ...54 14 0 21 100 15 5 48 81 5 107 100 8 30 G B 87 22 0 80 1224557 01 31059155 01 11081163 01 Process connection per EN 837 1 7 3 Lower mount LM NS 50 63 centre back mount CBM Dimensions in mm Standard v...

Страница 61: ...ular bezel Filling liquid Glycerine Page 2 of 3 WIKA data sheet PM 02 12 03 2015 CE conformity Pressure equipment directive 97 23 EC PS 200 bar module A pressure accessory Approvals GL ships shipbuild...

Страница 62: ...e sealed with lacquer paint and the set pressure is embossed on the body Technical data Temperature stability for diaphragm seal materials NBR EPDM FKM Silicone HNBR 40 C 100 C 30 C 120 C 5 C 120 C 40...

Страница 63: ...rmance and materials overview Type 0 14 0 0 141 0 17 0 0 17 1 0 18 0 0 18 1 0 18 3 0 18 4 0 18 5 0 18 6 0 18 7 0 19 0 0 19 1 0 19 4 0 19 5 0 19 6 0 19 7 24 V 42 V 250 V 50 mA 2 A 4 A Gold contacts Sil...

Страница 64: ...nection Pg9 Tightening range 6 9 mm When attached to socket device IP65 Suitable for voltages up to 250 V Socket device with indicator light According to DIN EN 175301 803 A DIN 43650 Threaded connect...

Страница 65: ...at room temperature Thread Order number 0186 Diaphragm pressure switch with spade terminals 3001 0 5 5 0 2 G 1 4 0186 457 03 X 003 1 10 0 5 0186 458 03 X 006 10 50 3 0 0186 459 03 X 009 10 100 3 0 5...

Страница 66: ...ity 1 F S constant pressure cycle CE conformity Low Voltage Directive LVD 2006 95 EC Pressure Equipment Directive PED 97 23 EC ATEX Directive 94 9 EC Protection rating IP 66 EN 60529 Process Connectio...

Страница 67: ...62 1150 2300 3500 7000 280 700 2100 3960 1400 3500 0 25 63 1350 2700 4200 8400 360 900 2700 5500 1800 4500 0 40 64 1700 3400 5350 10700 440 1100 3300 7350 2200 5500 0 60 65 2100 4200 6900 13800 520 1...

Страница 68: ...Vdc 0 4 20 A N A 10 50 mA 0 1 8 A 0 4 4 A 0 4 15 A 12 Vdc 0 4 20 A N A 10 50 mA 0 1 8 A 0 4 4 A 0 4 15 A 24 Vdc 0 4 5 A N A 10 50 mA 0 1 8 A 0 4 4 A 0 4 6 A 30 Vdc 0 4 5 A N A 10 50 mA 0 1 8 A 0 4 2...

Страница 69: ...1 SPDT change over switch with adjustable dead band R 2 SPDT double change over switch U Process connection G1 2 male standard 3 1 2 NPT male 6 1 4 NPT female 8 1 2 NPT female N Pressure range bar Ov...

Страница 70: ...70 Subject to technical modifications TA 435 Rev 11 en 03 2016 Piston diaphragm pump 409 2 Operating instructions www sera web com NOTE...

Страница 71: ...71 TA 435 Rev 11 en 03 2016 Subject to technical modifications Piston diaphragm pump 409 2 Operating instructions www sera web com NOTE...

Страница 72: ......

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