Sera R 204.1 Series, Operating Instructions Manual

Page 1: ...S 204 1 1 2 e RS 204 1 2 4 e RS 204 1 6 0 e RS 204 1 7 0 e RS 204 1 10 e RS 204 1 14 e RS 204 1 25 e RS 204 1 30 e RS 204 1 35 e 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...

Page 2: ... 6 3 Technical data 14 6 4 Usable stroke length range with self ventilation 16 7 Functional description 18 7 1 General 18 7 2 Components of the solenoid diaphragm pump R RS 204 1 18 7 2 1 Assembly pump Motor housing 18 7 2 2 Pump body 19 7 2 3 Manual vent valve only FRP execution R 204 1 1 2e 14e RS 204 1 6 0 14e 19 7 2 4 Electronics with control panel 19 7 2 5 Suction pressure valve 20 7 2 6 Auto...

Page 3: ...earing parts 36 11 3 1 Solenoid diaphragm pump R 204 1 0 4e 14e 36 11 3 2 Solenoid diaphragm pump R 204 1 25e 35e 37 11 3 3 Solenoid diaphragm pump RS 204 1 0 4e 14e 38 11 3 4 Solenoid diaphragm pump RS 204 1 25e 35e 39 11 4 Changing working diaphragm 40 12 Fault analysis and corrective action 41 13 Foreseeable misuse 43 13 1 Transport 43 13 2 Assembly and installation 43 13 3 Start up 43 13 4 Ope...

Page 4: ...single solenoid diaphragm pump 2 2 Type plate Each sera solenoid 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 8 9 10 Fig 01 Type plate Explanation of the indications on the type plate 1 Type Pump type 2 QN l h Nominal delivery rate Delivery rate which the pump was or dered for based on the stroke frequen cy nN the nomi...

Page 5: ...s 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 o...

Page 6: ...if the pump is modified arbitrarily the manufacturer refuses any liability claims 3 9 Improper operations Operating safety of the supplied diaphgram pump is only guar anteed if the product is used as intended according to the de scriptions in Chapter 3 10 of these operating instructions 3 10 Intended use The sera diaphragm pump is only to be deployed according to the intended purpose stated in the...

Page 7: ...e unit during subsequent storage and should only be opened when the solenoid dia phragm pump is installed Proper storage increases the service life of the solenoid dia phragm pump and comprises prevention of negative influences such as heat humidity dust chemicals etc The following storage instructions are to be observed Storage place cool dry dust free and slightly ventilated Storage temperatures...

Page 8: ... pump 5 1 R 204 1 The solenoid diaphragm pump may be composed of the following main components Motor housing with stroke magnet Electronics with operating panel Assembly pump Pump body Valves Electronics with operating panel Pressure valve Pump body PVC design Assembly pump Motor housing with stroke magnet Suction valve Pump body FRP design Fig 02 Overview of the components R 204 1 ...

Page 9: ...d diaphragm pump may be composed of the following main components Motor housing with stroke magnet Electronics with operating panel Assembly pump Pump body Valves Vent valve Vent valve Electronics with operating panel Pressure valve Pump body PVC PP PVDF design Assembly pump Motor housing with stroke magnet Suction valve Pump body FRP design Fig 03 Overview of the components RS 204 1 ...

Page 10: ...uctions 10 www sera web com Subject to technical modifications TA 416 Rev 11 en 04 2013 6 Technical specifications 6 1 Dimensions R 204 1 Fig 04 Dimensions R204 1 Disign PP and PVDF FRP 1 2e until 14e Disign PVC 1 4571 and PP and PVDF FRP 25e until 35e View X ...

Page 11: ...Double valve 1 4571 1 4581 76 76 76 Double valve PP PVC PVDF 65 D1 Double valve PP FRP PVDF FRP 80 80 80 80 80 80 D2 Double valve PP FRP PVDF FRP 75 75 75 Single valve PVC 85 85 85 Chamber valve PVC 1 4571 70 70 70 70 70 70 Double valve 1 4571 1 4581 76 76 76 Double valve PP PVC PVDF 65 G Connection thread Suction pressure valve G G G G G G G G G G Assembly pump A Assembly pump 24 24 24 24 24 24 2...

Page 12: ...ating Instructions 12 www sera web com Subject to technical modifications TA 416 Rev 11 en 04 2013 6 2 Dimensions RS 204 1 Fig 05 Dimensions RS 204 1 Disign PP and PVDF FRP 6 0e until 14e Disign PVC PP PVDF and PP and PVDF FRP 25e until 35e View X ...

Page 13: ...alve PP PVC PVDF 65 D1 Double valve PP FRP PVDF FRP with vent valve 168 168 168 168 D2 Double valve PP FRP PVDF FRP with vent valve 163 163 163 Chamber valve PVC PP PVDF with vent valve 158 158 158 158 158 158 Single valve PVC with vent valve 173 173 173 Double valve PP PVC PVDF with vent valve 153 G Connection thread Suction pressure valve G G G G G G G G G G Assembly pump A Assembly pump 24 24 2...

Page 14: ...nge at a stroke length between 20 and 100 Type Pump data Diaphragm diameter Nominal delivery rate adjustable by stroke length ad justment and stroke frequency adjust ment Maximum permissi ble pressure in the pump outlet Minimum maxi mum permissible pressure in the pump inlet Maximum suction height 1 Inlet nominal width Outlet nominal width Nominal stroke frequency Maximum stroke length Usable stro...

Page 15: ...90 33 100 240 50 60 4 8 RS 204 1 10 e 90 33 190 240 50 60 4 8 R 204 1 14 e 75 26 100 240 50 60 4 1 RS 204 1 14 e 75 26 190 240 50 60 4 1 R 204 1 25 e 90 33 100 240 50 60 5 1 RS 204 1 25 e 90 33 190 240 50 60 5 1 R 204 1 30 e 90 33 100 240 50 60 5 1 RS 204 1 30 e 90 33 190 240 50 60 5 1 R 204 1 35 e 90 33 100 240 50 60 5 1 RS 204 1 35 e 90 33 190 240 50 60 5 1 Table 06 Technical data drive Table 07...

Page 16: ...iagram describes the operating range of the stroke length of pump type RS Pump type RS 204 1 2 4e Fig 07 The dosing pump sucks independently between diagram value and 100 of the stroke length The diagram describes the operating range of the stroke length of pump type RS Usable stroke length range with self ventilation 60 80 60 80 0 10 20 30 40 50 60 70 80 90 1 1 5 Suction height m WS Stroke length...

Page 17: ...04 1 30e RS 204 1 35e Fig 08 The dosing pump sucks independently between diagram value and 100 of the stroke length The diagram describes the operating range of the stroke length of pump type RS CAUTION Note the usable stroke length acc to the preceding diagrams Priming problems may arise if these values are fallen below Usable stroke length range with self ventilation 40 50 60 70 70 40 50 60 70 7...

Page 18: ...lowing main components Motor housing with stroke magnet Electronics with connection operating panel Assembly pump Pump body Manual vent valve only by R 204 1 1 2e 14e RS 204 1 6 0e 14e in FRP design Suction and pressure valve Electronics with operating panel Motor housing with stroke magnet Pressure valve Vent valve Assembly pump Suction valve Pump body Fig 09 Components of solenoid diaphragm pump...

Page 19: ...dium into the pressure line Open again for another ventilation The vent valve consists of a vent screw with integrated hose nozzle which must be fitted with a hose inside diameter 6 mm as feedback line see Fig 11 The leaking medium incl the gas admixtures must be dis posed off properly Vent screw Integrated hose nozzle Hose Pump body Fig 11 Vent valve The vent screw is inserted during normal opera...

Page 20: ... which is in stalled on the pump pressure nozzle and which cannot be ret rofitted The pump vents the dosing head of the pump and the suction line either externally or manually controlled or automatically at a predefined interval The vent valve consists of a combination of a check valve which should prevent a back flow of the medium and a sole noid valve see Fig 14 When the controlled solenoid valv...

Page 21: ...nlet and outlet di ameters of the pump 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 sockets Drain cocks are to be provided Prior to connecting the pipes remove the plastic caps on the suction and pressure sockets of the pump see Fig 15 Check that the fixing screws for the pump body are tigh...

Page 22: ...if the line is blocked install overflow valve Fig 16 When using an overflow valve please note for the return line lead the overflow line with descending gradient in the storage tank which is under atmospheric pressure or in an open drain gutter 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 lanc...

Page 23: ...ontents in the dosing line is mixed unintentionally if a backflow from the main pipe is not prevented CAUTION Note avoid chemical reactions during a backflow 8 1 3 Eliminate undesired siphoning when dosing into a main line with negative pressure install a pressure keeping valve in the dosing line CAUTION When installating the pump it is to be ensured that an ex cess supply due to a positive pressu...

Page 24: ...ir gas enters the suction line CAUTION In the case of media which are lightly crystallizing when they come in contact with air the return line should be laid with a loop Thus a contact between the medium and air in the outlet area of the vent valve is prevented Pressurised line Injection fitting Pressure line Solenoid diaphragm pump RS 204 1 Ventilation valve Return line Suction lance Suction line...

Page 25: ...he density of the pumped medium and under consideration of mass accelearation and viscosity of the medium Pressure line Suction lance Suction line H Foot valve Container Fig 22 Avoiding an emptying of the suction line 8 1 7 Line strainer Connect the suction line slightly above the bottom of the tank and install a line strainer 0 1mm aperture size depend ing on nominal width of the valve Container ...

Page 26: ...ine Shut off valve Hand vacuum pump Siphon tank Shut off valve Pressure line Container Shut off valve Suction lance Suction line Foot valve Fig 24 Installing a siphon tank sera fitting 8 1 9 In case of slightly degassing dosing media Install the pump in such a way that it can be operated with a supply line Container Pressure line Shut off valve Suction line Fig 25 Installation with supply line res...

Page 27: ... for procedural reasons a pulsation poor delivery rate is de sired Pulsation damper pressure side Pressure line Container Shut off valve Suction line Fig 27 Installing a pulsation damper I Acceleration forces which arise due to the pipe geometry must be reduced Container Pressure line Shut off valve Pulsation damper suction side Drain cock Suction line Fig 28 Installing a pulsation damper II Pulsa...

Page 28: ...e Pressure keeping valve Container Shut off valve Suction line Fig 30 Installing a pulsation damper and a pressure keeping valve 9 Electrical connections 9 1 Electric supply The sera magnetic diaphragm pump is delivered ready for installation Standard delivery includes a 2m power cable with Euro plug The standard version R 204 1 of the dosing pump is designed for an operating voltage range of 100 ...

Page 29: ...rnal stop Analog mode 4 20mA Analog mode 4 20mA with external stop NOTE The analog input has priority when pulse and analog input are activated simultaneously this means that the applied pulse signal will not be evaluated If the analog signal is 4mA then the pulses received at the pulse input will be evaluated and applied The digital inputs pulse and external stop can not only be switched by a pot...

Page 30: ...ng pulses must not exceed the maximum stroke frequency of the pump 150 l min 9 2 2 Analog input The pump can be activated via an analog signal 4 20mA Fig 33 A signal with a control current of 4mA corresponds to 0 stroke frequency a signal with 20mA corresponds to 100 stroke frequency In this range the stroke frequency behaves proportionally to the control current Fig 35 current mA stroke frequency...

Page 31: ...teadily If the level monitoring is connected the dry run is indicated by a flashing red LED In case of type RS 204 1 the red LED lights also when the vent valve opens Green LED Yellow LED Red LED Manual operation On Level pre alarm Flashes Dry run Flashes External stop On Manual stop On Ready Auto mode On Stroke confirmation Flashes Venting 1 Flashes On No mains 1 only with type RS 204 1 Tab 11 Ov...

Page 32: ...y to run CAUTION Stroke frequency can only be changed while the pump is switched off 10 6 Configuring the level input When leaving the factory the level input is configured as fol lows Pre alarm NO closing when floating down Dry run NO closing when floating down The level input can be freely configured In the level input set ting mode the yellow LED flashes and the selected configura tion is indic...

Page 33: ...his mode allows the external control of the vent valve via the external stop input After having removed the ex ternal stop signal the pump will vent for the preset time For deactivating the mode please see the description in Chap ter 10 7 4 Cyclical venting In this mode venting is cyclically repeated after a predeter mined pause time Venting time and pause time duration are set upon activation of ...

Page 34: ...ed as described in the follow ing diagram Go to the venting setting mode Keep pressing the STOP START key until all 3 LEDs flash quickly Press AUTO MANU key green LED goes out programming is enabled Exit the venting setting mode Switch on the pump independent of the selected operation mode Keep pressing the AUTO MANU key venting starts after 3 sec yellow LED flashes keep pressing for the desired v...

Page 35: ...nections tight fit of the screws for fastening the pump body check this at least every three months For the tightening torques of the fixing screws please see Chapter 8 1 Installation Repairs on the stroke mechanism may only be performed by sera 11 1 Wearing parts Depending on their use and period of use wearing parts must be replaced at regular intervals in order to ensure a safe func tion of the...

Page 36: ... of the spare and wearing part kits Solenoid diaphragm pump R 204 1 0 4e 14e Suction valve kit Item Designation 9 Suction valve incl o rings Pressure valve kit Item Designation 2 Pressure valve incl o rings Diaphragm kit Item Designation 11 Drive diaphragm 12 Insert Pump body kit FRP design Item Designation 1 Vent valve 3 Cheese head screw s 4 Disk s 5 Pump body Pump body kit 1 4571 PVC design Ite...

Page 37: ... spare and wearing part kits Solenoid diaphragm pump R 204 1 25e 35e Suction valve kit Item Designation 8 Suction valve incl o rings Pressure valve kit Item Designation 4 Pressure valve incl o rings Diaphragm kit Item Designation 9 Drive diaphragm 10 Insert Pump body kit FRP design Item Designation 1 Cheese head screw s 2 Disk s 3 Pump body Pump body kit 1 4571 PVC design Item Designation 5 Cheese...

Page 38: ...204 1 0 4e 14e Suction valve kit Item Designation 9 Suction valve incl o rings Pressure valve kit Item Designation 2 Pressure valve incl o rings Diaphragm kit Item Designation 11 Drive diaphragm 12 Insert Pump body kit FRP design Item Designation 1 Vent valve 3 Cheese head screw s 4 Disk s 5 Pump body Pump body kit PVC PP PVDF design Item Designation 6 Cheese head screw s 7 Disk s 8 Pump body Auto...

Page 39: ...agm pump RS 204 1 25e 35e Suction valve kit Item Designation 8 Suction valve incl o rings Pressure valve kit Item Designation 4 Pressure valve incl o rings Diaphragm kit Item Designation 9 Drive diaphragm 10 Insert Pump body kit FRP design Item Designation 1 Cheese head screw s 2 Disk s 3 Pump body Pump body kit PVC design Item Designation 5 Cheese head screw s 6 Disk s 7 Pump body Automatic venti...

Page 40: ...rting Take appropriate protective measures wear protective clothing breathing mask and safety goggles Prepare a container with appropriate fluid right beside the pump for being able to remove splashes of the pumped medium Use an appropriate detergent to rinse the solenoid dia phragm pump until no residues of the pumped medium remain in the pump body Otherwise pumped medium may leak when disassembl...

Page 41: ...hapter 8 1 Ta ble 09 When mounting the pump body please note CAUTION Pressure valve above suction valve below Consider the direction of the arrows on the valves described in Chapter 7 2 5 Note direction of arrow on pump body Fix suction and pressure line Reset original stroke length Apply voltage The solenoid diaphragm pump is ready for operation 12 Fault analysis and corrective action sera produc...

Page 42: ...ve and clean valves Pressure on suction side higher than at the end of the pressure line Check geodetic conditions install float valve or pressure keeping valve if necessary Acceleration height too high due to pipe geometry Check acceleration height on suction and pressure side with manometer and compare with design data install a pulsation damper if necessary Material which is in contact with the...

Page 43: ... for the operator 13 3 Start up Cover on vent openings e g motor Suction or pressure pipes closed i e foreign matters particle size stop valves Operation without connected return pipe of the vent valve Start up with damaged system Wrong parameterization of the pump inadvertent start Control cable and power cable laid in parallel mal functions due to EMC 13 4 Operation Fault message ignored faulty ...

Page 44: ...irst Disconnection from the power supply not ensured danger through electricity Poorly ventilated room 13 8 Disassembly Residues of the pumped medium and utilities in the sys tem Use of wrong disassembly tools Wrong or no protective clothing at all Poorly ventilated room 13 9 Disposal Improper disposal of the pumped medium utilities and materials No marking of hazardous media Wrong disposal of the...

Page 45: ...Solenoid diaphragm pump Series R RS 204 1 Operating Instructions TA 416 Rev 11 en 04 2013 Subject to technical modifications www sera web com 45 Notes ...

Page 46: ...Solenoid diaphragm pump Series R RS 204 1 Operating Instructions 46 www sera web com Subject to technical modifications TA 416 Rev 11 en 04 2013 Notes ...

Page 47: ...Solenoid diaphragm pump Series R RS 204 1 Operating Instructions TA 416 Rev 11 en 04 2013 Subject to technical modifications www sera web com 47 ...