Sera AP05 User manual

OPERATING INSTRUCTIONS
TRANSLATION OF THE ORIGINAL OPERATING INSTRUCTIONS EN
AIR OPERATED DIAPHRAGM PUMP AP05
(plastic design)

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TABLE OF CONTENT
IMPORTANT INFORMATION ����������������������������������������������������������������������������������������������������������������4
Export Information ................................................................................................................4
Chemical Reaction Disclaimer.................................................................................................4
Unpacking & Inspection ......................................................................................................... 4
SAFETY PRECAUTIONS������������������������������������������������������������������������������������������������������������������������4
MATERIAL SPECIFICATION �������������������������������������������������������������������������������������������������������������������7
Material Profiles....................................................................................................................7
DimensIons...........................................................................................................................8
Characteristic curves .............................................................................................................8
Performance data .................................................................................................................9
INSTALLATION/OPERATION ����������������������������������������������������������������������������������������������������������������9
Installation Drawing .............................................................................................................. 9
installation / Start up...........................................................................................................10
Troubleshooting Tips and Suggestions.................................................................................... 11
MAINTENANCE ��������������������������������������������������������������������������������������������������������������������������������12
Recommended tools for servicing pump .................................................................................12
Wet End Servicing (Installing Wet End Kit)..............................................................................12
Disassembly ..................................................................................................................12
Mounting ......................................................................................................................14
Air End Servicing (Installing Air End Kit)................................................................................. 16
Shaft, Bushing and O-ring Replacement ............................................................................17
Air Valve O-Ring Replacement .........................................................................................18
Valve and Muffler Gasket Replacement ............................................................................. 19
Replacement Air Valve Kit Installation ..............................................................................20
Exploded View and Spare Parts List.......................................................................................20
CLEARENCE CERTIFICATE �������������������������������������������������������������������������������������������������������������������24
EC DECLARATION OF CONFORMITY��������������������������������������������������������������������������������������������������25

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IMPORTANT INFORMATION
SAFETY PRECAUTIONS
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 apply-ing 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. Please
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
sera airPUMPs maximum temperature limits are based upon the material’s mechanical stress only. Maximum temperature is
ap-plication 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 pro-
tec-tive 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
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
For polypropylene or PVDF pumps do not exceed 6.9 bar (100 psig) air supply and 8.3 bar (120 psig) for
aluminum and stainless steel.
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.
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.

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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.
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.

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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)
PVDF Pure Polyvinylidene Fluoride Strong fluoropolymer with excellent chemical
resistance.
-12°C
(10°F)
104°C
(220°F)
Stainless Steel 316 Stainless Steel Excellent chemical resistance, high tensile
and impact strength, abrasion resistant.
Limited by other
materials used
Aluminium ADC 12, LM24, LM25 Moderate chemical resistance with good
impact strength and abrasion resistance.
Limited by other
materials used
Buna Acrylonitrile-butadiene Rubber General purpose elastomer.Resistant to oil,
water, solvent, and hydraulic fluid.
-12°C
(10°F)
88°C
(190°F)
EPDM Ethylene Propylene Diene
Rubber
Good resistance to mild acids, detergents,
alkalis, ketones, and alcohols.
-40°C
(-40°F)
121°C
(250°F)
FKM Fluorocarbon Rubber
Good chemical resistance and high tempe-
rature properties. Resistant to most acids,
aliphatic, aromatic, and halogenated
hydrocarbons, oils, grease, and fuels.
-40°C
(-40°F)
177°C
(350°F)
Neopren 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)
Santopren
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)
Hytrel Thermoplastic polyester elasto-
mer
Combines resistance and flexibility of elasto-
mers with the strength of plastics. Resistant to
acids, bases, amines, and glycols. Injection
molded with no fabric layer.
-29°C
(-20°F)
104°C
(220°F)
PU Polyester Urethane
Thermoplastic that exhibits excellent abrasi-
on resistance.Injection molded with no fabric
layer.
0°C
(32°F)
66°C
(150°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)

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DIMENSIONS
CHARACTERISTIC CURVES

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PERFORMANCE DATA
INSTALLATION DRAWING
INSTALLATION/OPERATION
Air operated diaphragm pump AP05 (Plastic)
Max Flow Rate: 77 Litre/min. (20 gal/m) Suction/Discharge Size: ½“ FBSP or FNPT
Displacement Per Stroke: 0,08 Litre (0.020 gal) Air Inlet/Exhaust Size: ¼“ FNPT / ½“ FNPT
Max Outlet Pressure: 6,9 bar (10-0 psig) Air Consumption @ 6,9 bar: 51 Nm³/h (30 sfcm)
Max Particle Size: 0,7 bar (10 psig) Max Material Inlet Pressure: 8,3 bar (120 psig)
Noise Level: 4,7 mm (0.19“) Max Air Inlet Pressure: 72,1 dB(A)
Max Suction Lift (Water) dry:
wet:
2,7 mWC (9 ft.)
8,8 mWC (29 ft.) Weight: PP: PVDF:
3,8 kg (8.3 lbs)
5,4 kg (11.9 lbs)
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 di-ameter
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 oper-ating
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.