Transcript
Diaphragm Pump Series 410.2 Operating Instructions
Product:
Diaphragm pump
Type:
M… R…
RF…
…410.2 - 200 (e) …410.2 - 280 (e) …410.2 - 450 (e) …410.2 - 570 (e) …410.2 - 700 (e) …410.2 - 900 (e) …410.2 - 1100 (e) …410.2 - 1450 (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: sera GmbH sera-Straße 1 34376 Immenhausen Germany Tel. +49 5673 999-00 Fax. +49 5673 999-01 www.sera-web.com
[email protected]
TA 412 Rev. 9 en 11/2014
CAUTION ! Keep the operating instructions for future application!
Subject to technical modifications!
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1
Diaphragm Pump Series 410.2 Operating Instructions Table of contents
1
General ................................................................... 4
6.3
2
Types...................................................................... 4
6.3.1 6.3.2
7 2.1
Type code ............................................................... 4
2.2
Type plate ............................................................... 4
2.3
Materials ................................................................. 5
2.4
Viscosity, pumped medium ..................................... 5
2.5
Dosing range .......................................................... 5
2.6
Noise measurement ................................................ 5
3 3.1
Note on quality ........................................................ 5
3.2
Marking of notes ..................................................... 5
3.2.1 3.2.2
Marking of notes in these operating instructions ............ 5 Marking of notes on the product ..................................... 5
Motor data for size 80 ................................................... 13 Motor data for size 90 ................................................... 13
Functional description............................................ 14 7.1
General ................................................................. 14
7.2
Components of the diaphragm pump 410.2 ........... 14
7.2.1 7.2.2 7.2.3 7.2.4 7.2.5 7.2.6 7.2.7 7.2.8
7.3
Safety instructions .................................................. 5
Motor data ............................................................. 13
7.3.1 7.3.2 7.3.3 7.3.4 7.3.5 7.3.6 7.3.7
8
Stroke mechanism ........................................................ 14 Stroke length adjustment .............................................. 14 Assembly pump ............................................................ 16 Pump body .................................................................... 17 Pump body with integrated overflow valve ................... 17 Suction/pressure valve ................................................. 18 Stroke frequency transmitter (option) ........................... 18 Diaphragm rupture monitoring device (option) ............. 19
Drive motor............................................................ 19 Motor connection (standard design) ............................. 19 Direction of rotation ....................................................... 19 Terminal box ................................................................. 19 Start-up ......................................................................... 20 Motor protection ............................................................ 20 Maintenance of the drive motor .................................... 20 Restart........................................................................... 20
Assembly / Installation ........................................... 20
3.3
Personnel qualification and training......................... 5
3.4
Dangers in case of inobservance of the safety instructions ............................................................. 5
3.5
Safety conscious working........................................ 6
3.6
Safety instructions for the owner / operator ............. 6
3.7
Safety instructions for maintenance-, inspection and installation work ...................................................... 6
3.8
Arbitrary modification and spare parts production ... 6
3.9
Improper operation.................................................. 6
9.1
General ................................................................. 28
3.10 Intended use ........................................................... 6
9.2
Identification .......................................................... 28
3.11 Personal protection for maintenance and service .... 6
9.3
Installation ............................................................. 28
3.12 Utilities .................................................................... 6
9.3.1 9.3.2
8.1
4
8.1.1 8.1.2 8.1.3 8.1.4 8.1.5 8.1.6 8.1.7 8.1.8 8.1.9 8.1.10 8.1.11
9
Transport and intermediate storage ........................ 7 4.1
General ................................................................... 7
4.2
Transport ................................................................ 7
4.3
Storage ................................................................... 7
5
Components of the diaphragm pump ...................... 8
6
Technical specifications .......................................... 9 6.1
Dimensions ............................................................. 9
6.2
Performance data ................................................. 12
2
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Provide overpressure protection ................................... 21 Prevent a backflow of the pumped medium ................. 23 Eliminate undesired siphoning ...................................... 23 How to ensure an air-free suction ................................. 24 Install the empty-tank alarm ......................................... 24 How to avoid draining of the suction line ...................... 25 Line strainer .................................................................. 25 Suction via a siphon pipe .............................................. 26 In case of slightly degassing dosing media .................. 26 Dosing of suspensions .................................................. 26 Damping of the pulsation .............................................. 27
Operation in explosion-hazardous areas ............... 28
General ......................................................................... 28 Working in explosion-hazardous areas ........................ 28
9.4
Potential equalisation ............................................ 28
9.5
Start-up ................................................................. 28
9.6
Operation .............................................................. 28
9.6.1 9.6.2 9.6.3
9.7 10
Installation instructions .......................................... 20
General ......................................................................... 28 Degassing of the pumped medium ............................... 29 Temperature indications ............................................... 29
Maintenance.......................................................... 29 Maintenance.......................................................... 29
10.1 Wearing parts ........................................................ 29 10.2 Spare parts............................................................ 29
Subject to technical modifications!
TA 412 Rev. 9 en 11/2014
Diaphragm Pump Series 410.2 Operating Instructions
10.3 Spare and wearing parts ....................................... 30 10.3.1 10.3.2
Diaphragm pump...410.2-200 (e) ...1450 (e)............... 30 Diaphragm pump with integrated overflow valve ...410.2200 (e) ...570 (e) ......................................................... 32
10.4 Changing the diaphragm ....................................... 34 10.4.1 10.4.2 10.4.3
General ......................................................................... 34 Single diaphragm pump................................................ 34 Double diaphragm pump .............................................. 35
10.5 Diaphragm change of the overflow valve............... 36 10.6 Oil change ............................................................ 38 11
Lubricant ............................................................... 38 11.1 Lubricant in the stroke mechanism ........................ 38 11.2 Buffer fluid ............................................................ 39
12
Fault analysis and corrective action ...................... 39
13
Foreseeable misuse.............................................. 41 13.1 Transport .............................................................. 41 13.2 Assembly and installation...................................... 41 13.3 Start-up: ................................................................ 41 13.4 Operation: ............................................................. 41 13.5 Maintenance/Repair .............................................. 41 13.6 Cleaning ............................................................... 42 13.7 Shut-down ............................................................ 42 13.8 Disassembly ......................................................... 42 13.9 Disposal ................................................................ 42
14
Shut-down ............................................................ 42
15
Disposal ................................................................ 42 15.1 Dismantling and transport ..................................... 42 15.2 Complete disposal ................................................ 42
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Diaphragm Pump Series 410.2 Operating Instructions
1
2.2
General
Before commissioning and during operation of the sera – diaphragm pump the respective regulations valid at the place of installation are to be observed.
Type plate
Each sera diaphragm pump is factory provided with a type plate. The following information can be found on this type plate.
The sera – diaphragm pump is delivered ready for installation. Carefully read these instructions and especially the safety instructions herein contained before installation and initial startup of the pump.
2
Types
2.1
Type code
Example: Diaphragm pump type R 410.2-280 e
R
410.2
280
1
e
2
3
4
5
6
7
Fig. 01 Type plate
Pump control M
not controlled
R
manually controlled (stroke length adjustment)
F
with three-phase AC motor, suitable for frequency converter operation
(‘RF’ combination possible)
R
410.2
280
e
Indication of model range/stroke mechanism
R
410.2
280
Explanation of the indications on the type plate 1 Type
Pump type
2 No.
Serial number of the pump
Minimum/maximum permissible pressure in the pump inlet Minimum/maximum permissible pressure in the inlet cross section which the 3 P1min/max [bar] pump can be used for. Please consider that pressure depends on rotation speed, delivery rate, temperature and static pressure at the inlet.
e
4 P2max [bar]
Maximum permissible pressure in the pump outlet Maximum permissible pressure in the outlet cross section which the pump can be used for. Please consider that pressure depends on rotation speed, delivery rate, temperature and static pressure at the outlet.
5 QN l/h
Nominal delivery rate Delivery rate which the pump was ordered for, based on the nominal rotation speed nN, the nominal delivery height p2max. and the delivery medium stated in the supply contract.
6 nN 1/min
Nominal stroke frequency Stroke frequency which the pump has been designed for
Indication of nominal delivery rate
This number states the nominal delivery rate in litres/hour. (standard version referring to water)
R
410.2
280
e
Indication of the pump design e
single diaphragm pump
without
double diaphragm pump
Hydraulic 7 [cm3]
Buffer fluid fluid Quantity of buffer fluid in the diaphragm ring (in the case of double diaphragm pumps)
Table 01 Explanation of type plate
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TA 412 Rev. 9 en 11/2014
Diaphragm Pump Series 410.2 Operating Instructions
2.3
Materials
3.2
The materials used are stated in the order confirmation and the product description.
2.4
Viscosity, pumped medium
The diaphragm pump is suitable for fluids with viscosities < 100 mPas.
Marking of notes
3.2.1
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)
2.5
Dosing range
The delivery rate of the diaphragm pump can be set manually via the stroke length adjustment (0…100%). The linear dosing range is between 20% and 100%.
2.6
If improper observance or non-observance of the operating manual, work instructions, specified operating procedures and similar can lead to personal injury or accidents.
If improper observance or non-observance of the operating manual, work instructions, specified operating procedures and similar can lead to damage to property.
Due to danger of causticization personnel must wear protective clothing (safety goggles, safety gloves and safety apron) for maintenance and repair work on parts which come into contact with hazardous products or for changing the containers.
Noise measurement
According to DIN 45635 the sound pressure level measured of the diaphragm pumps is between 50 and 60 dB (A).
3
The safety sign appears in the following cases:
Safety instructions
CAUTION ! The notes in Chapter 9 are to be observed if the pump is operated in explosion-hazardous areas.
3.1
3.2.2
Marking of notes on the product
Symbols which are directly attached to the pump, e.g. arrows for direction of rotation or symbols for fluid connections are to be observed and kept in legible condition.
Note on quality
Observance of these operating instructions and, in particular, the safety instructions, helps to
avoid dangers to persons, machines, and environment
increase the reliability and service life of the pump and the entire system
reduce repair cost and downtime.
The sera quality management and quality assurance system for pumps, systems, fittings, and compressors is certified according to ISO 9001:2008.. sera – diaphragm pump complies with the valid safety requiremens and accident prevention regulations.
Personnel qualification and training
The personnel who operate, maintain, inspect and install the diaphragm pump must be suitably qualified. Range of responsibility, and supervision of the personnel are to be clearly defined by the owner. If the personnel do not have the knowledge required it is to be trained and instructed accordingly. If required such a training can be carried out by the manufacturer /supplier upon order of the owner. The owner must also ensure that the personnel have understood the operating instructions.
3.4
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.
CAUTION ! Always keep these operating instructions within reach at the place of installation of the pump.
CAUTION ! Pay attention to the safety data sheet of the pumped medium! The owner must take corresponding accident prevention measures to protect operating personnel from danger through the pumped media used!
TA 412 Rev. 9 en 11/2014
3.3
Subject to technical modifications!
Inobservance can result in:
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
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Diaphragm Pump Series 410.2 Operating Instructions
3.5
Safety conscious working
The safety instructions specified in this operating manual, the national regulations for accident prevention, the safety regulations for the pumped medium valid at the place of installation as well as internal working-, operating-, and safety instructions of the owner are to be observed.
3.6
Safety instructions for the owner / operator
Leaking pumped media and utilities must be disposed off in such a way that any danger to persons and hazards to the environment are excluded. The legal regulations are to be observed. Dangers through electric energy are to be precluded.
3.7
Safety instructions for maintenance-, inspection and installation work
The owner must ensure that all maintenance-, inspection- and installation work are exclusively carried out by authorized and qualified personnel who have read the operating instructions carefully. The spare parts and utilities used must comply with the requirements of the respective operating conditions. All screwed connections and connections may only be removed when the system is not under pressure.
3.8
Arbitrary modification and spare parts production
Modification to and changement of the pump is only permitted after previous agreement of the manufacturer. Original spare parts and accessories approved by the manufacturer increase safety.
3.10 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. If the diaphragm pump is to be used for other applications, then the suitability of the pump for the new operating conditions must be discussed with sera beforehand! Criteria for the proper use of the diaphragm pump are:
Observe characteristics of the pumped medium (please see safety- and product data sheet of the pumped medium used – the safety data sheet is to be provided by the supplier / owner of the pumped medium)
Resistance of the materials which come in contact with the pumped medium
Operating conditions at the place of installation
Pressure and temperature of the pumped medium
Voltage supply
3.11 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 Sheet) and relevant national safety regulations for the pumped medium must strictly be adhered to. In case of an incident pay attention to the following leaking media:
fluids
vapours
noise emissions (sound level)
Emissions are to be monitored by corresponding monitoring systems.
CAUTION !
CAUTION ! If non-approved parts are used or if the pump (e.g. drive motor) is modified arbitrarily the manufacturer refuses any liability claims.
Wear protective clothing, gloves, and a face protecting and breathing mask.
CAUTION ! 3.9
Improper operation
Personal protective equipment must be provided by the owner!
Operational reliability of the supplied diaphgram pump is only guaranteed if the product is used as intended, according to the descriptions in Chapter 3.10 of these operating instructions.
3.12 Utilities If not agreed otherwise in the contract conditions, the sera diaphragm pump will always be supplied with the necessary utilities. (For type and quantitiy of utilities/lubricants, see Chapter 11)
6
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TA 412 Rev. 9 en 11/2014
Diaphragm Pump Series 410.2 Operating Instructions
4
Transport and intermediate storage
4.3
4.1
General
An undamaged packaging protects the unit during subsequent storage and should only be opened when the diaphragm pump is installed.
sera - products are checked for proper condition and functioning. The customer has to check the product for transport damage immediately after receipt. Any damage detected is to be reported immediately to the responsible carrier and the supplier.
Storage
Proper storage increases the service life of the diaphragm pump and comprises prevention of negative influences such as heat, humidity, dust, chemicals etc.
The packaging material must be disposed of appropriately!
The following storage instructions are to be observed: Storage place: cool, dry, dust-free and slightly ventilated Storage temperatures between +2°C and +40°C Relative air humidity not more than 50%. The maximum storage time for the standard system is 12 months.
4.2
If these values are exceeded, metal products should be sealed in foil and protected from condensation water with a suitable desiccant.
CAUTION !
Transport
Select a hoist which is adapted to the weight of the pump and attach it to the motor flange of the pump (see Fig. 02).
Do not store solvents, fuels, lubricants, chemicals, acids, disinfectants and similar in the storage room.
Fig. 02 Transport/handling
TA 412 Rev. 9 en 11/2014
Subject to technical modifications!
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Diaphragm Pump Series 410.2 Operating Instructions
5
Components of the diaphragm pump
The diaphragm pump may be composed of the following (main) components:
Stroke mechanism with drive Stroke length adjustment Assembly pump Pump body Valves
Optional accessories:
Not depicted:
Diaphragm rupture electrode Stroke frequency transmitter Actuator Frequency converter
Actuator for Ex-area Pneumatic actuator EExeIIT4 - motor
Blind plug (M-design) Drive motor for frequency converter operation
Drive motor Manual stroke length adjustment
Manual stroke length adjustment with position indicator Attached frequency converter
Stroke frequency transmitter (with inductive contact) Pump body with integrated overflow valve
Stroke length adjust ment with actuator
Pressure valve
Pump body (standard design)
Assembly pump (single diaphragm design)
Suction valve Diaphragm rupture electrode MBE-02 (for single diaphragm pumps) Assembly pump (double diaphragm design) Diaphragm rupture electrode MBE-04 (for double diaphragm pumps) Fig. 03 Overview of the components
8
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Diaphragm Pump Series 410.2 Operating Instructions
6
Technical specifications
6.1
Dimensions
M (1-4)
View X Ansicht X
239,5
17
M10 / d=8,5 M10 / d=8,5 Mounting holes Befestigungsbohrungen Mounting holes
a
N (1-4)
135
44
I
57
S
100
b
90 130 150
12
K7
K3 206
K1
K2
K (4-6)
min. 200 (for removing (zum Abnehmen der the actuator cover) Stellmotorhaube)
115
J E
DN
H
F
C
D
X
T
S1 B
A
described as um follows: by 45 degree 45° turned gedreht dargestellt
Fig. 04 Dimensions
TA 412 Rev. 9 en 11/2014
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9
Diaphragm Pump Series 410.2 Operating Instructions Table 02 Dimensions
Single diaphragm pump …410.2-900e
…410.2-1100e
…410.2-1450e
Valves
A
B
C
Single valves PVC Single valves 1.4571/1.4581 PP-GFK, PVDF-GFK Single valves PVC Single valves 1.4571/1.4581 PP-GFK, PVDF-GFK Connection thread Suction-/pressure valve
---
119
---
119
---
119
150
150
150
150
122
---
122
---
122
---
122
---
148
148
148
148
---
138
---
138
---
138
---
138
170
170
170
170
122
---
122
---
122
---
122
---
148
148
148
148
G1 ¼
G1
G1 ¼
G1
G1 ¼
G1
G1 ¼
G1
G1 ¼
G1 ¼
G1 ¼
G1 ¼
DN Nominal width Assembly pump
20
15
20
15
20
15
20
15
20
20
20
20
Pump body (PK)
410.2-570e
D
Assembly pump
41
41
41
41
57
57
57
57
E
Centre of connection thread
30
30
30
30
37
37
37
37
Pump body, standard
74
74
74
74
83
83
83
83
77
77
77
77
86
86
86
86
158
158
158
158
---
---
---
---
102
102
102
102
---
---
---
---
110
110
110
110
---
---
---
---
---
---
---
---
F
H
I
J K1 Stroke length adjustment (SLA)
…410.2-450e
119
Connection thread G1 with single valves DN15
…410.2-280e
---
…410.2-200e
1)
…410.2-700e
All dimensions in mm !
K2 K3
Pump body, standard with front plate Pump body with Integrated overflow valve Overflow valve socket (PVC, PP, PVDF) max. Overflow valve socket (1.4571) max. Connection thread of overflow valve nozzle 1) Blind flange for pump without SLA Manual stroke length adjustment Manual SLA with position indicator
K4 Electric actuator K5 K6
Electric actuator with PMR3 Electric actuator Ex-design
K7 Pneumatic actuator Option
Diaphragm rupture S1 signalling MBE-02/04 Stroke frquency transmitT ter Angle of overflow valve b nozzle a. o. Dimensions for Stroke mechanism fastening of pump
10
G1 ¼
1)
G1 ¼
1)
G1 ¼
1)
G1 ¼
1)
14
14
14
14
14
14
14
14
79
79
79
79
79
79
100
100
110
110
110
110
110
110
115
115
260
260
260
260
260
260
260
260
340
340
340
340
340
340
340
340
430
430
430
430
430
430
430
430
435
435
435
435
435
435
435
435
102
102
102
102
128
128
128
128
181
181
181
181
181
181
181
181
45°
45°
45°
45°
---
---
---
---
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See Fig. 04
Subject to technical modifications!
TA 412 Rev. 9 en 11/2014
Diaphragm Pump Series 410.2 Operating Instructions Table 03 Dimensions
Double diaphragm pump …410.2-900
…410.2-1100
…410.2-1450
Valves
A
B
C
Single valves PVC Single valves 1.4571/1.4581 PP-GFK, PVDF-GFK Single valves PVC Single valves 1.4571/1.4581 PP-GFK, PVDF-GFK Connection thread Suction-/pressure valve
---
119
---
119
---
119
150
150
150
150
122
---
122
---
122
---
122
---
148
148
148
148
---
138
---
138
---
138
---
138
170
170
170
170
122
---
122
---
122
---
122
---
148
148
148
148
G1 ¼
G1
G1 ¼
G1
G1 ¼
G1
G1 ¼
G1
G1 ¼
G1 ¼
G1 ¼
G1 ¼
DN Nominal width Assembly pump
20
15
20
15
20
15
20
15
20
20
20
20
Pump body (PK)
410.2-570
D
Assembly pump
68
68
68
68
90
90
90
90
E
Centre of connection thread
30
30
30
30
37
37
37
37
Pump body, standard
74
74
74
74
83
83
83
83
77
77
77
77
86
86
86
86
158
158
158
158
---
---
---
---
102
102
102
102
---
---
---
---
110
110
110
110
---
---
---
---
---
---
---
---
F
H
I
J K1 Stroke length adjustment (SLA)
…410.2-450
119
Connection thread G1 with single valves DN15
…410.2-280
---
…410.2-200
1)
…410.2-700
All dimensions in mm !
K2 K3
Pump body, standard with front plate Pump body with Integrated overflow valve Overflow valve socket (PVC, PP, PVDF) max. Overflow valve socket (1.4571) max. Connection thread of overflow valve nozzle 1) Blind flange for pump without SLA Manual stroke length adjustment Manual SLA with position indicator
K4 Electric actuator K5 K6
Electric actuator with PMR3 Electric actuator Ex-design
K7 Pneumatic actuator Option
Diaphragm rupture S2 signalling MBE-04 Stroke frquency transmitT ter Angle MBE 04 a (double diaphragm design) Angle of overflow valve b nozzle a. o. Dimensions for Stroke mechanism fastening of pump
TA 412 Rev. 9 en 11/2014
G1 ¼
1)
G1 ¼
1)
G1 ¼
1)
G1 ¼
1)
14
14
14
14
14
14
14
14
79
79
79
79
79
79
100
100
110
110
110
110
110
110
115
115
260
260
260
260
260
260
260
260
340
340
340
340
340
340
340
340
430
430
430
430
430
430
430
430
435
435
435
435
435
435
435
435
145
145
145
145
163
163
163
163
181
181
181
181
181
181
181
181
70°
70°
70°
70°
70°
70°
70°
70°
45°
45°
45°
45°
---
---
---
---
See Fig. 04
Subject to technical modifications!
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11
Diaphragm Pump Series 410.2 Operating Instructions Table 04 Dimensions
Drive motor
N1
410.2570 (e)
…410.2700 (e)
…410.2900 (e)
…410.21100 (e)
…410.21450 (e)
270
270
270
270
270
270
310
310
120
120
120
120
120
120
130
130
M2 Motor for frequency conN2 verter operation
270
270
270
270
270
270
310
310
120
120
120
120
120
120
130
130
M3
257
257
257
257
257
257
341
341
120
120
120
120
120
120
127
127
209
209
209
209
247
247
247
247
142
142
142
142
142
142
142
142
N3 M4 N4
AC motor
EExellT4 – motor
Performance data
p2 max.
min. / max.
Maximum suction height
Inlet/outlet nominal width
Nominal stroke frequency
Maximum stroke length
p1
WS
DN
min -1
h100
Motor size (standard design)
QN l/h
(1)
Minimum / maximum permissible pressure in the pump inlet
Pump data
Maximum permissible pressure in the pump outlet
Type
Nominal delivery rate (2) adjustable by stroke length adjustment
6.2
Standard motor
…410.2450 (e)
M1
…410.2280 (e)
All dimensions in mm !
…410.2200 (e)
Diaphragm pump
Size
50 Hz
60 Hz
bar
bar
M
mm
50 Hz
60 Hz
mm
…410.2-200 (e)
0-200
0-240
8
-0,5/0
5
15
76
91
13
80
…410.2-280 (e)
0-280
0-336
8
-0,5/0
5
15
97
116
13
80
…410.2-450 (e)
0-450
0-540
6
-0,5/0
5
15
76
91
13
80
…410.2-570 (e)
0-570
0-684
6
-0,5/0
5
15
97
116
13
80
…410.2-700 (e)
0-700
0-840
5
-0,3/0
3
20
76
91
13
80
…410.2-900 (e)
0-900
0-1080
5
-0,3/0
3
20
97
116
13
80
…410.2-1100 (e)
0-1100
0-1320
5
-0,3/0
3
25
76
91
20
90
…410.2-1450 (e)
0-1450
---
5
-0,3/0
3
25
97
---
20
90
Table 05 Performance data (1)
Achievable suction height with media similar to water and filled suction line
(2)
Linear dosing range at a stroke length between 20% and 100%
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Diaphragm Pump Series 410.2 Operating Instructions
Motor data Motor data for size 80
[Volt]
[A]
[IP]
50 Hz / 60 Hz
50 Hz / 60 Hz
0,75
~1500
~1800
50/60
55
F
---
Motor for frequency converter operation
0,75
~1500
~1800
50/60
55
F
---
AC motor
0,75
~1500
---
50
55
F
---
EExeIIT4-motor
0,55
~1500
---
50
55
F
II2GEExeIIT4
EExdeIICT4-motor
0,75
~1500
---
50
55
F
II2GEExdeIICT4
Motor speed
Standard motor
Output
ATEX-design
[Hz]
Thermal class
Protection category
Motor data
Nominal current
Motor type
Voltage range
6.3.1
Mains frequency
6.3
[kW]
[min ]
–1
50 Hz
60 Hz
Observe the type plate! The data can be read off the type plate on the drive motor of the respective diaphragm pump !
(pressure-tight enclosed)
Table 06 Motor data (size 80)
Motor data for size 90
Nominal current
Protection category
[min–1]
[Hz]
[Volt]
[A]
[IP]
50 Hz
60 Hz
Standard motor
1,5
~1500
~1800
50/60
Motor for frequency converter operation
1,5
~1500
~1800
50/60
AC motor
1,1
~1500
---
50
EExeIIT4-motor
1,1
~1500
---
50
ATEX-design
Voltage range
[kW]
Thermal class
Mains frequency
Motor data
Motor speed
Motor type
Output
6.3.2
55
F
---
Observe the type plate!
55
F
---
The data can be read off the type plate on the drive motor of the respective diaphragm pump !
55
F
---
55
F
II2GEExeIIT4
50 Hz / 60 Hz
50 Hz / 60 Hz
Table 07 Motor data (size 90)
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Diaphragm Pump Series 410.2 Operating Instructions
7
Functional description
7.1
General
7.2
Components of the diaphragm pump 410.2
7.2.1 sera - diaphragm pumps are run-dry safe oscillating displacement pumps that are characterised by high tightness of the dosing head. The liquid is conveyed by a deformable drive diaphragm. Diaphragm pumps consist of the following (main) components:
Drive motor
Stroke mechanism
Stroke length adjustment
Assembly pump
Pump body
Suction and pressure valve
Stroke mechanism
Function Diaphragm pumps of this type series use a rotary cam drive to transmit the rotation of the drive motor to the displacement 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 suction stroke (see stroke length adjustment).
Stroke mechanism Drive motor
Scale knob (stroke length adjustment)
Eccentric
Return spring
Stroke mechanism Vent screw Pressure valve
Stroke length adjustment
Adjusting spindle Drive diaphragm
Assembly pump
Connecting rod
Fig. 06 Stroke mechanism
Suction valve Pump body Fig. 05 Components
7.2.2
Stroke length adjustment
General The delivery rate of the pump is regulated by changing the stroke length. The stroke length is infinitely variable between 0% and 100%. A linear dosing behaviour is achieved with stroke length adjustments between 20% and 100%.
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Diaphragm Pump Series 410.2 Operating Instructions
7.2.2.1
Manual stroke length adjustment (standard)
7.2.2.2
The effective stroke length of the connecting rod is changed by turning the scale knob / handwheel. The stroke length can be adjusted both during operation and at standstill of the pump (system not under pressure). The set stroke length can be read off a scale, e.g. 75% (see Fig. 07/ 08). With the 20-steps adjustment on the scale knob, the stroke length can be set individually with a tolerance of 0.5%. Turning counterclockwise (see Fig. 07/08)
the effective stroke length is increased, the delivery rate creases.
Manual stroke length adjustment by means of percent scale (option)
The stroke length is adjusted by turning the hand wheel. The stroke length can be adjusted both during operation and at standstill of the pump (not under pressure). Turning counterclockwise (see Fig. 09) Turning clockwise
in
the effective stroke length is increased, the delivery rate increases. the effective stroke length is reduced, the delivery rate reduces.
the effective stroke length is reduced, the delivery rate reduces.
Turning clockwise
Locking
% 10 30 50 70
20 40 60 80
0
4 5 6 100
0 10
90
%
20
The set stroke length can be read off the percent scale (the example shows a set stroke length of 65%).
Scale knob
80
30
70 40 50 60
Fig. 07 Stroke length adjustment / Scale knob (410.2-200(e) – 900(e)) Fig. 09 Stroke length adjustment with position indicator Locking
In delivery state, the stroke length adjustment is factory set to 50%. 10 30 50 70
%
0 20 40 60
4 5 6
CAUTION ! The percent scale may get misdajusted during transport. If the pointer does not match the 50%-setting the percent scale is to be readjusted with the pump running!
Handwheel
Fig. 08 Stroke length adjustment (410.2-1100(e) – 1450(e))
CAUTION ! The locking (see Fig. 07 / 08 and 10) is to be released (using a spanner SW3) before the stroke length is changed. Then the locking must be tightened again. This ensures that the set stroke length does not change during operation.
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Diaphragm Pump Series 410.2 Operating Instructions In case of dosing pumps with electric actuator, the stroke length can no longer be adjusted manually on the pump. (Exception: actuator with hand wheel)
Set screw Hand wheel
Locking
The actuator is equipped with two integrated limit switches as standard as well as with a position potentiometer for position feedback. Both limit switches are factory set so that the drive switches 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. Adjusting spindle
Activation is performed by appropriate control units (see sera – accessories).
Percent scale
The set stroke length can be read off on the pump (percent scale).
Fig. 10 Stroke length adjustment with position indicator
Information on the electrical connection is given inside the cover of the actuator.
Adjusting the percent scale:
Switch the diaphragm pump on Loosen the set screw Remove the percent scale from the hand wheel Manually turn the percent scale to 0% setting Loosen the locking 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 adjusting spindle) Insert percent scale again Use set screw to secure the percent scale to the hand wheel Adjust desired stroke length Tighten the locking
7.2.2.3
Automatic stroke length adjustment by means of an electric actuator
The electric 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.
CAUTION ! The adjustment is only possible when the pump is running!
7.2.2.4
Automatic stroke length adjustment by means of an electric actuator with integrated positioner (PMR3)
same as Chapter 7.2.2.3, in addition:
PMR3 positioner
This PMR3 positioner which is integrated in the actuator enables an actuator setting from 0…100% that is proportional to the connected input signal. As an option, the actuator can also be provided with a collective fault signal. Information on the electrical connection is given inside the cover of the actuator.
Dosing pump Actuator
7.2.2.5
Automatic stroke length adjustment by means of an electric actuator (Exdesign)
Pay attention to the documents of the actuator.
7.2.2.6
Automatic stroke length adjustment by means of a pneumatic actuator
Pay attention to the documents of the actuator.
7.2.3 Clutch Stroke mechanism
Fig. 11 Stroke length adjustment by means of electric actuator
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Assembly pump
General There are two different pump types: a) Single diaphragm pump b) Double diaphragm pump
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TA 412 Rev. 9 en 11/2014
Diaphragm Pump Series 410.2 Operating Instructions
Function
7.2.4
Pump body
a) Single diaphragm pump The drive diaphragm connected to the drive via the connecting rod transmits the stroke movement directly to the pumped medium. Connecting rod
Depending on the applied backpressure, movements of the plastic pump body in elastic materials are possible. This does not affect the pumps’s service life or operational reliability.
Stroke mechanism
Pressure valve
7.2.5
Pump body with integrated overflow valve
The integrated diaphragm overflow valve protects the pump from unacceptable overpressure when the pressure line is closed. Pipes and fittings, however, are not protected and have to be protected separately, if necessary. It can be used for liquid media without solid matters according to the manufacturer specifications.
Pump body
Pumped medium
Pump bodies with integrated overflow valve are equipped with an additional relief channel through which the pumped medium is drained in case of an unacceptable overpressure. The relief channel is closed by the mechanically prestressed diaphragm of the overflow valve.
Suction valve Drive diaphragm Fig. 12 Functional principle of the single diaphragm pump
b) Double diaphragm pump The stroke movement of the drive diaphragm is transmitted hydromechanically to the intermediate diaphragm which is in contact with the medium. The intermediate diaphragm protects the drive diaphragm from chemical affects of the pumped medium.
The mechanical prestress which is executed by a pressure spring can be adjusted with a set screw. If the pressure of the pumped medium on the diaphragm exceeds the set pressure, the diaphragm is lifted and the pumped medium flows in the relief channel.
Pump body Diaphragm
Connecting rod
Stroke mechanism Pressure disk
Diaphragm ring Set screw Pressure valve
Pump body Lid
Pumped medium
Cover Pressure spring Relief nozzle
Relief channel
Fig. 14 Pump body with integrated overflow valve Drive diaphragm Suction valve
Hydraulic chamber Intermediate diaphragm
Fig. 13 Functional principle of the double diaphragm pump
A proper function can only be guaranteed when there are no gas- or air bubbles in the hydraulic chamber and the correct volume of buffer fluid has been filled in.
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Diaphragm Pump Series 410.2 Operating Instructions
When the pressure in the pump body falls below the pressure set the diaphragm closes the inlet channel again.
CAUTION ! The integrated overflow valve is always set to the maximum pump pressure (P2 max.) if no other value is specified.
7.2.6
7.2.7
Stroke frequency transmitter (option)
sera – dosing pumps are oscillating displacement pumps with an exactly defined stroke volume per each pump stroke. If these dosing pumps should be used for automatic filling processes or charge dosing, then the single pump strokes must be determined and converted into electrical signals. For this purpose, a stroke frequency transmitter (inductive contactor) is added to the pump and reports each single pump stroke to the evaluation unit (e.g. preselection counter, SPS-control unit, etc.)
Suction/pressure valve Stroke mechanism of the dosing pump
The pump valves are always ball valves which can only function properly when they are installed in a vertical position. The condition of the valves is decisive for the operational behaviour of the pump. The valves should only be exchanged completely. Pay attention to the flow direction when installing the valves (see Fig. 15).
Lid Inductive contactor
CAUTION ! Right angle plug with cable
Pressure valve above, suction valve below! Fig. 16 Stroke frequency transmitter
Technical specifications
Flow direction
Nominal voltage: Steady current: Short-circuit proof Connection: LED (green): LED (yellow):
10 - 60 V DC < 200 mA Plug connector with 2 m cable Indicates supply voltage Indicates switching status
Circuit diagram 1
brown
4
black
3
blue
+ 10-60 V DC
-
CAUTION ! When switching inductive loads (protectors, relays, etc.), surge protectors (varistors) must be fitted owing to the high self-induction voltage.
CAUTION ! For usage in explosion-hazardous areas a NAMUR-type stroke frequency transmitter is to be provided (II2G EExia IICT6, according to ATEX95).
Fig. 15 Single valves, GFK design
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Diaphragm Pump Series 410.2 Operating Instructions
7.2.8
Diaphragm rupture monitoring device (option)
sera - diaphragm pumps of the 410.2 series can be equipped with a conductive diaphragm rupture monitoring device as option.
7.3
Drive motor
sera - diaphragm pumps are driven by a three-phase motor or an AC motor.
7.3.1
Motor connection (standard design)
CAUTION !
In case of a three-phase motor
The pumped medium must have a minimum conductivity of at least 5 µS/cm!
The motor connection depends on the voltage specification on the type plate and the applied supply voltage.
W2
An electrode together with an approprate evaluation unit (option, e.g. sera – diaphragm rupture relay, type ER-104 (or ER142 for Ex-areas respectively) is used for monitoring.
V2
W2
The diaphragm rupture electrode is mounted directly to the pump, the evaluation unit inside the switch cabinet. One must distinguish between the single and the double diaphragm pump. The diaphragm rupture electrode type MBE-02 is used for single diaphragm pumps, type MBE-04 for double diaphragm pumps.
U2
U1
L1
V1
W1
L2
U2
U1
L3
L1
Delta connection
Y
V2
V1
L2
W1
L3
Star connection
Fig. 19 Circuit diagram(s) of three-phase motor
Single diaphragm pump
Example: Specification on type plate: Existing three-phase mains: Correct motor connection:
The diaphragm rupture electrode type MBE-02 is put in the base ring of the dosing pump from below Fig. 17 MBE-02
230/400 V 400 V Y Star connection
In case of an AC motor The AC motor has a main and an auxiliary winding. The operating capacitor is connected in series of the auxiliary phase.
Double diaphragm pump The diaphragm rupture electrode type MBE-04 is screwed in the side of the diaphragm ring of the dosing pump (see Fig. 03)
W2
U2
V2 CB
Fig. 18 MBE-04
U1
CAUTION !
V1
L1
W1
N
Fig. 20 Circuit diagram of AC motor
7.3.2
Direction of rotation
The direction of rotation of the drive motor is arbitrary.
7.3.3
Before closing the terminal box, please check that:
CAUTION ! sera - diaphragm pumps can be retrofitted with a diaphragm rupture electrode.
Maintenance of the diaphragm rupture electrodes is limited to cleaning (e.g. during an exchange, please see Chapter 10.4).
TA 412 Rev. 9 en 11/2014
Terminal box
Subject to technical modifications!
all terminal connections are tightly fitted
the inside is clean and free from foreign bodies
unused cable entries are closed and screw plugs are tightened
the sealing is correctly inserted in the cover of the terminal box; check proper condition of all sealing surfaces so that the requirements of the protection category are fulfilled.
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19
Diaphragm Pump Series 410.2 Operating Instructions
7.3.4
Start-up
8
Preconditions:
CAUTION !
Make sure that voltage and frequency correspond with the specifications on the type plate of the motor. Permissible voltage tolerance (DIN VDE 0530) for rated voltage + 10 % for rated voltage range +/- 5 %
The notes in Chapter 9 are to be observed if the pump is operated in explosion-hazardous areas.
8.1 The connector cable must be dimensioned according to the motor characteristics. Secure connector cable with a strain relief. The nominal motor power refers to an ambient temperature of maximum 40°C and an installation site below 1000m above sea level. Motor output will be reduced if these values are exceeded (see VDE 0530). Suitable for “moderate” group of climates according to IEC 721-2-1.
CAUTION ! The drive motor will heat by operation of the pump. Do not touch the motor during operation!
7.3.5
Assembly / Installation
Motor protection
Provide for adequate motor protective equipment in order to protect the motor from overload (e.g. protective motor switch with thermal overcurrent release). Connect ground wire to the marked earth screw in accordance with VDE 0100.
CAUTION !
Fuses do not protect the motor.
Installation instructions The standard model of the pump is only approved for installation in dry rooms in a non-aggressive atmosphere, at temperatures between +2°C and +40°C and at permitted humidity until approx. 90%. (For operation in explosion-hazardous areas, see Chapter 9). Protect the pump against any sources of heat and against the direct irradiation of sun and ultraviolet light For dimensions of the pump connections and fixing holes, see Fig. 04, Table 02 - 04 Install the pump in such a way that there is no vibration and no tension and that it is aligned precisely. Install the pump at the optimum possible operating height. Mount the pump in such a way that the valves are vertical. 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 and indicator scale 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 nominal inlet and outlet diameters of the pump. To check the pressure ratios in the pipe system, we recommend to provide for connections for pressure gauges (e.g. manometers) near the suction and pressure nozzles. Drain cocks are to be provided. Prior to connecting the pipes, remove the plastic caps on the suction and pressure nozzles of the pump. Check that the fixing screws for the pump body are tightly fitted and, if necessary, retighten.
Tightening torques of the fixing screws Pump body
7.3.6
15 Nm
Maintenance of the drive motor
The electric motor should always be kept clean so that neither dust, dirt, oil nor other contaminates may affect correct operation. 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).
Plastic cap
Front plate
The ball bearings inserted in the motor are lubricated for life
7.3.7
Fixing screws
Restart
Restart the system as described in Chapter 7.3.4 after maintenance work of after longer periods of standstill
Plastic cap Fig. 21 Diaphragm pump with plastic caps
.
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Diaphragm Pump Series 410.2 Operating Instructions
If the pump is equipped with an actuator provide for sufficient space to remove the cover (please see Chapter 6.1 “Dimensions”).
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, tension-free and intact.
8.1.1
if the permissible pressure in the pump head may be exceeded, e.g. when a shut-off valve is closed or if the line is blocked:
install overflow valve (Fig 22)
use sera - diaphragm pump with integrated overflow valve (Fig. 23).
When using an overflow valve, please note for the return line:
CAUTION ! If toxic, crystallizing or corrosive liquids are conveyed the pipe system is to be equipped with facilities for emptying, cleaning and rinsing with an appropriate medium, if necessary.
Provide overpressure protection
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 lance) (please see Fig. 24 / 25).
CAUTION ! Shut-off valves must not be closed when the pump is running!
CAUTION ! If the pump is connected to a 60Hz mains the pipe geometry must be designed according to the elevated stroke frequency.
CAUTION ! Provide an overpressure protection (e.g. overflow valve) if the permissible operating pressure may be exceeded.
CAUTION !
CAUTION !
Mount the diaphragm pump in such a way that leaking medium cannot cause any damage.
If the permissible operating pressure is exceeded and the pump is not equipped with an overpressure protection the pump may be damaged.
In order to avoid cavitation, overloading and excessive delivery, 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 pumped medium may spout out if the pump is damaged.
CAUTION ! The operator must provide for appropriate protective measures (collecting basin, diaphragm rupture electrode) in the supply pipe so that the container does not drain off in case of a diaphragm rupture.
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Diaphragm Pump Series 410.2 Operating Instructions
Diaphragm overflow valve
Diaphragm overflow valve
Pressure line
Shut-off valve Return line
Pressure line
Return line Shut-off valve
Container
Dosing pump (diaphragm pump)
Diaphragm pump
Shut-off valve Shut-off valve Suction line
Suction line
Fig. 24 System with (external) overflow valve
Fig. 22 System with (external) overflow valve
Shut-off valve
Shut-off valve
Pressure line
Pressure line Diaphragm pump with integrated overflow valve
Diaphragm pump with integrated overflow valve
Return line Overflow line
Shut-off valve Shut-off valve
Suction line Suction line Container Container
Fig. 23 System with integrated overflow valve
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Fig. 25 System with integrated overflow valve
Subject to technical modifications!
TA 412 Rev. 9 en 11/2014
Diaphragm Pump Series 410.2 Operating Instructions
8.1.2
Prevent a backflow of the pumped medium
8.1.3
Eliminate undesired siphoning
when dosing in a main pipe with negative pressure: if the dosing line is linked with a main pipe:
install an injection fitting (dosing valve).
install a pressure keeping valve in the dosing line.
CAUTION ! Main pipe
When installing the pump it is to be ensured that an excess supply (due to a positive pressure difference (> 1 bar) between pressure and suction side) is avoided. Injection fitting
Dosing line Main pipe
Injection fitting Diaphragm pump with integrated overflow valve
Pressure line Diaphragm pump with integrated overflow valve
Pressure keeping valve
Shut-off valve
Container Suction line
Fig. 26 Installing an injection fitting
CAUTION !
Container
The contents in the dosing line is mixed unintentionally if a backflow from the main pipe is not prevented.
Suction line
Shut-off valve
CAUTION ! Fig. 27 Installing a pressure keeping valve
Note / avoid chemical reactions during a backflow.
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Diaphragm Pump Series 410.2 Operating Instructions
8.1.4
How to ensure an air-free suction
if, due to a falling fluid level in the tank, air may be drawn in and delivered to a pressurised line or against a pressure keeping valve:
8.1.5
Install the empty-tank alarm
so that the tank is refilled before air is drawn in.
install a vent valve in the pressure line. Pressure line
CAUTION !
Diaphragm pump
The delivery flow may be interrupted if air enters the suction line! Empty-tank alarm e.g. magnetic float switch
Pressurised line Suction lance / Suction line
Injection fitting
Container Vent valve Foot valve Pressure line
Fig. 29 Installing an empty-tank alarm
Diaphragm pump with integrated overflow valve
CAUTION !
Suction lance / Suction line
The delivery flow may be interrupted if air enters the suction line!
Foot valve
Container
Fig. 28 Installing a vent valve
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Diaphragm Pump Series 410.2 Operating Instructions
8.1.6
How to avoid draining of the suction line
8.1.7
Install a foot valve at the end of the suction line.
Line strainer
Connect suction line slightly above the bottom of the tank and install a line strainer (0.1 – 0.5mm aperture size – depending on nominal width of the valve).
Based on calculations, the dimension ‘H’ may not exceed the number that is equal to the specified maximum suction height of the pump divided by the density of the pumped medium and in consideration of mass acceleration and viscosity of the medium.
Container Diaphragm pump Pressure line
Pressure line
Diaphragm pump
Suction lance / Suction line
H Shut-off valve Line strainer Suction line
Container
Fig. 31 Installing a line strainer
CAUTION ! Foot valve
If contaminations are not removed this may result in malfunctions of the pump and the system.
Fig. 30 Avoid draining of the suction line
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25
Diaphragm Pump Series 410.2 Operating Instructions
8.1.8
Suction via a siphon pipe
8.1.9
In case of slightly degassing dosing media
for use with high tanks without connection at the tank bottom:
install a siphon tank.
Pay attention to acceleration pressures which may be generated in a long suction line.
Install the pump in such a way that it can be operated with a supply line.
Diaphragm pump Container Pressure line
Shut-off valve
Hand vacuum pump Siphon tank
Shut-off valve
Diaphragm pump Shut-off valve
Suction line
Fig. 33 Installation with supply line
8.1.10 Dosing of suspensions requires that the pump head is rinsed to prevent precipitations. The following methods are recommended:
Pressure line
Container
intermittent rinsing
or
rinsing when the pump was switched off Pressure line
Diaphragm pump
Container Shut-off valve Rinsing medium Suction lance / Suction line Foot valve
Fig. 32 Installing a siphon tank (sera - fitting) Shut-off valve
Suction line
Fig. 34
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Diaphragm Pump Series 410.2 Operating Instructions
8.1.11 Damping of the pulsation by installing pulsation dampers if: for procedural reasons, a pulsation-poor delivery rate is desired. Pulsation damper (pressure side) Pulsation damper (pressure side) Diaphragm pump Diaphragm pump Pressure line
Container Pressure line
Suction line Container Shut-off valve
Suction line
Shut-off valve
Fig. 35 Installing a pulsation damper (I)
Acceleration forces which arise due to the pipe geometry must be reduced.
Pulsation damper (suction side) Drain valve
Container
Pressure line Fig. 37 Installing a pulsation damper (III)
CAUTION !
Dosing pump (diaphragm pump)
Shut-off valve
Pulsation damper (suction side)
Suction line Drain valve
Undamped acceleration forces may lead to the following faults / damage: delivery rate fluctuations dosing errors pressure serges valve wobbles increased wear on the suction- and pressure side of the pump; mechanical damage of the pump leakage and valve wobbles if the permissible maximum pressure on the pump pressure side is exceeded.
Fig. 36 Installing a pulsation damper (II)
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27
Diaphragm Pump Series 410.2 Operating Instructions
Installation of suction and/or pressure pulsation damper near the pump head.
9.2
A label regarding the area/category/explosion group / temperature class in compliance with directive 94/9/EC is directly attached to the pump.
If both pulsation damper and pressure keeping valve should be integrated install the pressure keeping valve between pump and pulsation damper. Pulsation damper (pressure side) Pressure line Pressure keeping valve
Identification
Ex II2G c IIBT4
EX II2G c IICT4
(Special specifications in the order confirmation are to be observed)
9.3 Diaphragm pump
or
9.3.1
Installation General
The intended operating conditions in explosion-hazardous areas in compliance with the directive 94/9/EC can be seen from the order confirmation and the product description. The limit values mentioned therein may not be exceeded or fallen below. Installation regulations given in the operating instructions must be adhered to.
9.3.2
Working in explosion-hazardous areas
CAUTION ! Use only suitable tools for performing assembly and maintenance work on machines or plants in explosionhazardous areas. Directive 99/92/EC must be observed. Container Shut-off valve
Suction line
Fig. 38 Installing a pulsation damper and a pressure keeping valve
9
Operation in explosion-hazardous areas
9.1
General
9.4
After fixation, make sure that the pump is properly connected to the potential equalisation system on site.
9.5 CAUTION ! The prerequisite for the use in explosion-hazardous areas is an appropriate design of the pump.
Potential equalisation
Start-up
After installation, the pump must immediately be used for the suction of fluids, i.e. the pump must immediately be started after the tank has been installed and filled.
9.6
Operation
The product supplied by sera meets the requirements of directive 94/9/EC. This guarantees safe operation in explosionhazardous areas.
9.6.1
CAUTION !
The intended operating conditions in explosion-hazardous areas in compliance with the directive 94/9/EC can be seen from the order confirmation and the product description. The limit values mentioned therein may not be exceeded or fallen below.
It is the operator’s task to define the field of application and to check whether the pump is suited for this application. He/she must clearly define the zone, the device category, the explosion group and the temperature class.
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General
Details about explosion areas, device category, explosion group and temperature class can be seen from the Declaration of Conformity.
Subject to technical modifications!
TA 412 Rev. 9 en 11/2014
Diaphragm Pump Series 410.2 Operating Instructions
9.6.2
Degassing of the pumped medium
Never let the pump run dry. Check the liquid level in the tank during operation of the pump. Make sure that the pump is switched off if the liquid level in the tank falls below the minimum level required (explosive atmosphere may be carried over).
Check the following conditions at regular intervals:
Vapour bubbles from the pumped medium are harmless as they have no explosive potential.
CAUTION ! Formation of an explosion-hazardous gas mixture is to be excluded.
9.6.3
Temperature indications
permissible ambient temperature
tight fit of the the pipework
tight fit of pressure and suction valve
proper condition of the electrical connections
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”.
Repair on the stroke mechanism may only be performed by sera.
10.1 Wearing parts
0°C ≤ Ta ≤ +40°C
Depending on their use and period of use, wearing parts must be replaced at regular intervals in order to ensure a safe function of the diaphragm pump.
9.7
We recommend to replace the drive- or intermediate diaphragms after 3000 operating hours or at least once a year.
Maintenance
The maintenance notes listed in Chapter 10 are generally applicable.
In case of a premature diaphragm rupture caused by hard operating conditions, switch off the diaphragm pump and replace the diaphragms (see Chapter 10.4).
Exception: As an option, the diaphragm pump can be equipped with a diaphragm rupture signaling device MBE-… (please see Chapter 7.2.8).
CAUTION ! The oil level in the stroke mechanism of the pump must be checked once a week!
10
Maintenance
CAUTION ! Before starting maintenance work make sure the the spare- and wearing parts as well as the utilities required are available. Place / deposit components in such a way that any damage is prevented.
The following parts are considered as wearing parts of the diaphragm pump:
Drive diaphragm
Intermediate diaphragm (only for double diaphragm pump)
Diaphragm of the integrated overflow valve (if installed)
Suction valve
Pressure valve
10.2 Spare parts The following parts are considered as spare parts of the diaphragm pump:
CAUTION !
Pump body
Diaphragm ring (only for double diaphragm pump)
Check the wearing parts for proper functioning at regular intervals and replace, if necessary.
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Diaphragm Pump Series 410.2 Operating Instructions
10.3 Spare and wearing parts 10.3.1 Diaphragm pump...410.2-200 (e) ...1450 (e) …410.2 – 200 (e) …410.2 – 280 (e) …410.2 – 450 (e) …410.2 – 570 (e) …410.2 – 700 (e) …410.2 – 900 (e) …410.2 – 1100 (e) …410.2 – 1450 (e)
6 5 4 3 2 1
13
10 9 8 7
Fig. 39 Spare- and wearing parts (...410.2-200 (e) ...-1450 (e))
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Diaphragm Pump Series 410.2 Operating Instructions Overview of the spare- and wearing part kits Diaphragm pump ...410.2-200 (e) ...- 1450 (e)
Suction valve (kit) Item 7
Designation Suction valve (incl. O-rings)
Pressure valve (kit) Item 6
Pump body kit (plastic) Item
Designation
Designation
1
Protective cap(s)
2
Hexagon screw(s)
3
Disk(s)
4
Front plate
5
Pump body
Item
Designation
Pressure valve (incl. O-rings) Pump body kit (special steel) Diaphragm kit (single diaphragm pump)
Item 10
Designation
1
Protective cap(s)
Drive diaphragm
2
Hexagon screw(s)
3
Disk(s)
5
Pump body
Diaphragm kit (double diaphragm pump) Item
Designation
8
Intermediate diaphragm
10
Drive diaphragm Buffer fluid
Diaphragm ring kit (only for double diaphragm pump) Item 9
Designation Diaphragm ring, complete
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Diaphragm Pump Series 410.2 Operating Instructions
10.3.2 Diaphragm pump with integrated overflow valve ...410.2-200 (e) ...570 (e) ...410.2 – 200 (e) ...410.2 – 280 (e) ...410.2 – 450 (e) ...410.2 – 570 (e)
3 2 1
11 10 9
8 7 6 5 4
19 18
23
17
22
16
21
15 14
20
13 12
Fig. 40 Spare- and wearing parts (...410.2-200 (e) ...570 (e) with integrated overflow valve
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Diaphragm Pump Series 410.2 Operating Instructions Overview of the spare- and wearing part kits Diaphragm pump with integrated overflow valve ...410.2-200 (e) ...570 (e)
Overflow valve kit
Suction valve (kit) Item 20
Item
Designation
12
Lid
13
Set screw
14
Pressure spring
15
Pressure spring
Designation
16
Hexagon screw(s)
Pressure valve (incl. O-rings)
17
Disk(s)
18
Cover
19
Pressure disk
Suction valve (incl. O-rings)
Pressure valve (kit) Item 11
Diaphragm kit (single diaphragm pump) Item
Designation
3
Drive diaphragm
9
Diaphragm (overflow valve)
Pump body kit (plastic) Item
Diaphragm kit (double diaphragm pump) Item
Designation
1
Intermediate diaphragm
3
Drive diaphragm
9
Diaphragm (overflow valve) Buffer fluid
Diaphragm ring kit (only for double diaphragm pump) Item 2
Designation
Designation Diaphragm ring, complete
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Designation
4
Protective cap(s)
5
Hexagon nut(s)
6
Locking screw(s)
7
Disk(s)
8
Front plate
10
Pump body
23
O-ring
Pump body kit (special steel) Item
Designation
4
Protective cap(s)
5
Hexagon nut(s)
6
Locking screw(s)
7
Disk(s)
10
Pump body
21
O-ring
22
Nozzle
23
O-ring
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Diaphragm Pump Series 410.2 Operating Instructions
10.4 Changing the diaphragm
10.4.2 Single diaphragm pump
10.4.1 General
Set the stroke length adjustment to a stroke length of 0% (front position).
Loosen fixing screws or –nuts on the pump body.
Remove pump body and front plate (if installed) to the front.
Remove drive diaphragm out of the connecting rod.
In order to ensure a correct function of the diaphragm pump and to fulfil the required safety and protective provisions – especially in explosion-hazardous areas – it is absolutely necessary to check and replace the diaphragms at regular intervals.
CAUTION ! Prior to replacing the diaphragm, drain the pump and, if necessary, rinse it with appropriate fluid in order to avoid contact with aggressive and/or toxic media!
Drive diaphragm
Pressure valve
Pump body
CAUTION ! For replacing the diaphragm, the system must be depressurised!
During maintenance or repair work, switch off the drive motor of the diaphragm pump and secure it against inadvertent or unauthorised reactivation.
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 diaphragm pump until no residues of the pumped medium remain in the pump body. Otherwise, pumped medium may leak when disassembling the pump. Collect the rinsed liquid in a safe way (avoid contact with it) and dispose of it in an environmentally compatible way. This measure is also necessary if the diaphragm pump should be returned for repair.
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Connecting rod
Suction valve
Fixing screw
Fig. 41
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Diaphragm Pump Series 410.2 Operating Instructions
Assemble the pump in reversed order
Assemble the pump in reversed order
Installation of the drive diaphragm (see Chapter 10.4.2).
If the pump is not equipped with a stroke length adjustment (M-design), move the diaphragm to the middle position by turning the fan blade of the drive motor.
Insert intermediate diaphragm in the diaphragm ring (in case of a PTFE-laminated intermediate diaphragm the PTFE-coated side must point towards the pump body).
When assembling the pump body, please note: suction valve below, pressure valve above!
When assembling the pump body, please note: suction valve below, pressure valve above
Observe the tightening torques (see Chapter 8.1).
Set the stroke length to 100%. If the pump is not equipped with a stroke length adjustment (M-design), move the diaphragm to the rear position by turning the fan blade of the drive motor (see Fig. 44).
Fill buffer fluid in the diaphragm ring (type and quantity are indicated on the type plate).
Set the stroke length to 50%. Move diaphragm to the base ring – the diaphragm must be in the middle position (see Fig. 42).
Base ring
Drive diaphragm
Buffer fluid Fig. 42
Drive diaphragm
Add the suction and pressure line and connect pump to the power supply. The diaphragm pump is then again ready for operation.
10.4.3 Double diaphragm pump
Drain buffer fluid (by opening the screw plug).
Loosen fixing screws on the pump body and remove intermediate diaphragm.
Remove the diaphragm ring to the front if the drive diaphragm is to be replaced, too. Intermediate diaphragm
Pressure valve
Drive diaphragm
Pump body
Diaphragm ring Screw plug
Fig. 44
Vent the buffer fluid chamber: wait for appr. 2 minutes after filling in until the air dissolved in the buffer fluid has degassed.
Diaphragm ring
Buffer fluid Suction valve
Fixing screws
Fig. 43
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Diaphragm Pump Series 410.2 Operating Instructions
Move the drive diaphragm to the front by turning the fan blade of the drive motor (or the stroke length adjustment in clockwise direction) until the buffer fluid level has reched the top edge of the filling hole(s).
Screw in screw plug(s) (see Fig. 45).
Reset stroke length to the initial value.
Loosen and unscrew lid of the overflow valve.
Lid
Screw plug(s)
Integrated overflow valve
Fig. 46
Buffer fluid Diaphragm ring Fig. 45
Add the suction and pressure line and connect pump to the power supply. The diaphragm pump is then again ready for operation.
CAUTION ! Before the set screw is unscrewed the dimension T (distance between top edge of the cover and the set screw) is to be determined and documented. This ensures that the overflow valve can be reset to the same pressure during subsequent assembly.
Measuring device (e.g. caliper gauge)
10.5 Diaphragm change of the overflow valve Proceed as follows to change the diaphragm of the overflow valve (only dosing pumps with integrated overflow valve).
Diaphragm Pressure disk
Cover
Note: All diaphragms should be replaced completely (see Chapter 10.4).
CAUTION ! Prior to replacing the diaphragm, drain the pump and, if necessary, rinse it with appropriate fluid in order to avoid contact with aggressive and/or toxic media!
Set screw
CAUTION !
Pressure springs
For replacing the diaphragm, the system must be depressurised! Fig. 47 Installation depth of the set screw
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Diaphragm Pump Series 410.2 Operating Instructions
Unscrew the set screw.
Check overflow valve for damage and contamination.
Remove pressure springs.
Insert new diaphragms. In case of PTFE-laminated diaphragms the PTFE-coated side must point towards the pump body.
Assemble the pump in reversed order.
Set screw Pressure springs Cover
CAUTION ! The individual components should be cleaned thoroughly before assembly!
CAUTION ! When the set nut is screwed in the dimension “T” which was determined beforehand is of great importance (see Fig. 47). The initial opening pressure of the overflow valve is only reached when the set screw is screwed in exactly according to dimension “T”! Fig. 48
CAUTION !
Loosen and unscrew fixing screws.
Remove cover to the front.
Remove pressure disk and diaphragm.
The screw-in depth of the set screw must not exceed the initial value. If the set pressure is increased, sera has to be consulted beforehand.
Fixing screw(s) Cover
CAUTION ! Never screw in the set screw to a depth so that the pressure spring is compressed to solid length!
Pressure disk Diaphragm
Fig. 49
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Diaphragm Pump Series 410.2 Operating Instructions
10.6 Oil change
Check oil level at regular intervals (oil sight glass).
Perform an oil change once a year. To do so, proceed as follows:
Unscrew the vent screw (see Fig. 05).
Prepare an appropriate container. Open screw plug and drain off oil. Oil sight glass
Close hole with screw plug (pay attention to the sealing ring!).
Fill oil in threaded hole of the vent screw.
For type and quantitiy of the gear oil, please see Chapter 11.1.
Screw in vent screw.
Stroke mecha nism of dosing pump
Diaphragm pump
Oil can
Sealing ring
Screw plug
Gear oil
Oil collecting tank Fig. 51 Filling gear oil
Fig. 50 Oil change
11
Lubricant
11.1 Lubricant in the stroke mechanism Pump type
Lubricant
Quantity
Gear oil ARAL DEGOL BG220
1,25 liter
…410.2-200 (e) …410.2-280 (e) …410.2-450 (e) …410.2-570 (e) …410.2-700 (e) …410.2-900 (e) …410.2-1100 (e) …410.2-1450 (e) Table 08 Lubricant in the stroke mechanism
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Diaphragm Pump Series 410.2 Operating Instructions 11.2 Buffer fluid Pump type
Buffer fluid
Quantity
…410.2-200
240 cm3
…410.2-280
240 cm3
…410.2-450
270 cm3
…410.2-570
270 cm3
Glycerine 1) DAB 87
…410.2-700
525 cm3
…410.2-900
525 cm3
…410.2-1100
525 cm3
…410.2-1450
525 cm3
Table 09 Buffer fluid 1)
If no other specification is stated in the product description.
12
Fault analysis and corrective action
sera - products are sophisticated technical products which are only shipped after having been thoroughly tested and checked at our factory. Should there be any faults, these can be detected and rectified easily and quickly if the steps in Table 10 are carried out.
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Diaphragm Pump Series 410.2 Operating Instructions
Fault analysis and corrective action
Pump valves leaky
Remove and clean valves
Pump valves (ball seats) damaged
Remove and clean valves, check function; replace valves if necessary
Delivery rate is not reached
Leakage on pump head
Fill storage tank
Damage in stroke mechanism / drive
No delivery medium in storage tank
Drive is overloaded
Low service life of the diaphragm
Open shut-off valves or check opening – check pump for damage
High noise development
Shut-off valves in pipe closed
Pipe oscillates heavily
Check gaskets, tighten pipe connections
Drive motor does not start
Suction line leaky
Maximum delivery rate exceeded
Reduce suction height or suction resistance
Delivery rate fluctuates
Suction height too high
Delivery height is not reached
Corrective action
Diaphragm pump does not deliver
Possible cause
Diaphragm pump does not draw in
Fault type
Pump valves incorrectly mounted or Check installation position and completeness – replace valve balls missing missing parts or install correctly
Filter in suction line clogged
Electric data of the drive motor do not Check order data. Check electric installation. Adjust motor match mains data to mains data.
Measure pressure with manometer directly above pressure valve and compare with permissible backpressure.
Foreign matter in pump valves
Remove and clean valves
Check acceleration height on suction- and pressure side Acceleration height too high due to with manometer and compare with design data – install a pipe geometry pulsation damper if necessary Material which is in contact with the Check whether the pumped medium corresponds with the medium not suitable for the pumped design data and select other materials if necessary medium Too high viscosity of the pumped me- Check viscosity of the pumped medium and compare with dium design data – reduce concentration or increase temperature if necessary
Backpressure too high
Pressure on suction side higher than Check geodetic conditions, install float valve or pressure at the end of the pressure line keeping valve if necessary
Clean filter
Pumped medium degasses in the Check geodetic conditions and compare with data of the suction line pumped medium. Operate pump with suction side supply, reduce temperature of the pumped medium
Air in suction line while pressure is Vent pressure side applied to the pressure valve ball
Pipe connections leaky
Tighten connection according to type of material. Be careful with plastic – risk of fracture
Temperature too low
Check flowability of the pumped medium Temperature of pumped medium and ambient temperature must not fall below -10°C
Pumped medium frozen in pipe
Remove diaphragm pump and check for damage – increase temperature of the pumped medium
Diaphragm rupture
Replace diaphragm according to Chapter 10.4.
Table 10 Fault analysis and corrective action
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Diaphragm Pump Series 410.2 Operating Instructions
13
Foreseeable misuse
13.4 Operation
The following misuse is assigned to the life cycles of the machine.
CAUTION ! Misuse can result in danger to the operating personnel!
13.1 Transport
Tipping behavior during transport, loading and unloading ignored. Weight for lifting underestimated.
13.2 Assembly and installation
Power supply not fuse protected (no fuse/fuse too large, power supply not conforming to standards). No or improper fastening material of the pump. Improper connection of the pressure pipes, wrong material i.e. PTFE tape and unsuitable connection pieces. Liquid pipes confused. Threads overturned/damaged. Pipes bent during connection in order to compensate for alignment errors. Supply voltage connected without earthed conductor. Socket for safe disconnection of the power supply difficult to reach. Wrong connecting cables for supply voltage (crosssection too small, wrong insulation). Parts damaged (e.g. vent valve, flow meter broken off). Wrongly dimensioned pressure and suction pipe. Incorrect dimensioned and improperly fastened pump panel (panel broken off).
13.3 Start-up:
13.5 Maintenance/Repair
Cover on vent openings (e.g. motor). Suction or pressure pipes closed (i.e. foreign matters, particle size, stop valves). Integrated overflow valve misadjusted (no protection function). Operation without connected return pipe of the integrated overflow valve. No free return flow of the overflow valve.
TA 412 Rev. 9 en 11/2014
Subject to technical modifications!
Fault message ignored faulty dosing / process error. Integrated overflow valve misadjusted. No free return flow of the integrated overflow valve. Pipes hit, pulsation damper not used damage to the pipes, medium is leaking. Pumped medium contains particles or is contaminated. External fuse bridged no cut off in case of an error. Ground wire removed no cut off by fuse in case of an error, supply voltage directly at the housing. Insufficient lighting of the working place. No supervision of leakages MBE opening. Diaphragm rupture is not indicated when the MBE plug was disconnected. Medium can escape into the environment through the vent hole “Danger to the operator and the environment”. Arbitrary modification of the pump (valves, internal fuse, …). Suction height too high, pump capacity too low process error.
Works carried out which are not described in the operating instructions (works on the stroke mechanism and the Assembly pump, electronics opened). If the screw-in depth of the setscrew for the integrated overflow valve is not noted, this may lead to dangerous consequences, i.e. rupture of the pressure pipe or leaking medium. …). Prescribed maintenance schedules ignored. Use of wrong spare parts/oils (e.g. no sera original spare parts, wrong viscosity). Improper mounting of spare and wearing parts (e.g. wrong tightening torque for pump body). Oil level not checked. Use of cables with damaged insulation. No shut down / no protection against a restart before maintenance work. Pumped medium or utilities during an oil change insufficiently removed. Restart without sufficient fastening. Valves confused. Sensor pipes confused. Pipes not connected (e.g. suction- and pressure pipes, gas pipes). Gaskets damaged, medium is leaking. Gaskets not fitted, medium is leaking. Wearing of unsuitable protective clothing / no protective clothing at all. Operation of an uncleaned system. Pumped medium contaminated with oil. Poorly ventilated room.
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Diaphragm Pump Series 410.2 Operating Instructions
13.6 Cleaning
14
Wrong rinsing medium (material changed, reaction with the medium). Wrong cleaning agent (material changed, reaction with the medium). Cleaning agent remains in the system (material changed, reaction with the medium). Protective clothing insufficient or missing. Use of unsuitable cleaning utensils (material changed, mechanical damage by high pressure cleaner). Untrained personnel. Vent openings clogged. Parts torn off. Sensors damaged. Non-observance of the safety data sheet. Control elements actuated. Poorly ventilated room.
Shut-down
Switch the diaphragm pump off. Rinse pump head to remove the pumped medium and make sure that the detergent is suitable for the pumped medium and the material of the pump head.
15
Disposal
Shut-down system. Please see “Shut-down”.
15.1 Dismantling and transport
Remove all fluid residues, clean thoroughly, neutralize and decontaminate. Package unit and ship.
13.7 Shut-down
Pumped medium not completely removed. Disassembly of pipes with the pump running/with residual pressure. Disconnection of the electrical connections in a wrong sequence (ground wire first). Disconnection from the power supply not ensured danger through electricity. Poorly ventilated room.
13.8 Disassembly
15.2 Complete disposal
Remove all fluid residues from unit.
Drain off lubricants and dispose of according to regulations!
Dismount materials and send them to a suitable waste disposal company!
CAUTION !
Residues of the pumped medium and utilities in the system. Use of wrong disassembly tools. Wrong or no protective clothing at all. Poorly ventilated room.
The consignor is responsible for damage caused by leaking lubricants and fluids!
13.9 Disposal
Improper disposal of the pumped medium, utilities and materials. No marking of hazardous media.
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Diaphragm Pump Series 410.2 Operating Instructions
Notes
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Diaphragm Pump Series 410.2 Operating Instructions
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