Sera C 409.2 Series User manual

Controllable Piston Diaphragm Pump
Series C 409.2
Operating instructions
TA436-03 / en / 01.06.12 / li
www.sera-web.com
Subject to technical modifications!
1
Product: Piston diaphragm pump
Type: C 409.2 –7,5 KM
C 409.2 –10 KM
C 409.2 –12 KM
C 409.2 –18 KM
C 409.2 –30 KM
C 409.2 –45 KM
C 409.2 –70 KM
C 409.2 –95 KM
C 409.2 –135 KM
C 409.2 –190 KM
Please state here the exact type and serial
number of your pump.
(can be read off the type plate on the pump)
Type:
Serial-No.:
These data are important in case of queries or for ordering
spare and wearing parts and must absolutely be stated.
Manufacturer:
Seybert & Rahier
GmbH + Co. Betriebs-KG
sera-Straße 1
34376 Immenhausen
Germany
Tel. [phone]
Fax. [phone]
www.sera-web.com
[email protected]
CAUTION !
Keep the operating instructions for future application!

Controllable Piston Diaphragm Pump
Series C 409.2
Operating instructions
2
Subject to technical modifications!
www.sera-web.com
TA436-03 / en / 01.06.12 / li
Table of contents:
1Quickstart ...............................................................4
1.1 Electric supply.........................................................4
1.2 Operating elements.................................................4
1.3 LED operation indicators.........................................4
1.4 Key operation..........................................................5
1.5 Factory settings ......................................................5
1.6 Control inputs and outputs......................................5
1.6.1 Control via a contact signal ............................................5
1.6.2 Control via an analog signal...........................................5
Selecting the operating mode...........................................5
2General...................................................................6
3Types......................................................................6
3.1 Type designation ....................................................6
3.2 Type plate...............................................................6
3.3 Materials................................................................. 7
3.4 Viscosity, pumped medium.....................................7
3.5 Dosing range..........................................................7
3.6 Noise measurement................................................7
4Safety instructions ..................................................7
4.1 Quality instructions..................................................7
4.2 Marking of notes.....................................................7
4.2.1 Marking of notes in these operating instructions............7
4.2.2 Marking of notes on the product.....................................7
4.3 Personnel qualification and training.........................7
4.4 Dangers in case of inobservance of the safety
instructions .............................................................7
4.5 Safety conscious working........................................8
4.6 Safety instructions for owner / operator...................8
4.7 Safety instructions for maintenance, servicing and
installation work......................................................8
4.8 Arbitrary modification and production of spare parts8
4.9 Improper operations................................................8
4.10 Intended use........................................................... 8
4.11 Personal protection for maintenance and service....8
4.12 Utilities....................................................................9
5Transport and intermediate storage.........................9
5.1 General...................................................................9
5.2 Storage ...................................................................9
6Assembly groups of the piston diaphragm pump ...10
7Technical Data......................................................11
7.1 Dimensions ...........................................................11
7.2 Technical Data......................................................13
7.2.1 Output data ...................................................................13
7.2.2 Motor data.....................................................................13
8Functional description............................................14
8.1 General.................................................................14
8.2 Assembly groups of the piston diaphragm pumps
409.2.....................................................................14
8.2.1 Stroke mechanism ........................................................14
8.2.2 Stroke length adjustment..............................................14
8.2.3 Assembly pump ............................................................16
8.2.4 Pump body....................................................................17
8.2.5 Suction-/Pressure valve................................................17
8.2.6 Diaphragm rupture monitoring......................................18
8.3 Drive motor............................................................18
8.3.1 Start-up .........................................................................18
8.3.2 Motor protection............................................................18
8.3.3 Maintenance of the drive motor....................................18
8.3.4 Restart...........................................................................18
9Installation.............................................................18
9.1 Installation instructions..........................................18
9.1.1 Provide for an overpressure protection ........................20
9.1.2 Preventing a backflow of the pumped medium ............21
9.1.3 Eliminating undesired siphoning...................................21
9.1.4 How to ensure suction free from air..............................22
9.1.5 Install the empty-tank alarm .........................................22
9.1.6 How to avoid an emptying of the suction line...............23
9.1.7 Line strainer ..................................................................23
9.1.8 Suction via a siphon vessel ..........................................24
9.1.9 In case of easily degassing pumped media .................24
9.1.10 Dosing of suspensions..................................................25
9.1.11 Damping of the pulsation..............................................25
10 Electrical connections............................................28
10.1 Electric supply.......................................................28
10.2 Electrical interfaces ...............................................28
10.2.1 Control inputs and outputs............................................28
10.2.2 Level input with pre-alarm and dry run.........................29
10.2.3 Input for flow control and flow meter.............................30
11 Operation..............................................................30
11.1 Operating elements...............................................30
11.2 LED operation indicators.......................................30
11.3 Key operation........................................................31

Controllable Piston Diaphragm Pump
Series C 409.2
Operating instructions
TA436-03 / en / 01.06.12 / li
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Subject to technical modifications!
3
11.4 Parameter table.................................................... 32
11.5 Menu ....................................................................33
11.5 Menu ....................................................................33
11.5.1  .....................................33
11.5.2 Fault and warning messages .......................................33
11.5.3  .....................................................34
11.5.4 Value entry....................................................................34
11.5.5 Menu guide...................................................................35
11.6 Selecting the operation mode................................39
11.7 Additional settings for the operation mode ............ 39
11.7.1 Additional settings for the ANALOG operation mode ..39
11.7.2 Additional settings for the PULSE mode......................41
11.7.3 Additional settings for the BATCH mode......................42
11.7.4 Settings for the EXTERNAL operation mode...............43
11.8 Configuring the inputs and outputs........................43
11.8.1 Digital input 01..............................................................44
11.8.2 Digital/analog inputs 02 and 03....................................44
11.8.3 Outputs 01 and 02........................................................44
11.9 Flow rate indicator ................................................45
11.10Calibration ............................................................ 46
11.11System .................................................................47
11.12Totalizer................................................................48
11.13Password..............................................................48
11.14Info.......................................................................48
11.15Extras................................................................... 48
11.15.1 Slow-Mode....................................................................48
11.15.2 Dosing monitoring.........................................................49
11.15.3 Diaphragm rupture detection (OPTION) ......................49
11.15.4 Level monitoring ...........................................................50
12 Maintenance.........................................................51
12.1 Wearing parts .......................................................51
12.2 Spare parts...........................................................51
12.3 List of spare and wearing parts.............................52
12.3.1 Piston diaphragm pump ...409.2-...KM........................52
12.4 Replacing the diaphragm......................................54
12.4.1 General.........................................................................54
12.4.2 Piston diaphragm pump................................................54
12.4.3 Ventilation after diaphragm replacement .....................55
12.4.4 Setting the compensating valve ...................................56
12.5 Oil change ............................................................58
13 Lubricants.............................................................58
13.1 Lubricant in stroke mechanism..............................58
13.2 Hydraulic fluid.......................................................59
14 Fault analysis and corrective action.......................59
14.1 Fault analysis and corrective action.......................60
14.2 Analysis of other faults ..........................................62
15 Foreseeable misuse..............................................63
15.1 Transport...............................................................63
15.2 Assembly and installation......................................63
15.3 Start-up.................................................................63
15.4 Operation..............................................................63
15.5 Maintenance/Repair ..............................................64
15.6 Cleaning................................................................64
15.7 Shut-down.............................................................64
15.8 Disassembly..........................................................64
15.9 Disposal................................................................64
16 Shut-down.............................................................64
17 Disposal................................................................64
17.1 Dismantling and transport......................................64
17.2 Complete disposal.................................................64
17.3 Pressure switch.....................................................65

Controllable Piston Diaphragm Pump
Series C 409.2
Operating instructions
4
Subject to technical modifications!
www.sera-web.com
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START
STOP ENTER
1 Quickstart
-up the pump quickly without having
read the operating instructions in detail.
CAUTION !
The Quickstart does not claim to be complete and does
not relieve the user from reading the complete instruc-
tions!
1.1 Electric supply
The sera magnetic diaphragm pump is delivered ready for in-
stallation. Standard delivery includes a 2m power cable with
Euro plug. The standard version C 409.2 is designed for an
operating voltage range of 210 250 V, 50/60 Hz.
CAUTION !
The specifications on the type plate must absolutely be
adhered to!
The C 409.2 is available in two versions:
210 –250 V, 50/60 Hz
100 –120 V, 50/60 Hz
Symbol:
Fig. 01 (Electric supply)
CAUTION !
Only operate the pump when it is connected to an earthed
power supply!
CAUTION !
The pump restarts in the selected operating mode after
the power supply was switched on or a power supply re-
covery following a mains failure!
1.2 Operating elements
START
STOP ENTER
LC-Display
UP-Button
ENTER-Button
STOP/START-Button
DOWN-Button
LED indication
Fig. 02 (Electronics control panel)
1.3 LED operation indicators
Three light-emitting diodes (LED) indicate the status of the
pump.
Green: Operation and stroke indicator
When switching on the pump, the green LED lights steadily.
The operation indicator works in combination with a stroke in-
dicator; during pump operation, the LED flashes in accordance
with the current stroke frequency.
Yellow: Warning indicator
The yellow LED indicates all occurring warning messages (see
Tab. 07). The warning is not only indicated by the LED but also
as plain text in the LCD display.
Red: Fault indicator
The red LED indicates all occurring faults (see Tab. 07). The
fault is not only indicated by the LED but also as plain text in
the LCD display.

Controllable Piston Diaphragm Pump
Series C 409.2
Operating instructions
TA436-03 / en / 01.06.12 / li
www.sera-web.com
Subject to technical modifications!
5
1.4 Key operation
Operation of the pump is performed with 4 keys:
START
STOP
STOP/START key
After connection to the power supply, the pump is switched
ON/OFF using the STOP/START key.
ENTER
ENTER key
You can use the ENTER key to open and confirm value input
fields and to select menu items.
UP / DOWN key
Using the UP/DOWN key, you can scroll the different menu
items / menu levels and select the display of various operating
messages.
During parameter adjustment, the UP key is used to increase
the parameter value and the DOWN key is used to decrease
the parameter value.
1.5 Factory settings
The factory setting of the pump electronics is specified in
Chapter 11.4.
1.6 Control inputs and outputs
1.6.1 Control via a contact signal
WH
BN
GN
YE
GY
PK
RD + BU
Contact signal
Contact signal
Extern Stop
Pulse
Collecting Fault (15 V DC)
-
+
Fig. 03 (Control of digital inputs via a potential-free
contact signal and control of a relay via
an output of the dosing pump)
1.6.2 Control via an analog signal
C204.1 / C409.2
white
brown
green
yellow
grey
pink
red + blue
0 V (Ground)/ - 4..20mA
Output 01 Collecting fault
Control cabinet customer
+
-
max. 50 mA
+ 4..20 mA
Analog 01
Extern Stop
Fig. 04 (Control of analog/digital inputs via
an analog signal, potential-free contact signal
and control of a relay via
an output of the dosing pump)
Selecting the operating mode
Proceed as follows to select the operating mode:
1. Input the password PW01 (factory setting 9990) to re-
lease the programming levels.
2. Change the operating mode.
Operation Mode >Operation Mode< Manual
Extern
Batch
Analog
Pulse
Operation Menu
+
e.g. current stroke frequency (depending on
chosen operation mode)
PW01
PW02
Main Menu
PW01
PW02
Locking by Password 01
(pre setting ex work: 9990,
not activated)
Locking by Password 02
(pre setting ex work: 9021)

Controllable Piston Diaphragm Pump
Series C 409.2
Operating instructions
6
Subject to technical modifications!
www.sera-web.com
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2 General
Before commissioning and during operation of the sera piston
diaphragm pumps the respective regulations valid at the place
of installation are to be adhered to.
The sera piston diaphragm pump is delivered ready for con-
nection. Please read these instructions and especially the
safety notes before you install and start up the pump.
3 Types
3.1 Type designation
Example:
Piston diaphragm pump type C 409.2-30KM
C
409.2
30
KM
Information for adjustment
Ccontrollable
C
409.2
30
KM
Indication of model range/stroke mechanism
C
409.2
30
KM
Indication of nominal delivery rate
This number states the nominal delivery rate in
litres/hour.
(standard version referring to water)
C
409.2
30
KM
Indication of the execution of the pump
KM Designed as piston diaphragm pump
3.2 Type plate
Each sera piston 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. 05 Type plate
Explanation of the indications
on the type plate
1
Type
Pump type
2
No.
Serial number of the 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, temperature 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
p2max. and the pumped medium stated
in the supply contract.
6
nN1/min
Nominal stroke frequency
Stroke frequency which the pump has
been designed for
7
Hydrfl. [cm3]
Buffer fluid
Quantity of buffer fluid in the diaphragm
ring (in the case of piston double dia-
phragm pumps)
Tab. 01 Designation type plate

Controllable Piston Diaphragm Pump
Series C 409.2
Operating instructions
TA436-03 / en / 01.06.12 / li
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Subject to technical modifications!
7
3.3 Materials
The materials used are stated in the order confirmation and the
product description.
3.4 Viscosity, pumped medium
The piston diaphragm pump is suitable for fluids with viscosi-
ties < 100 mPas.
3.5 Dosing range
The rate of delivery of the piston diaphragm pump can be set

The linear dosing range is between 20 and 100%.
3.6 Noise measurement
The sound pressure level measured according to DIN 45635 of
the piston diaphragm pumps is between 50 and 64 dB (A).
4 Safety instructions
CAUTION !
Controllable piston diaphragm pumps are not authorized
for Operating in Ex-Areas!
4.1 Quality instructions
Observance of these operating instructions and, in particular,
the safety instructions, helps to
avoid dangers to persons, machines and environment
increase reliability and service life of the pump and the
complete system
reduce repair cost and downtime
The sera quality management and quality assurance system
for pumps, systems, valves and fittings and compressors is
certified according to ISO 9001:2000.
The sera piston diaphragm pump meets the valid safety and
accident prevention regulations.
CAUTION !
Always keep these operating instructions within reach at
the place of installation.
CAUTION !
Pay attention to the safety data sheet of the pumped me-
dium! The owner must take corresponding accident pre-
vention measures to protect operating personnel from
danger through the delivery media used!
4.2 Marking of notes
4.2.1 Marking of notes in these operating
instructions
Special notes in these operating instructions are marked with
the general danger symbol
(safety symbol in compliance with 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.
4.2.2 Marking of notes on the product
Information signs which are directly attached to the pump, e.g.
arrows of direction of rotation or signs for fluid connections are
to be observed and kept in legible condition.
4.3 Personnel qualification and training
The personnel for operation, maintenance, inspection and in-
stallation must be suitably qualified for their tasks. The owner
must clearly define responsibility and supervision of the per-
sonnel. If the personnel do not have the knowledge required,
then personnel is to be trained and instructed correspondingly.
Such training can be provided by the manufacturer / supplier
upon order of the owner. In addition, the owner has to ensure
that personnel have understood the operating instructions
completely.
4.4 Dangers in case of inobservance of the
safety instructions
Inobservance of these safety instructions can result in danger
to persons, hazards to the environment and damage to the
pump.
Inobservance of the safety instructions may lead to:
Failure of important functions of the pump/system
Inobservance of prescribed methods for maintenance and
servicing
Danger to persons through electrical, mechanical and
chemical influences
Hazards to the environment through leaking dangerous
media

Controllable Piston Diaphragm Pump
Series C 409.2
Operating instructions
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Subject to technical modifications!
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4.5 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.
4.6 Safety instructions for owner / operator
Leaking hazardous delivery media and operating supplies are
to be disposed off in such a way that any danger to persons
and the environment is excluded. The legal regulations are to
be observed.
Danger caused by electrical energy is to be avoided.
4.7 Safety instructions for maintenance,
servicing and installation work
The owner must ensure that any maintenance-, servicing- and
installation work is only entrusted to authorized and suitably
qualified personnel who have carefully read and understood
the operating instructions.
Only those spare parts and operating supplies are to be used
which meet the requirements of the specified operating condi-
tions.
Threaded joints and connections may only be disconnected
when the system is not under pressure.
4.8 Arbitrary modification and production of
spare parts
Modifications of or changements to the pump are only permit-
ted after previous agreement of the manufacturer. Original
spare parts and accessories which were approved by the
manufacturer are essential for safety reasons.
CAUTION !
If the pumps (e.g. drive motor) are modified without au-
thorization of the manufacturer or spare parts are used
which are not approved, any warranty claim becomes null
and void.
4.9 Improper operations
Operating safety of the supplied piston diaphgram pump is
only guaranteed if the product is used as intended, according
to the descriptions in Chapter 4.10 of these operating instruc-
tions.
4.10 Intended 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
CAUTION !
Controllable piston diaphragm pumps are not authorized
for Operating in Ex-Areas!
If the piston diaphragm pump is to be used for other applica-
tions, then the suitability of the pump for the new operating
conditions must be discussed with sera beforehand!
Criteria for operation of the piston diaphragm pump
in accordance with the intended use
Observe characteristics of the pumped medium (please
see safety- and product data sheet of the delivery me-
dium the safety data sheet is to be provided by the sup-
plier / owner of the pumped medium)
Resistance of the materials which come into contact with
the pumped medium
Operating conditions at the place of installation
Pressure and temperature of the pumped medium
Voltage supply
4.11 Personal protection for maintenance and
service
In order to avoid risks to health, the provisions of the German
Ordinance on Hazardous Substances (GefStoffV) (§14 Safety
Data Shee) and relevant national safety regulations for the
pumped medium must strictly be adhered to.
In case of accidents check whether the following substances
are emitted:
Leaking fluids
Leaking vapours
Noise emissions (sound level)
Emissions are to be monitored by corresponding controly sys-
tems of the total installation.
CAUTION !
Wear protective clothing, gloves, breathing mask and a
face protecting mask.
CAUTION !
Personal protective equipment must be provided by the
owner!

Controllable Piston Diaphragm Pump
Series C 409.2
Operating instructions
TA436-03 / en / 01.06.12 / li
www.sera-web.com
Subject to technical modifications!
9
4.12 Utilities
If not agreed otherwise in the contract conditions, the sera -
piston diaphragm pump will always be supplied with the nec-
essary utilities.
(For type and quantitiy of utilities/lubricants, see Chapter 12)
5 Transport and intermediate storage
5.1 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.
CAUTION !
The packaging material must be disposed of appropri-
ately!
5.2 Storage
An undamaged packaging protects the unit during storage and
should only be opened when the piston diaphragm pump is
installed.
Proper storage increases the service life of the piston
disphragm pump and includes prevention of negative influ-
ences such as heat, moisture, dust, chemicals etc.
The following storage specifications are to be obsered:
Storage place: cool, dry, dustfree and slightly ventilated
Storage temperature between +2°C and +40°C
Relative air humidity not more than 50 %.
The maximum storage time for the standard system is 12
months.
If these values are exceeded, metal products should be sealed
in foil and protected from condensation water with a suitable
desiccant.
Do not store solvents, fuels, lubricants, chemicals, acids, disin-
fectants and similar in the storage room.

Controllable Piston Diaphragm Pump
Series C 409.2
Operating instructions
10
Subject to technical modifications!
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6 Assembly groups of the piston diaphragm pump
The piston diaphragm pump may be assembled of the
following (main) components:
Stroke mechanism with drive
Stroke length adjustment
Assembly pump
Pump body with diaphragm
rupture electrode
Suction- and Pressure valve
Optional accessories:
Actuator
Frequency converter
Manual stroke
length adjustment
Manual stroke
length adjustment
with position indicator
Drive motor
with electronic
Pressure valve
Pump body
with diaphragm rupture signal
Stroke length
adjustment with
actuator
Assembly pump
Suction valve
Fig. 06 Overview of assemblies

Controllable Piston Diaphragm Pump
Series C 409.2
Operating instructions
TA436-03 / en / 01.06.12 / li
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Subject to technical modifications!
11
(zum Abnehmen der Stellmotorhaube)
min. 200
7
80
98
98 80
30
39
M8, d=6,5
Befestigungsbohrungen
A
E
F
D 148 K 2
10
75
21ca. 190
154ca. 210
B
C
K 3 K 4...6
ca. 110
H
7 Technical Data
7.1 Dimensions
Fig. 07 Dimensions
1) Drive with electronics can be rotated throughout 90° each and can be put to the positions I and II.
(release the motor fastening screws, put the motor carefully to the desired position and fasten with screws again).
I
II
1)
M8, d=6,5
Mounting holes
(for removing the actuator cover)

Controllable Piston Diaphragm Pump
Series C 409.2
Operating instructions
12
Subject to technical modifications!
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Tab. 02
Dimensions
All dimensions in mm !
Pump type
C409.2 - 7,5 KM
C409.2 –10 KM
C409.2 - 12 KM
C409.2 - 18 KM
C409.2 - 30 KM
C409.2 - 45 KM
C409.2 - 70 KM
C409.2 - 95 KM
C409.2 - 135 KM
C409.2 - 190 KM
Valves
A
Single valves
PVC
---
---
---
---
97
97
97
97
97
97
Chamber valves
PVC
88
88
88
88
---
---
---
---
---
---
Single valves
PP-FRP, PVDF-FRP
---
---
---
---
---
---
83
83
83
83
Double valves
PP-FRP, PVDF-FRP
83
83
83
83
83
83
---
---
---
---
Double valves
1.4571/1.4581
84
84
84
84
95
95
95
95
95
95
B
Single valves
PVC
---
---
---
---
104
104
104
104
104
104
Chamber valves
PVC
88
88
88
88
---
---
---
---
---
---
Single valves
PP-FRP, PVDF-FRP
---
---
---
---
---
---
83
83
83
83
Double valves
PP-FRP, PVDF-FRP
83
83
83
83
83
83
---
---
---
---
Double valves
1.4571/1.4581
84
84
84
84
95
95
95
95
95
95
C
Screw-in thread
Suction-/pressure valve
G ¾
G ¾
G ¾
G ¾
G ¾
G ¾
G ¾
G ¾
G ¾
G ¾
DN
Nominal diameter
8
8
8
8
8
8
8
8
8
8
Build-in
pump
D
Built-in pump
76
76
76
76
118
118
118
118
118
118
Pump
body (PK)
E
Centre screw-in thread of
valves
20
20
20
20
31
31
31
31
31
31
F
PK special steel
(without front plate)
53
53
53
53
58
58
58
58
58
58
PK plastic
(with front plate)
56
56
56
56
67
67
67
67
67
67
Stroke length
adjustment (HLV)
K1
Blind flange for execution
without HLV
8
8
8
8
8
8
8
8
8
8
K2
Manual stroke length
adjustment (max.)
70
70
70
70
70
70
70
70
70
70
K3
Manual HLV with position
indicator
110
110
110
110
110
110
110
110
110
110
K4
Electric servo motor
240
240
240
240
240
240
240
240
240
240
K5
Electric servo motor with
PMR3
320
320
320
320
320
320
320
320
320
320
Option
T
Stroke frequency transmitter
125
125
125
125
125
125
125
125
125
125
H1
MBE Pressure swtich
143
143
143
143
151
151
151
151
151
151
Stroke
mechanism
Amongst others dimensions
for fastening the pump
siehe Fig. 07

Controllable Piston Diaphragm Pump
Series C 409.2
Operating instructions
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13
7.2 Technical Data
7.2.1 Output data
Type
Pump data
Nominal capacity (2) adjustable by changing lift of strokes
Maximum permissible pressure in the pump outlet
Min./max. permissible pressure in the pump inlet
Max. suction height
Inlet / outlet nominal width
Nominal stroke fre- quency
Max. stroke length
Motor size
QN
l/h
ml/Hub
p2
max.
p1
min. / max.
WS
DN
min -1
h100
BG
50/60 Hz
bar
bar
m
mm
50/60 Hz
mm
C 409.2 7,5 KM
0 - 7,5
0 - 1,25
10 (3)
-0,2/0
2
10
100
10
71
80
C 409.2 10 KM
0 - 10
0 - 1,1
10 (3)
-0,2/0
2
10
150
10
71
80
C 409.2 12 KM
0 - 12
0 - 2
10 (3)
-0,2/0
2
10
100
10
71
70
C 409.2 18 KM
0 - 18
0 - 2
10 (3)
-0,2/0
2
10
150
10
71
50
C 409.2 30 KM
0 - 30
0 - 5
10 (3)
-0,3/0
3
10
100
10
71
35
C 409.2 45 KM
0 - 45
0 - 5
10 (3)
-0,3/0
3
10
150
10
71
25
C 409.2 70 KM
0 - 70
0 - 11,6
10 (3)
-0,3/0
3
15
100
10
71
20
C 409.2 95 KM
0 - 95
0 - 10,6
10 (3)
-0,3/0
3
15
150
10
71
16
C 409.2 135 KM
0 - 135
0 - 22,5
10
-0,3/0
3
15
100
10
71
C 409.2 190 KM
0 - 190
0 - 21,1
8
-0,3/0
3
15
150
10
71
Tab. 03 Output data
(1) Achievable height with media similar to water and filled suction line
(2) Linear dosing range between 20 and 100% stroke length
(3) Maximum pressure for pump bodies made of plastics
7.2.2 Motor data
Typ
Motordaten
Output
Frequency
230V, 50/60Hz
115V, 50/60Hz
Isolation class
Protection class
Nominal volt- age
Nominal cur- rent
Nominal volt- age
Nominal cur- rent
[kW]
[Hz]
[V]
[A]
[V]
[A]
[ISO]
[IP]
C 409.2 - ... KM
0,37
50/60
210-250
3,0
100-125
6,0
F
55
Tab. 04 motor data

Controllable Piston Diaphragm Pump
Series C 409.2
Operating instructions
14
Subject to technical modifications!
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6
4 5
%0
20
40
60
80
70
50
10
30
8 Functional description
8.1 General
sera - piston diaphragm 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 dia-
phragm.
Piston diaphragm pumps consist of the following
(main) components:
Drive motor
Stroke mechanism
Stroke length adjustment
Built-in pump
Pump body
Suction- and Pressure valve
Drive motor
with electronic
Hydraulic-
regulating valve
Pressure valve
Stroke length
adjustment
Stroke mechanism
Assembly pump Suction valve
Pump body with diaphragm rupture signalization
Fig. 08 Assembly groups
8.2 Assembly groups of the piston
diaphragm pumps 409.2
8.2.1 Stroke mechanism
Function
Piston diaphragm pumps of this type series use a rotary cam
drive to transmit the rotation of the drive motor to the dis-
placement body.
In case of the rotary cam drive, the eccentric provides the
pressure stroke while the suction stroke is performed by a
pressure spring (return spring).
The effective stroke length can be changed by means of an
adjustable scale knob which prevents the connecting rod from
following the rotary cam up to the rear dead centre during suc-
tion stroke (see stroke length adjustment).
Adjusting
spindle
Stroke
mechanism
Return spring
Eccentric
Connecting rod
Fig. 09 Stroke mechnism
8.2.2 Stroke length adjustment
General
The delivery rate of the pump is set by changing the stroke
length. The stroke length is infinitely variable between 20%
and 100%.
A linear dosing behaviour is achieved with stroke length ad-
justments between 20% and 100%.
8.2.2.1 Manual stroke length adjustment
(standard)
The effective stroke length of the connecting rod is changed by
turning the scale knob.
The stroke length can be adjusted both during operation and
standstill of the pump (depressurized condition).
The set stroke length can be read off a scale, e.g. 75% (see
Fig. 10).
With the 20-steps adjustment on the scale knob, the stroke
length can be set individually with a tolerance of 0.5%.
Turning counter-clockwise the effective stroke length
(see Fig. 10) increases, the
delivery rate increases.
Turning clockwise the effective stroke length
decreases, the
delivery rate decreases.
Scale knob
Fig. 10 Stroke length adjustment/Scale knob

Controllable Piston Diaphragm Pump
Series C 409.2
Operating instructions
TA436-03 / en / 01.06.12 / li
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Subject to technical modifications!
15
0
10
20
3040 50 60 70
80
90
100
%
8.2.2.2 Manual stroke length adjustment by
a dial scale with indication of percent
(option)
The stroke length is adjusted by turning the hand wheel. The
stroke length can be adjusted both during operation and
standstill (in unpressurized condition) of the pump.
Turning counter-clockwise the effective stroke length
(see Fig. 11) increases, the
delivery rate increases.
Drehen im Uhrzeigersinn the effective stroke length
decreases, the
delivery rate decreases.
The set stroke length can be
read off the percent scale
(the example shows a
set stroke length of 65%).
Fig. 11 Stroke length adjustment with position indicator
In delivery state, the stroke length adjustment is factory set to
50%.
CAUTION !
The dial scale with indication of percent may become
misadjusted during transport.
If the indicator does not match the 50% setting, then the
percent scale must be re-adjusted during operation (!) of
the pump!
Set screw
Hand wheel
(Adjusting spindle)
Dial scale with indication of percent
Fig. 12 Stroke length adjustment with position indicator
Adjusting the percent scale:
Switch on the piston diaphragm pump
Loosen setscrew
Remove percent scale from the hand wheel
Manually turn the percent scale to 0% setting
Use the hand wheel to set the stroke length to 0%. Turn
hand wheel clockwise until there is no further stroke
movement (connecting rod does no longer hit the adjust-
ing spindle)
Insert percent scale again
Use the setscrew to secure the percent scale to the hand
wheel
Adjust desired stroke length
8.2.2.3 Automatic stroke length adjustment
by means of an electrical actuator
The electrical actuator is directly mounted to the stroke
mechanism of the dosing pump. A clutch transmits the rotary
motion of the actuator drive shaft to the adjusting
spindle. The axial displacement is compensated in the clutch.
Actuator
Coupling
Stroke mechnism
Fig. 13 Stroke length adjustment by electrical actuator
In case of dosing pumps with electrical actuator, a manual ad-
justment of the stroke length on the pump is no longer possi-
ble.
(Exception: actuator with hand wheel)
The actuator is equipped with two integrated limit switches as
well as a position potentiometer for position feedback as stan-
dard.
Both limit switches are factory set so that the drive will switch
off at a stroke length of 0% and 100%, even if a control voltage
is applied.
This guarantees that adjustments can only be made within the
permissible range. The position potentiometer is driven by a
safety clutch which prevents damage caused by incorrectly
adjusted limit switches.
Activation is performed by appropriate control units
(see sera - accessories)
The set stroke length can be read off on the pump (percent
scale)

Controllable Piston Diaphragm Pump
Series C 409.2
Operating instructions
16
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Information on the electrical connection is given inside the
cover of the actuator.
CAUTION !
The adjustment is only possible when the pump is
running.
8.2.2.4 Automatic stroke length adjustment
by means of an electrical actuator
with integrated positioner (PMR3)
same as Chapter 8.2.2.3, additionally:
PMR3 positioner
This PMR3 positioner which is integrated in the actuator allows
       oportional to the
connected input signal.
Information on the electrical connection is given inside the
cover of the actuator.
8.2.3 Assembly pump
Function
The stroke movement of the mechanically linked piston is
transferred hydromechanically to the intermediate diaphragm
and thus to the pumped medium.
The multi-layer diaphragm touches the spherical cap (pump
body or diaphragm ring) when the pressure stroke finishes in
the front dead centre.
The compensating valve ensures an optimum quantity of hy-
draulic fluid between diaphragm and piston.
The so-called blow valve and the hydraulic discharge valve are
the most important components of the compensating valve.
Both valves are spring-loaded and can be adjusted according
to the operating conditions (see Chapter 11.4.4.).
Minimum quantities of fluid may leak on the piston which are
compensated for by the adjustable blow valve at each suction
stroke.
The leaking fluids are returned to the store tank via a return
pipe (see Fig. 15).
ACHTUNG !
During the operation the pump`s hydraulic fluid may
change the color. This will not affect the life time respec-
tively the safety of the pump.
Thus, the system is closed and no more hydraulic fluid 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 suction
stroke.
The excess quantity is returned into the store tank via the
hydraulic discharge valve at the end of a pressure stroke when
the diaphragm touches the calotte.
If a stop valve is closed in the pressure pipe during operation
of the pump, the complete stroke volume of hydraulic fluid is
returned into the store tank to protect the pump from overload.
If the pressure in the pressure pipe falls below the set pressure
of the hydraulic discharge valve, the blow valve sucks in hy-
draulic fluid until the optimum volume has been reached.
This process can take up to several minutes, depending on the
operating conditions.
Blow- and hydraulic discharge valve are set to the pressure
specified in the order confirmation before shipment.
CAUTION !
The hydraulic discharge valve is not a safety valve accord-
ing to the pressure equipment directive 97/23EC.
Blow valve
Hydraulic
compensating valve
Hydraulic
fluid
Store tank
Hydraulic Hydraulic chamber
discharge valve
Pressure valve Connecting rod
Stroke
mechanism
Piston
Suction valve Diaphragm set
Pump body Pumped medium
Fig. 14 Functional principle of the piston diaphragm pump

Controllable Piston Diaphragm Pump
Series C 409.2
Operating instructions
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17
Return pipe
Store tank
Fig.15 Return pipe
8.2.3.1 Multi-layer Diaphragm
The multi-layer diaphragm consists of a package
of a total of three individual diaphragms.
Working diaphragm (A)
Signal diaphragm (B)
Protection diaphragm (C)
A
B
C
Fig. 16 Mounting position of multi-layer diaphragm
Working diaphragm Signal diaphragm
(medium-contacted) (slotted)
Protection diaphragm
(with notch)
Fig. 17 Assembly of multi-layer diaphragm
The notch of the protection diaphragm indicates the correct
mounting position changing the diaphragm set (see Chapter.
12.4)
8.2.4 Pump body
Depending on the applied counterpressure, movements of the
plastic pump body in elastic materials are possible.

The diaphragm rupture signalization is integrated in the pump
body (see kap. 7.2.7)
8.2.5 Suction-/Pressure valve
The pump valves are ball valves that only work properly in a
vertical position. The condition of the valves has a deciding
effect on the operating capability of the pump.
Valves must be exchanged as complete units.
When replacing the valves it is important to check the flow
direction (see Fig. 18).
CAUTION!
Pressure valve above; Suction valve below !
Flow direction
Fig. 18 Mounting position of valves, flow direction

Controllable Piston Diaphragm Pump
Series C 409.2
Operating instructions
18
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8.2.6 Diaphragm rupture monitoring
sera - piston diaphragm pumps of the series C 409.2
are equipped with a diaphragm rupture monitoring.
CAUTION!
For more detailed information about the indicators of the
diaphragm rupture monitoring, please see enclosed
Documentation!
In case of a rupture of the working diaphragm, a pressure is
generated on the pressure switch. The present signal must be
evaluated and further processed in such a way that the pump
is switched off instantly.
Pressure swtich
Working diaphragm
Pump body
Fig. 20 Diaphragm rupture monitoring by pressure switch
8.3 Drive motor
A sera diaphragm pump of series C 409.2 is driven by a
threephase-motor controlled by the electronics.
8.3.1 Start-up
Preconditions:
Make sure that voltage and frequency correspond with the
specifications on the type plate of electrics.
The nominal motor power on the type plate of the motor refers
to an ambient temperature of 40°C and an installation site be-
low 1000m above sea level. Motor output will be reduced if
these values are exceeded (see VDE 0530).
        
721-2-1.
CAUTION !
The drive motor will heat by operation of the pump.
Do not touch the motor during operation!
8.3.2 Motor protection
A protective motor switch is not necessary due to the fact that
a thermic overload protection is integrated in the pump for the
protection of the motor.
8.3.3 Maintenance of the drive motor
The electric motor should always be kept clean so that neither
dust, dirt, oil nor other contaminates may affect the correct op-
eration.
In addition, we recommend to ensure that:
the motor does not produce strong vibrations
suction and blowing openings for the supply of cooling air
are not closed or restricted (may lead to unnecessary
high temperatures in the windings).
The ball bearings inserted in the motor are lubricated for life.
8.3.4 Restart
Restart the system as described in Chapter 9.3.1 after main-
tenance work of after longer periods of standstill.
9 Installation
CAUTION !
Controllable piston diaphragm pumps are not authorized
for Operating in Ex-Areas!
9.1 Installation instructions
The standard model of the pump is only approved for in-
stallation in dry rooms in a non-aggressive atmosphere,
at temperatures between +2°C and +40°C, permitted hu-
midity until approx. 90%, altitude 1000 m above sea level
For dimensions of the pump connections and fixing holes,
see Fig. 07, Table 02.
Install the pump in such a way that there is no vibration
and no tension and that it is aligned precisely.

Controllable Piston Diaphragm Pump
Series C 409.2
Operating instructions
TA436-03 / en / 01.06.12 / li
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19
CAUTION !
When the C 409.2 is installed next to a pump of series
204.1 and C 410.2 a minimum distance of 100 mm between
the pumps (motor housings) has to be kept!
Install the pump at the optimum possible operating height.
Mount the pump in such a way that the valves are verti-
cal.
Ensure that there is sufficient space around the pump
body and the suction and pressure valve so that these
parts may be easily dismantled, if required.
The stroke length adjustment, indicator scale and visual
diaphragm rupture signalling must be easily accessible
and readable.
Design the nominal diameters of the downstream pipes
and of the connections built into the system to be the
same size or larger than the inlet / outlet nominal widths
of the pump valves.
To check the pressure ratios in the pipe system, we rec-
ommend to provide for connections for pressure gauges
(e.g. manometers) near the suction and pressure attach-
ments.
Provide evacuation fittings
Prior to connecting the pipes, remove the plastic caps on
the suction and pressure attachments of the pump.
Check that the fixing screws for the pump body are tightly
fitted and, if necessary, retighten.
CAUTION !
The pump is designed for operation in non-hazardous ar-
eas!
Torque for tightening the fixing screws
Pump type
Torque
(Nm)
..409.2 7,5 KM
15,0
..409.2 10 KM
..409.2 12 KM
..409.2 18 KM
..409.2 30 KM
..409.2 45 KM
..409.2 70 KM
..409.2 95 KM
..409.2 135 KM
..409.2 190 KM
Tab.05 Torque for tightening
Plastic cap
Fixing
screws
Plastic cap
Fig. 21 Piston diaphragm pump with plastic caps
For models with a built-on actuator, ensure sufficient
space for removal of the cover
(see Chapter 7.1 
Connect pipes to the pump in such a way that there are
no forces acting on the pump, such as e.g. misalignment,
weight or stress of the pipe.
Keep the suction lines as short as possible.
Use pressure- and medium-resistant hoses / pipes.
All pipes and containers connected to the pump must
comply with the regulations and must be cleaned, ten-
sion-free and intact.
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.
CAUTION !
When toxic, crystal-forming or corrosive liquids are being
delivered, the pipe system must be equipped with devices
so that it can be emptied, cleaned and, if necessary,
rinsed with a suitable medium.
CAUTION !
The piston diapraghm pump must be installed in such a
way that no damage can be caused if medium is leaking
out.

Controllable Piston Diaphragm Pump
Series C 409.2
Operating instructions
20
Subject to technical modifications!
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In order to avoid cavitation, overloading and excessive deliv-
ery, the following points should be noted:
avoid high suction heights
keep pipes as short as possible
choose sufficiently large nominal diameters
avoid unnecessary choke points
install a pulsation damper
install a pressure relief
install a pressure keeping valve, if necessary
in the case of degassing media, provide for a supply
CAUTION !
The operator must take suitable precautions on the supply
side (collecting tray, diaphragm rupture electrode) to en-
sure that the container does not run dry in the event of a
diaphragm rupture.
9.1.1 Provide for an overpressure protection
If the permissible pressure in the system may be exceeded,
e.g. when a shut-off valve is closed or if the line is blocked:
install the overflow valve
When using an external relief valve the following is valid for the
feed back pipe:
lead the overflow line with descending gradient in the
store tank which is under atmospheric pressure or in an
open drain gutter (see Fig. 22)
or connect the overflow line directly to the pump suction
line, but only if there is no check valve inside the suction
line (e.g. foot valve of a suction lance) (see Fig. 23).
The hydraulic discharge valve installed in the pump protects
the pump from overload. Under certain circumstances an ex-
ternal discharge- or safety valve mounted on the pump pres-
sure side is not required.
In general, however, an external overpressure protection
should be provided.
CAUTION !
Do not connect shut-off valves when the
pump is operating.
CAUTION !
An overpressure protection (e.g. discharge valve) should
always be installed if the permissible operating pressure
may be exceeded.
CAUTION !
The pumped medium may spout out if the pump is dam-
aged.
Diaphragm relief valve
Shut-off valve
Feedback pipe Pressure line
Tank
Piston diaphragm
pump
Shut-off valve
Suction line
Fig. 22 Installation with (external) relief valve
Diaphragm relief valve Pressure line
Shut-off valve
Feedback pipe
Piston diaphragm
pump
Suction line
Shut-off valve
Fig. 23 Installation with (external) relief valve