Sera airPUMP AP025 User manual

OPERATING INSTRUCTIONS
TRANSLATION OF THE ORIGINAL OPERATING INSTRUCTIONS EN
AIR OPERATED DIAPHRAGM PUMP
airPUMP AP025 (plastic design)

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TABLE OF CONTENT
IMPORTANT INFORMATION ����������������������������������������������������������������������������������������������������������������4
Export Information ................................................................................................................4
Chemical Reaction Disclaimer.................................................................................................4
Unpacking & Inspection ......................................................................................................... 4
SAFETY PRECAUTIONS for ATEX pumps �����������������������������������������������������������������������������������������������4
SAFETY PRECAUTIONS (General)���������������������������������������������������������������������������������������������������������6
MATERIAL SPECIFICATION �������������������������������������������������������������������������������������������������������������������8
Material Profiles....................................................................................................................8
DimensIons...........................................................................................................................9
Performance data ...............................................................................................................10
Characteristic curves ...........................................................................................................10
INSTALLATION/OPERATION ��������������������������������������������������������������������������������������������������������������11
Installation Drawing ............................................................................................................ 11
installation / Start up........................................................................................................... 12
Troubleshooting Tips and Suggestions....................................................................................13
MAINTENANCE ��������������������������������������������������������������������������������������������������������������������������������14
Recommended tools for servicing pump ................................................................................. 14
Wet End Servicing (Installing Wet End Kit)..............................................................................14
Disassembly ..................................................................................................................14
Mounting ......................................................................................................................16
Air End Servicing (Installing Air End Kit)................................................................................. 19
Shaft, Bushing and O-ring Replacement ............................................................................19
Air Valve O-Ring Replacement .........................................................................................20
Valve Gasket Replacement .............................................................................................. 21
Replacement Air Valve Kit Installation ..............................................................................22
Exploded View and Spare Parts List.......................................................................................22
CLEARENCE CERTIFICATE �������������������������������������������������������������������������������������������������������������������26
DECLARATION OF CONFORMITY�������������������������������������������������������������������������������������������������������27

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IMPORTANT INFORMATION
SAFETY PRECAUTIONS FOR ATEX PUMPS
Export Information
Chemical Reaction Disclaimer
Unpacking & Inspection
U.S. Export Administration Regulations, pursuant to ECCN 2B350, prohibit the export or re-export to certain enumerated
countries of air operated double diaphragm pumps in which all wetted materials are constructed from fluoropolymers without
first applying for and obtaining a license from the U.S. Bureau of Industry and Security(BIS). This affects all sera airPUMP
pumps constructed from PVDF with PTFE balls and diaphragms.
The user must exercise primary responsibility in selecting the product’s materials of construction which are compatible with the
fluid(s) that come(s) in contact with the product. The user may consult a manufacturer’s representative/distributor agent to seek
a recommendation of the product’s material of construction that offers the optimum available chemical compatibility.
However neither manufacturer nor agent shall be liable for product damage or failure, injuries, or any other damage or loss
arising out of a reaction, interaction or any chemical effect that occurs between the materials of the product’s construction and
fluids that come into contact with the product’s components.
Unpack the pump and examine for any signs of shipping damage.
If damage is detected, save the packaging and notify the carrier immediately.
To install the pump, follow the installation instructions provided.
WARNING
READ THIS SUPPLEMENTAL INSERT COMPLETELY BEFORE INSTALLING AND OPERATING THIS PUMP� FAILURE TO FOLLOW
THESE PRECAUTIONS CAN RESULT IN SERIOUS INJURY OR DEATH�
WARNING
Static sparking can cause explosion. When operating in a hazardous area or pumping a hazardous fluid, the pump’s
grounding screw and entire pump system must be grounded to earth to prevent static discharge. This includes but is not li-
mited to pipes, hoses, tanks, containers, valves, etc. Before operating the pump, ensure the electrical continuity throughout
the pumping system and earth ground is 1 Ohm or less. If it is greater than 1 Ohm, re-check all grounding connections.
WARNING
Static sparking can cause explosion. Excessive fluid flow rates and improper tank filling methods can produce static
electricity causing an explosion. Ensure safe fluid velocities and tank filling procedures in compliance with EN 13463-1
and CLC/TR 50404.
WARNING
Vibrations from operation may cause mounting surfaces and connections to loosen and generate a spark.
Ensure the pump and connections are securely mounted and fastened prior to each operation.

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WARNING
Do not exceed minimum and maximum temperature limits of pump components.
A table of temperature limits is provided in the “Pump Data” section of the manual.
WARNING
Do not exceed maximum pressure stated on the pump serial number sticker.
WARNING
Prior to operating, check pump for any worn o-rings, gaskets, or seals. Any leaking or damaged o-rings, gaskets, or seals
must be repaired or replaced immediately.
WARNING
Pump exhaust may be loud and contain particles. Wear appropriate ear and eye protection. In the event of a diaphragm
rupture material can be forced out of the air exhaust muffler. If product is hazardous or toxic, pipe exhaust to appropriate
safe area.
WARNING
Pump must be cleaned on a regular basis to avoid dust buildup greater than 5mm.
WARNING
The surface temperature of the pump depends upon the temperature of the fluid that is being pumped. The chart below
lists different fluid temperatures and the corresponding pump surface temperatures, which determine the Temperature Class
when used in a hazardous area.
Fluid Temperature Maximum Surface
Temperature
Temperature
Class
Maxium Allowable
Surface Temperature
80°C (176°F) 80°C (176°F) T6 85°C (185°F)

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WARNING
Hot surfaces. sera airPUMPs are capable of handling liquids with temperatures as high as 104ºC (220ºF).
This may cause the outer areas of the pump to become hot as well and could cause burns.
WARNING
Do not exceed 8.3 bar (120 psig) air supply.
WARNING
If a diaphragm rupture occurs, material being pumped may be forced out of the air exhaust. Proper care should be taken,
always wear protective clothing, eye protection & follow standard safety procedures.
SAFETY PRECAUTIONS (GENERAL)
WARNING
sera airPUMPs maximum temperature limits are based upon the material’s mechanical stress only. Maximum temperature is
application dependent. Consult a chemical resistance guide or the chemical manufacturer for chemical compatibility and
temperature limits.
WARNING
Chemical Hazard. This pump is used for transferring many types of potentially dangerous chemicals.
Always wear protective clothing, eye protection and follow standard safety procedures when handling corrosive or
personally harmful materials. Proper procedures should be followed for draining and decontaminating the pump before
disassembly and inspection of the pump. There may be small quantities of chemicals present during inspection.
EXPLOSION HAZARD
sera airPUMP with standard materials of construction should not be used with halogenated hydrocarbons. Halogenated
hydrocarbon solvents can cause explosion when used with aluminum components in a closed (pressurized) system. sera
airPUMPs with standard materials of construction contain aluminum components and will be affected by halogenated
hydrocarbon solvents.
1-1-1 Trichloroethane and Methylene Chloride are the most common halogenated hydrocarbons. However, other haloge-
nated hydrocarbon solvents are suspect if used either as part of paint or adhesive formulation, or for clean-up flushing.
For applications that may involve halogenated hydrocarbons, contact sera to discuss the availability of alternative pump
materials of construction.

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WARNING
When pumping hazardous liquids, or operating the pump in an enclosed room, it is important to pipe the exhaust air to a
safe area.
WARNING
Pump exhaust may be loud and contain particles. Wear appropriate ear and eye protection. In the event of a diaphragm
rupture material can be forced out of the air exhaust muffler. If product is hazardous or toxic, pipe exhaust to appropriate
safe area.
CAUTION
Before attaching air supply to pump to make sure all airline debris is clear. It is recommended to use a
minimum 5µ (micron) air filter before the air valve.
CAUTION
Do not over-tighten the air inlet fitting or muffler. Too much torque could damage the air valve or muffler plate.
CAUTION
Before maintenance or repair, close the compressed air line supply valve, bleed the pressure and disconnect air line from
the pump. Discharge line may also be pressurized. Any pressure must be relieved prior to servicing. Remove suction /
discharge lines & drain the pump.
CAUTION
If pump is used with materials that tend to solidify or settle, the pump should be flushed after each use to prevent damage.
CAUTION
Use only genuine sera replacement parts to assure compatibility and longest service life.
CAUTION
Check the temperature limits for all wetted components when choosing pump materials. See table below.

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MATERIAL SPECIFICATION
MATERIAL PROFILES
Material Chemical composition Description Operating temperature
min� max�
PP Pure Polypropylene Thermoplastic that is resistant to alkali and
strong acids.
0°C
(32°F)
70°C
(158°F)
Conductive PP Carbon filled Polypropylen Thermoplastic that is resistant to alkali and
strong acids and conductive.
0°C
(32°F)
70°C
(158°F)
PVDF Pure Polyvinylidene Fluoride Strong fluoropolymer with excellent chemical
resistance.
-12°C
(10°F)
104°C
(220°F)
Buna Acrylonitrile-butadiene Rubber General purpose elastomer.Resistant to oil,
water, solvent, and hydraulic fluid.
-12°C
(10°F)
88°C
(190°F)
Neoprene Chloroprene Rubber
General purpose elastomer with good resi-
stance to moderate chemicals, oils, grease,
solvents, and some refrigerants.
-18°C
(0°F)
100°C
(212°F)
SantopreneTM
Fully cured EPDM rubber
particles encapsulated in a
polypropylene (PP) matrix
Thermoplastic elastomer with good abrasion
resistance with chemical resistance to a wide
range of solvents and chemicals.
Injection molded with no fabric layer.
-40°C
(-40°F)
107°C
(225°F)
PTFE Polytetrafluoroethylene Chemically inert. Resistant to a wide range
of chemicals.
4°C
(40°F)
107°C
(225°F)
FEP Fluorinated Ethylene Propylene
Similar to PTFE in composition and chemical
resistance. Used to encapsulate FKM o-rings
for superior chemical resistance.
-40°C
(-40°F)
107°C
(225°F)
SantopreneTM is a registered tradename of Exxon Mobil Corp.

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DIMENSIONS

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CHARACTERISTIC CURVES
PERFORMANCE DATA
Air operated diaphragm pump AP025 (Plastic)
Max Flow Rate: 22 Litre/min. (5.8 gal/m) Suction/Discharge Size: 1/4“ BSB (i) / FNPT or
3/4“ BSP (a) / MNPT
Displacement Per Stroke: 0,02 Litre (0.005 gal) Air Inlet: 1/8“ FNPT or FBSPT
Max Outlet Pressure: 8,3 bar (120 psig) Air Consumption @6,9 bar: 13,6 Nm³/h (8 sfcm)
Max Particle Size: 0,06“ (1,8 mm) Max Material Inlet Pressure: 0,7 bar (10 psig)
Noise Level: 65,3 dB(A) Max Air Inlet Pressure: 8,3 bar (120 psig)
Max Suction Lift (Water) dry:
wet:
1,8 mWC (6 ft.)
8,5 mWC (28 ft.) Weight: PP & CFPP: PVDF:
1,0 kg (2.3 lbs)
1,4 kg (3.1 lbs)

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INSTALLATION DRAWING
INSTALLATION/OPERATION
Shut off valve
Shut off valve
Shut off valve
Drain valve
flexible connection
flexible connection
DISCHARGE
SUCTION
Pressure gauge
Compound vacuum/
Pressure gauge
Pulsation damper
INLET
air supply
Air filter Air regulator
flexible connection
at air valve inlet
sera airPUMP

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INSTALLATION / START UP
Installation and Start up
Install the pump in a vertical position or it may not prime properly. Pump should be located as close to the product being
pumped as possible. Suction line length should be as short as possible and limit the number of fittings. Suction line diameter
should not be reduced smaller than the suction diameter of the pump. When using rigid pipe run short sections of flexible hose
or flexible connections between the pump & piping. Secure the pump to a suitable surface.
Air Supply
Connect the pump air inlet to an air supply with sufficient capacity to achieve desired performance. A pressure regulating
valve should be installed to insure air supply pressure does not exceed recommended limits.
Fasteners
Re-torque all fasteners before operation. Creep of housing and gasket materials may cause fasteners to loosen.
Re-torque all fasteners to the torque specifications listed on the exploded view drawing in this manual.
Air Inlet & Priming
Pump will start to operate as soon as the shut-off valve is opened. It is recommended to open the shut-off valve slowly at first.
Once the pump primes; the shut-off valve can be opened additionally to increase the pump’s flow. If the pump is operating
but not pumping any liquid see the troubleshooting section for tips & suggestions.
Accessories
Surge suppressors, spill stops & filter regulators are available and should be used with sera airPUMP.
Air Valve Lubrication
No lubrication is required for the air distribution system.

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TROUBLESHOOTING TIPS AND SUGGESTIONS
PUMP WILL NOT START OR CYCLEL:
■Blocked liquid pipe or hose - Clean out or replace
■Clogged liquid chamber - Remove debris
■Diaphragm shaft bushing / o-ring leak - Replace o-rings
■Air valve carrier not shifting - Inspect, clean
ERRATIC CYCLING:
■Diaphragm failure - Replace diaphragm
■Valve ball not seating properly, worn or damaged – Inspect, remove debris or replace
■Leak in suction line - Inspect, repair or replace
■Diaphragm shaft / o-ring leak - Replace o-rings
■Air valve carrier not shifting - Inspect and clean
■Over lubrication in air valve - Inspect, degrease, clean, and reuse. Remove lubrication
■Excess moisture in air valve – Inspect, dry, reuse. Consider installing an air dryer
■Worn carrier or valve bore – measure carrier and valve bore, diametrical clearance should be between 0,05 - 0,13 mm.
Replace worn components as needed
PUMP CYCLES BUT WILL NOT PUMP:
■Too much suction lift - Reduce suction lift or try filling up liquid chambers with fluid
■Leak in suction line - Inspect, repair or replace
■Valve ball not seating properly, worn or damaged - Inspect, remove debris or replace
■Clogged suction pipe or hose - Inspect & clear
■Clogged strainer if used - Inspect & clear
■Diaphragm failure - Replace diaphragm
PUMPED LIQUID RELEASED FROM AIR EXHAUST:
■Diaphragm failure - Replace diaphragm
■Outer plate unthreading - Tighten & re-torque

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MAINTENANCE
DISASSEMBLY
Recommended tools for servicing pump
■Torx bits (T20, T27 or T30)
■Socket wrenches (5/8“ (2x))
■Snap ring pliers
■Hex wrench (3mm)
■O-Ring pick
■Torque wrench
Wet End Servicing (Installing Wet End Kit)
■Relieve airline pressure and fluid line pressures before conducting maintenance.
■The pump can be drained by turning it upside down and allowing fluid to drain into an appropriate container. Use proper
safety equipment when conducting maintenance as internal components may still contain the pumped media.
■Lubricate all stainless steel to stainless steel fasteners to prevent galling.
2)
The discharge seat o-rings, valve seats and valve balls
(items 13, 14 &15) can now be accessed and replaced
if needed.
1)
Remove the four discharge manifold bolts (item 9) from
the discharge manifold (item 16) using a T30 or T20
Torx bit..

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3)
Repeat the above steps for the suction
manifold (item12). The seat o-rings, valve
seats and valve balls (items 13, 14, &
15) are located in the liquid chambers
(item 18).
4)
Remove both liquid chambers by remo-
ving the six self-threading screws (item
11) using a T30 or T27 Torx bit and (5)
button head cap screws (item 17) using
a T20 Torx bit. Inspect and replace
diaphragms as needed.
5)
Remove the diaphragms (items 20),
begin by loosening the two outer plates
(item 19) using two 5/8” wrenches.
Use 6-sided sockets or wrenches to
prevent damage to the hex portion of
the outer plate.
6)
Remove the outer plate, diaphragm(s), and inner plate (items 19, 20, 21, 22, & 23) from the side that is loosened.
Pull or push the shaft (item 27) and remaining plates and diaphragms out of the center section. If pulling, it may be easier
to grip the diaphragm if it is inverted.
7)
The remaining diaphragm (item 20) and plates (items 19 & 23)
may be removed from the shaft (item 27) by hand or by placing
the shaft in a vise fitted with soft jaws.
Use a 6-sided 5/8” wrench to remove the remaining diaphragm
and plates. Soft jaws are required to prevent damage to the shaft.
A damaged shaft with result in accelerated o-ring wear.
Jaws can be fitted with wood, plastic, rubber, or other soft material
to prevent shaft damage.
After performing required maintenance, the pump can be reassembled. The pump can also be reassembled using the
disassembly instructions in the reverse order as listed above. For detailed assembly instructions, follow steps „Mounting“
instructions on next page.

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MOUNTING
2)
For Santoprene fitted pumps place the inner plate (item
23) over the bolt so that the round groove in the inner
plate faces the diaphragm. For PTFE fitted pumps place
the small diaphragm o-ring (item 22) into the groove of
the diaphragm. Then place the inner plate over the bolt
so that the round groove in the inner plate faces the
diaphragm.
4)
The shaft (item 27) and shaft bushing assembly (items
24, 25 & 26) should retain the lubricant that was
factory applied. If they appear dry, apply a light coat
of lithium thickened grease. Avoid over lubrication as it
can cause decreased performance of the air distribution
system.
1)
Slide the center hole of one diaphragm (item 20) over
the molded in bolt of an outer plate (item 19).
For both PTFE and Santoprene™ fitted pumps the outer
plate should be on the convex face of the diaphragm as
shown.
3)
Apply a medium strength thread locker, such as Loctite®
246, to the outer plate (19) bolt threads and shaft (item
27) threads. To ensure thread locker cures quickly, a
primer such as Loctite®SF7649 should be used. Thread
the shaft onto the outer plate bolt until it is snug.

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6)
Push the shaft (item 27) through the center of the center
section (item 28).
9)
Tighten and torque the outer plates (item 19) to 40 in-lbs
(4,5 Nm).
5)
For PTFE fitted pumps place the large diaphragm o-ring
(item 21) into the groove in the center section (item 28).
8)
The other diaphragm(s) (item 17) and inner/outer plates
(items 19 & 23) can be installed onto the opposite end
of the shaft (item 27). It may be easier to thread the mol-
ded in bolt into the shaft if the diaphragm(s) is inverted
on one or both sides. This can be done by hand.

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12)
Place the suction manifold (item 12) atop the pump.
Tighten and torque the suction manifold bolts (item 11)
in an “X” pattern. Torque to 50 in-lbs (5,6 Nm)
12)
Flip the pump upside down and drop the suction valve
balls (item 15) into the liquid chambers (item 18) ball
cages.
11)
Place the valve seats (item 14) into the seat bore then
the valve seat o-rings (item 13) into the groove that is
formed by the seats.
11)
Install the liquid chambers (item 18) by placing one side
over the diaphragm. Start all 6 screws (item 11) before
tightening and torqueing. Torque all fasteners in a star
pattern to 50 in-lbs (5,6 Nm). Start all 5 screws (item
17) before tightening and Torqueing. Torque all screws
in a X Pattern to 30 in-lbs (3,4 Nm). Repeat to install
the second liquid chamber. Ensure both chambers are
orientated the same and that the inlet and outlet ports
are vertical when facing the front of the pump.
IMPORTANT: Threads must line up or stripping of
threads can occur�

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13)
Stand the pump upright onto the suction manifold feet
(item 12). Place the valve balls (item 15), valve seats
(item 14), and seat o-rings (item 13) into the discharge
manifold (item 16) in the same order as the suction side
was done in step 11. Place the discharge manifold atop
the pump, tighten, and torque the discharge manifold
bolts (item 11) in an “X” pattern. Torque to 50 in-lbs
(5,6 Nm).
2)
Bushings (item 24) are supplied with both o-rings (items
25 & 26). Lubricate the o-rings (item 25) with a com-
patible lubricant and push it into the bushing (item 28)
gland in the center section. Reinstall the bushing hold
down screw (item 17).
1)
To replace the shaft bushings (item 24), carefully remove
the old bushings. Remove the bushing hold down screw
(item 17) using a T20 Torx bit. Use 1 or 2 flat head
screw drivers to pry the bushing out. Repeat for the
other side.
AIR END SERVICING (INSTALLING AIR END KIT)
SHAFT, BUSHING AND O-RING REPLACEMENT
■Follow steps 1 – 6 in the Wet End Servicing disassembly section to access the shaft bushing (item 24) and o-rings (items 23
& 26), then follow steps below.

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2)
Plastic Air Valve
Remove and replace o-rings. Insert cap (item 6) push
down until groove for the retaining ring is visible. Make
sure to lubricate the o-rings prior to inserting into the
valve body with a compatible lubricant.
1)
Plastic Air Valve
Plastic Air Valve. To replace the valve cup (item 6) or
valve cup o-rings (item 5) remove the retaining ring
(item 7), then pull straight up. The use of an M6 bolt,
vise grip, and pry bars may be necessary. See 1 and
1A pictures.
AIR VALVE O-RING REPLACEMENT
■After determining if the condition of the shaft is acceptable, follow steps 5 - 13 in the Wet End Servicing - Wet End Reas-
sembly section to rebuild the rest of the pump.
4)
Inspect the shaft (item 27) for damage. It is common for
shafts to become grooved during service. Grooving is
normally caused by carbonized oil and/or abrasive fo-
reign material getting trapped between the seal and the
shaft. Over time, deep grooves can form in the shaft.
When that occurs, it is recommended that the shaft be
replaced.
3)
If replacing the bushings (item 24), then the muffler felt
(NS) should also be replaced prior to replacing the
second bushing. It is important when installing the felt
that it does not block the air slot. Lubricate the bushing
o-rings (item 25) and press it into the open bushing
gland. Reinstall the bushing, hold down screw (item 17).