Sera 409.2 ML Series User manual

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* available until 31.12.2016

Multi-layer diaphragm pump
Serie 409.2 ML
Operating instruction
2 www.sera-web.com Technical modifications reserved! TA
431 Rev. 8 en 06/2015
Content:
1General...................................................................4
2Types......................................................................4
2.1 Model key...............................................................4
2.2 Type plate...............................................................4
2.3 Materials.................................................................5
2.4 Viscosity, dosing medium........................................5
2.5 Dosing range ..........................................................5
2.6 Noise test................................................................5
3Safety instructions ..................................................5
3.1 Quality instructions..................................................5
3.2 Marking of instructions............................................5
3.2.1 Marking of instructions (operating manual)....................5
3.2.2 Marking of instructions (Product)....................................5
3.3 Qualification and training of personnel ....................5
3.4 Dangers in case of inobservance of the safety
instructions .............................................................6
3.5 Safety-conscious working .......................................6
3.6 Safety instructions for the operator..........................6
3.7 Safety instructions for maintenance, inspection and
installation...............................................................6
3.8 Arbitrary modification and spare parts production ...6
3.9 Improper use ..........................................................6
3.10 Proper use..............................................................6
3.11 Personal protection for service and maintenance....6
3.12 Utilities....................................................................7
4Transportation and intermediate storage.................7
4.1 General...................................................................7
4.2 Transport................................................................7
4.3 Storage...................................................................7
5Assembly groups of multi-layer diaphragm pump....8
6Technical data ........................................................9
6.1 Dimensions.............................................................9
6.2 Technical data......................................................11
6.2.1 Output data...................................................................11
6.2.2 Motor data BG71 ..........................................................11
7Functional discription.............................................12
7.1 General .................................................................12
7.2 Assembly groups of the multi-layer diaphragm
pumps 409.2 ........................................................12
7.2.1 Stroke mechanism........................................................12
7.2.2 Stroke length adjustment..............................................12
7.2.3 Assembly pump ............................................................14
7.2.4 Pump body....................................................................15
7.2.5 Suction-/Pressure valve................................................15
7.2.6 Stroke frequency transmitter (optional) ........................15
7.2.7 Diaphragm rupture monitoring......................................16
7.3 Driving motor.........................................................17
7.3.1 Motor connection (standard).........................................17
7.3.2 Direction of rotation.......................................................17
7.3.3 Terminal box .................................................................17
7.3.4 Start-up.........................................................................17
7.3.5 Motor protection............................................................17
7.3.6 Maintenance of the drive motor....................................18
7.3.7 Restart...........................................................................18
8Installation.............................................................18
8.1 Installation instructions..........................................18
8.1.1 Provide for an overpressure protection ........................19
8.1.2 How to prevent a backflow of the dosing medium........20
8.1.3 How to eliminate undesired siphoning..........................20
8.1.4 How to ensure an airless suction..................................21
8.1.5 Installing the empty-tank alarm.....................................21
8.1.6 How to avoid an emptying of the suction line...............22
8.1.7 Line strainer ..................................................................22
8.1.8 Suction via a siphon pipe..............................................23
8.1.9 In case of slightly degassing dosing media..................23
8.1.10 Damping of the pulsation..............................................23
9Operation in explosion-hazardous areas ...............25
9.1 General .................................................................25
9.2 Identification..........................................................25
9.3 Installation.............................................................25
9.3.1 General .........................................................................25
9.3.2 Working in explosion-hazardous areas ........................25
9.4 Potential equalisation ............................................25
9.5Start-up.................................................................25
9.6 Operation ..............................................................25
9.6.1 General .........................................................................25
9.6.2 Degassing of the dosing medium.................................25
9.6.3 Temperature indications...............................................25
9.7 Maintenance..........................................................25
10 Maintenance..........................................................26
10.1 Wearing parts........................................................26
10.2 Spare parts............................................................26
10.3 Spare- and wearing parts ......................................27
10.4 Replacing the diaphragm.......................................29
10.4.1 General .........................................................................29
10.4.2 Diaphragm change .......................................................29
10.5 Oil change.............................................................32
11 Lubricant ...............................................................32
11.1 Lubricant in stroke mechanism..............................32
12 Fault analysis and corrective action.......................32

Multi-layer diaphragm pump
Serie 409.2 ML
Operating instruction
TA 431 Rev. 8 en 06/2015 Technical modifications reserved! www.sera-web.com 3
13 Foreseeable misuse..............................................34
13.1 Transport..............................................................34
13.2 Assembly and installation......................................34
13.3 Start-up:................................................................34
13.4 Operation..............................................................34
13.5 Maintenance/Repair..............................................34
13.6 Cleaning ...............................................................35
13.7 Shut-down ............................................................35
13.8 Disassembly.........................................................35
13.9 Disposal................................................................35
14 Decommissioning .................................................35
15 Disposal................................................................35
15.1 Dismounting and transport....................................35
15.2 Complete disposal ................................................35

Multi-layer diaphragm pump
Serie 409.2 ML
Operating instruction
4 www.sera-web.com Technical modifications reserved! TA
431 Rev. 8 en 06/2015
1 General
Before commissioning and during operation of the sera multi-
layer diaphragm pump it is necessary to follow the relevant
local instructions.
The sera multi-layer diaphragm pump is delivered ready for
connection. Carefully read these instructions and especially
the safety instructions herein contained before putting the
diaphragm pump into service.
2 Types
2.1 Model key
Example:
Multi-layer diaphragm pump Type R 409.2-17 ML
R
409.2 17 ML
Information for adjustment
Mnot adjustable
Rmanual adjustable
(stroke length adjustment)
Fwith three phase motor, suitable for
operation with frequency converter
(Combination ‚RF’ is possible!)
R
409.2
17
ML
Indication of type series/stroke drive
R 409.2
17
ML
Indication of nominal delivery rate
This number states the nominal delivery rate in
litres/hour.
(standard version referring to water)
R
409.2
17
ML
Indication of the execution of the plug-in pump
ML Execution Multi-layer diaphragm
2.2 Type plate
Each sera multi-layer diaphragm pump is factory provided with
a type plate. The following information can be found on this
type plate.
1 2 3 4 5 6 7
Fig. 01 Type plate
Explanation of the indications
on the type plate
1
Typ
Pump type
2
Nr.
Serial-No. (Pump)
3 P1min/max [bar]
Minimum/maximum permissible
pressure in the pump inlet
Minimum/maximum permissible pres-
sure in the inlet cross section which the
pump is applicable for. Please consider
that the pressure depends on rotation
speed, delivery rate, t
emperature and
static pressure at inlet.
4 P2max [bar]
Maximum permissible pressure in
the pump outlet
Maximum permissible pressure in the
outlet cross section which the pump is
applicable for. Please consider that the
pressure depends on rotation speed,
delivery rate, temperature and static
pressure at outlet.
5 QNl/h
Nominal delivery rate
Delivery rate which the pump was or-
dered for, based on the nominal rotation
speed nN
, the nominal delivery height
p2
max. and the dosing medium stated
in the supply contract.
6
nN1/min
Nominal stroke frequency for
7 Hydrfl. [cm3]
Buffer fluid
Quantity of buffer fluid in the diaphragm
ring (in the case of double diaphragm
pumps)
Tab. 01 Designation type plate

Multi-layer diaphragm pump
Serie 409.2 ML
Operating instruction
TA 431 Rev. 8 en 06/2015 Technical modifications reserved! www.sera-web.com 5
2.3 Materials
The materials used are indicated in the order confirmation.
2.4 Viscosity, dosing medium
The multi-layer diaphragm pump is suitable for fluids with vis-
cosities < 100 mPas.
2.5 Dosing range
The flow capacity of the multi-layer diaphragm pump can be
controlled manually via the stroke length adjustment (0...100%)
The linear dosing range is between 20…100%
2.6 Noise test
The measured sound pressure level acc. to DIN 45635 for the
diaphragms pumps is between 50 and 60 dB (A).
3 Safety instructions
CAUTION !
If the pump should be operated in explosion-hazardous
areas, please also note the instructions in Chapter 9!
3.1 Quality instructions
Observance of these operating instructions and, in particular,
safety instructions, helps to
•Avoid danger to staff, machines, and environment.
•Increase the reliability and service life of the equipment
and the entire installation.
•Reduce expenses for repairs and downtimes.
The sera quality management and quality assurance system
for pumps, installations, fittings and compressors is certified
according to ISO 9001:2008.
The sera multi-layer diaphragm pump is compliant with the
valid safety requirements and accident prevention regulations
CAUTION !
Always keep these operating instructions within reach at
the workplace!
CAUTION!
Pay attention to the safety data sheet of the medium
conveyed! Take appropriate accident prevention
measures to avoid that operators are endangered by the
used conveying media!
3.2 Marking of instructions
3.2.1 Marking of instructions
(operating manual)
Special notes in these operating instructions are marked with
the general danger symbol
(safety symbol according to DIN 4844 – W9)
The safety sign appears in the following cases:
•If improper observance or non-observance of the operat-
ing manual, work instructions, specified operating proce-
dures and similar can lead to personal injury or accidents.
•If improper observance or non-observance of the operat-
ing manual, work instructions, specified operating proce-
dures and similar can lead to damage to property.
•Due to danger of causticization personnel must wear pro-
tective clothing (safety goggles, safety gloves and safety
apron) for maintenance and repair work on parts which
come into contact with hazardous products or for chang-
ing the containers.
3.2.2 Marking of instructions
(Product)
Information signs which are directly attached to the pump,
such as arrows indicating the direction of rotation or signs for
fluid connections must be adhered to and kept in a legible
condition.
This especially applies to the type plate of the pump.
3.3 Qualification and training of personnel
The personnel who operate, maintain, carry out inspections or
install the machine must be suitably qualified for their tasks.
The operator has to define clearly the responsibility, and the
supervision of the personnel. If the personnel do not have the
knowledge required, then the operator has to carry out
corresponding training and instructions. Such a training can be
realized - if required - upon order of the operator of the
machine by the manufacturer / supplier. The operator has to
ensure furthermore that the personnel have understood the
contents of the operating instructions completely.

Multi-layer diaphragm pump
Serie 409.2 ML
Operating instruction
6 www.sera-web.com Technical modifications reserved! TA
431 Rev. 8 en 06/2015
3.4 Dangers in case of inobservance of the
safety instructions
The inobservance of the safety instructions may result in
personal injuries, hazards to the environment and damages to
the pump.
The inobservance of the safety instructions may have the
following consequences:
•Failure of important functions of the pump
•Failure of prescribed methods for maintenance and
upkeep
•Danger to persons by electrical, mechanical and chemical
influences
•Danger to the environment due to leakage of hazardous
media
3.5 Safety-conscious working
The safety instructions specified in this operating manual, the
national regulations for accident prevention, the safety regula-
tions for the pumped medium valid at the place of installation
as well as internal working-, operating-, and safety instructions
of the owner are to be observed.
3.6 Safety instructions for the operator
Leakage of dangerous conveying media and materials must be
drained off so that a risk to persons and the environment can
be excluded. The legal regulations are to be adhered to.
Dangers caused by electrical energy are to be prevented.
3.7 Safety instructions for maintenance,
inspection and installation
The operator has to ensure that all maintenance, inspection
and installation tasks are carried out by authorized and
sufficiently qualified personnel, who have carefully read and
understood the operating instructions.
Only those spare parts and materials are to be used that
satisfy the requirements of the relevant operating conditions.
Loosen screws and connections only when the system is not
under pressure.
3.8 Arbitrary modification and spare parts
production
Modifications of or changements to the machine are only
allowed after previous agreement of the manufacturer. Original
spare parts and accessories that are authorized by the
manufacturer are essential for safety reasons.
CAUTION!
Use of other parts may result in loss of guarantee for
damages arising as a consequence thereof.
3.9 Improper use
The operating safety of the supplied multi-layer diaphgram
pump is only guaranteed if the product is used as intended,
according to the descriptions in Chapter 3.10 of these operat-
ing instructions.
3.10 Proper use
The sera diaphragm pump is only to be deployed according to
the intended purpose stated in the product description and the
acceptance test certificate.
If the pump is to be used for other purposes, it is required to
consult sera beforehand to settle whether the multi-layer
diaphragm pump is suitable for the new usage!
The criteria for determining whether the multi-layer -diaphragm
pump is appropriately used are:
•Characteristics of the medium conveyed (refer to the
safety and product data sheet of the used medium – the
safety data sheet is to be provided by the supplier /
operator of the conveying medium).
•Stability of the materials which have contact with the
medium conveyed
•Operating conditions at the place of installation
•Pressure and temperature of the conveying and cooling
medium
•Voltage supply
3.11 Personal protection for service and
maintenance
In order to avoid risks to health, the provisions of the German
Ordinance on Hazardous Substances (GefStoffV) (§14 Safety
Data Sheet) and relevant national safety regulations for the
dosing medium must strictly be adhered to.
In case of accidents check whether the following substances
are emitted:
•Leakage of fluids
•Leakage of fumes
•Noise emissions (sound level)
Emissions must be monitored by monitoring systems of the
total installation.
CAUTION!
Use protective clothing, gloves, breathing mask and
suitable goggles for face protection!
CAUTION!
Personal protective equipment must be provided by the
equipment operator at all times!

Multi-layer diaphragm pump
Serie 409.2 ML
Operating instruction
TA 431 Rev. 8 en 06/2015 Technical modifications reserved! www.sera-web.com 7
3.12 Utilities
If not agreed otherwise in the contract conditions, the sera
multi-layer diaphragm pump will always be supplied with the
necessary utilities.
(For type and quantitiy of utilities/lubricants, see Chapter 11)
4 Transportation and intermediate storage
4.1 General
Before shipment sera products are tested for proper
functioning and quality.
An undamaged packaging protects the device during subse-
quent storage and should only be opened when the multi-layer
diaphragm pump will be installed.
CAUTION !
The packaging material must be disposed of
appropriately!
4.2 Transport
Select a hoist which is adapted to the weight of the pump and
attach it to the motor flange of the pump (see Fig. 02).
Fig. 02 Transport/Handling
4.3 Storage
An undamaged packaging protects the device during
subsequent storage and should only be opened when the
multi-layer diaphragm pump will be installed.
A proper storage will increase the service life of the pump.
Proper storage means avoidance of negative influences, such
as heat, humidity, dust, chemicals etc.
The following storage conditions must be observed:
•Storage place: cool, dry, dust-free and slightly ventilated.
•Storage temperature between +2°C and + 40°C.
•Humidity not more than 50%.
•The maximum storage time for the standard system is 12
months.
If this value is exceeded, products made from metal should be
sealed in foil and protected against condensation water using
suitable desiccants.
Do not store solvents, fuels, lubricants, chemicals, acids,
disinfectants and similar together with the product in the
storage room.

Multi-layer diaphragm pump
Serie 409.2 ML
Operating instruction
8 www.sera-web.com Technical modifications reserved! TA
431 Rev. 8 en 06/2015
5 Assembly groups of multi-layer diaphragm pump
The multi-layer diaphragm pump may be assembled of the
following (main) components:
•Stroke mechanism with drive
•Stroke length adjustment
•Assembly pump
•Pump body
•Valves
Options:
•Stroke frequency transmitter
•Actuator
•Frequency converter
Not illustrated:
•Actuator for Ex-area
•pneumatical actuator
•EExeIIT4 – Driving motor
Blind plug
Driving motor for operation Driving motor (M-Execution)
with frequency converter mounted
frequency converter
manual stroke
length adjustment
manual stroke length
adjustment with
position indicator
Pressure valve
Pump body,
diaphragm rupture signal
by pressure switch
Ex-Execution
Stroke length adjustment
by actuator
Stroke frequency transmitter
(with Inductive-contact)
Assembly pump Suction valve
Pump body,
diaphragm rupture signal
by pressure switch
Pump body,
optical, local indication of
diaphragm rupture by Manometer
Fig. 03 Assembly - overview

Multi-layer diaphragm pump
Serie 409.2 ML
Operating instruction
TA 431 Rev. 8 en 06/2015 Technical modifications reserved! www.sera-web.com 9
(zumAbnehmender
Stellmotorhaube)
min. 200
H2
H3
B A
C
E
FD148
K1
K2
K3
K4 ... 6
H1
DN
10
75
154M1... 4
21
N1... 4
7
80
98
98 80
30
39
M8, d=6,5
Befestigungsbohrungen
T
6 Technical data
6.1 Dimensions
Fig. 04 Dimensions
(for removing
the actuator cover)
M 8 / Ø 6,5
mounting
holes

Multi-layer diaphragm pump
Serie 409.2 ML
Operating instruction
10 www.sera-web.com Technical modifications reserved! TA
431 Rev. 8 en 06/2015
Tab. 02
Dimensions
All dimensions in mm !
Pump type
R409.2- 11 ML R409.2- 17 ML R409.2- 30 ML R409.2- 45 ML R409.2- 72 ML R409.2- 110 ML R409.2- 150 ML R409.2- 220 ML
Valves
A
Single valves PVC --- --- 93 93 97 97 --- 124 --- 124
Single valves
1.4571/1.4581 --- --- --- --- --- --- 127 --- 127 ---
Single valves
PP-FRP, PVDF-FRP
--- --- --- --- 94 94 127 --- 127 ---
Double valves
PP-FRP, PVDF-FRP
83 83 90 90 --- --- --- --- --- ---
Double valves
1.4571/1.4581
83 83 91 91 95 95 --- --- --- ---
Chamber valves PVC, 1.4571 88 88 --- --- --- --- --- --- --- ---
B
Single valves PVC --- --- 100 100 104 104 --- 143 --- 143
Single valves
1.4571/1.4581
--- --- --- --- --- --- 127 --- 127 ---
Single valves
PP-FRP, PVDF-FRP
--- --- --- --- 94 94 127 --- 127 ---
Double valves
PP-FRP, PVDF-FRP 83 83 90 90 --- --- --- --- --- ---
Double valves
1.4571/1.4581
--- --- 91 91 95 95 --- --- --- ---
Chamber valves PVC, 1.4571 88 88 --- --- --- --- --- --- --- ---
C Connection thread
suction-/pressure valve
G ¾ G ¾ G ¾ G ¾ G ¾ G ¾
G1¼
G1
G1¼
G1
DN Nominal diameter 5 5 8 8 8 8 20 15 20 15
D Assembly pump 43 43 40 40 44 44 43 43
Pump body (PD)
E Centre – screw-in thread for valves (1.4571) 16 16 18 18 21 21 33 33
Centre – screw-in thread for valves
(PP, PVC, PVDF)
24 24 24 24 27 27 33 33
F Pump body, 1.4571 (without front plate) 49 49 51 51 54 54 80 80
Pump Body, PP, PVC, PVDF (with front plate) 62 62 65 65 65 65 83 83
H1Pumpbody with Manometer (1.4571) 134 134 138 138 141 141 155 155
Pump body with Manometer (PVC, PP, PVDF) 134 134 138 138 141 141 155 155
H2Pump body with pressure switch (1.4571) 139 139 144 144 146 146 161 161
Pump body with pressure switch
(PVC, PP, PVDF)
139 139 144 144 146 146 161 161
H3
PB with pressure switch EX-execution
(1.4571)
211 211 216 216 221 221 234 234
PB with pressure switch EX-execution
(PVC, PP, PVDF) 222 222 226 226 230 230 245 245
Stroke length
adjustment (SLA)
K1
Blind flange for execution without
stroke length adjustment
8 8 8 8 8 8 8 8
K2Manual stroke length adjustment (max.) 70 70 70 70 70 70 70 70
K3Manual stroke length adjustment
with position indicator
110 110 110 110 110 110 110 110
K4Electrical actuator 240 240 240 240 240 240 240 240
K5Electrical actuator with PMR2 320 320 320 320 320 320 320 320
K6Electrical actuator Ex-execution 470 470 470 470 470 470 470 470
Driving motor (BC 71)
M1Driving motor (Standard) 225 225 225 225 225 225 225 225
N1120 120 120 120 120 120 120 120
M2Driving motor for operation with
Frequency converter (FU) 225 225 225 225 225 225 225 225
N2120 120 120 120 120 120 120 120
M3AC - Motor 175 175 175 175 175 175 175 175
N3100 100 100 100 100 100 100 100
M4EExeIIT4 - motor 200 200 200 200 200 200 200 200
N4100 100 100 100 100 100 100 100
Option T Stroke frequency transmitter 110 110 110 110 110 110 110 110
Stroke
mechanism
Amongst others
, dimensions for fastening the
pump
See Fig. 04