Watson-Marlow APEX10 User Manual
Disc
The disc inserted in the front cover contains the user manual of the models APEX10,
APEX15 and APEX20. The user manual is available in the following languages:
The disc also contains quick-reference instructions for the replacement of the pump
hose. This replacement instruction is only for users that are familiar with the
replacement procedures in the user manual.
How to use the disc
1 Put the disc in the disc drive.
2 Close the disc drive.
The disc will start automatically.
3 Wait until the various language versions appear on screen.
4 Select the required language (click 1x with the left mouse button).
The PDF reader program will automatically start and the required user manual
appears on screen.
Shortcuts
In the left margin you will find the various chapters and paragraphs. These can be
accessed directly by clicking on the required chapter or paragraph.
In the text you will find hyperlinks to chapters or paragraphs. These hyperlinks are linked
with the required chapters or paragraphs. By clicking a shortcut the required chapter or
paragraph appears on screen.
System requirements
The program on the disc requires a PC with the following minimum system
requirements:
• CD drive
The following software must be installed on the PC:
• PDF reader program
• an internet browser
1
2
Hose pump series
TYPE EL - CLASS I
AUGUST 2012
Environmental
Management
ISO
14001
Quality
Management
ISO
9001
APEX10, APEX15 and APEX20
Manual
3
© 2014 Watson-Marlow Bredel B.V.
All rights reserved.
The information provided herein may not be reproduced and/or published in any form,
by print, photoprint, microfilm or any other means whatsoever (electronically or
mechanically) without the prior written authorisation of Watson-Marlow Bredel B.V.
The information provided can be changed without prior notification. Watson-Marlow
Bredel B.V. or one of its representatives cannot be held liable for possible damage
resulting from use of this manual. This is an extensive limitation of the liability which
applies to all damage, inclusive of (without limitation) compensating, direct, indire ct or
consequential damage, loss of data, income or profit, loss or damage to possessions
and claims of third parties.
Watson-Marlow Bredel B.V. provides the information in this manual "as is" and does not
take any responsibility and does not give any guarantee on this manual o r its content.
Watson-Marlow Bredel B.V. rejects all responsibilities and guarantees. Furthermore,
Watson-Marlow Bredel B.V. does not take responsibility for and does not guarantee that
the information in this manual is accurate, complete or up to date.
Names, trade names, brands, etc. used by Watson-Marlow Bredel B.V. may not, as per
the legislation concerning the protection of trade names, be considered as available.
4
CONTENTS
1GENERAL
1.1 How to use this manual .................................. ........................................ 8
1.2 Original instructions ................................................................................ 8
1.3 Other supplied documentation ................................................................ 8
1.4 Service and support .................................................................... ... ... ...... 8
1.5 Environment and disposal of waste ........................................................ 9
2SAFETY
2.1 Symbols ................................................................................................ 10
2.2 Intended use ......................................................................................... 10
2.3 Use in potentially explosive atmospheres ............................................. 11
2.4 EHEDG compliance .............................................................................. 11
2.5 Responsibility ........................................................................................ 12
2.6 Qualification of the user ........................................................................ 12
2.7 Regulations and instructions ................................................................. 12
3 WARRANTY CONDITIONS
4 DESCRIPTION
4.1 Identification of the product ................................................................... 14
4.1.1 Identification of the product ....................................................... 14
4.1.2 Identification of the pump .......................................................... 14
4.1.3 Identification of the gearbox ...................................................... 14
4.1.4 Identification of the electric motor .............................................. 15
4.1.5 Identification of the frequency controller .................................... 15
4.1.6 Identification of the pump hose ................................................. 15
4.2 Construction of the pump ...................................................................... 16
4.3 Operation of the pump .......................................................................... 17
4.4 Pump hose ...................................... .. ..................................... ... ............ 18
4.4.1 General ...................................................................................... 18
4.4.2 Hose compression force adjustment ......................................... 19
4.4.3 Lubrication and cooling ............................................................. 19
4.5 Gearbox ................................................................................................ 20
4.6 Electric motor ........................................................................................ 20
4.7 Available options ................................................................................... 20
5
5 INSTALLATION
5.1 Unpacking ............................................................................................ 21
5.2 Inspection ............................................................................................. 21
5.3 Installation conditions ........................................................................... 21
5.3.1 Ambient conditions .................................................................... 21
5.3.2 Setup ......................................................................................... 21
5.3.3 Pipework ................................................................................... 22
5.3.4 Motor ......................................................................................... 23
5.3.5 Frequency controller ................................................................. 23
5.4 Lifting and moving the pump ................................................................ 24
5.5 Placing the pump .................................................................................. 24
6 COMMISSIONING
6.1 Preparations ......................................................................................... 25
6.2 Commissioning ..................................................................................... 26
7 OPERATION
7.1 Temperature ......................................................................................... 27
7.2 Power rating ................................................. ... ... .................................. 27
7.3 Performance graphs ........................................ ..................................... 28
7.4 Dry running ........................................................................................... 30
7.5 Hose failure ...................................................................................... ... . 31
7.6 Fluid leakage ........................................................................................ 33
8 MAINTENANCE
8.1 General ................................................................................................. 34
8.2 Maintenance and periodic inspections ................................................. 34
8.3 Cleaning the pump hose ...................................................................... 36
8.4 Changing lubricant ............................................................................... 36
8.5 Replacing the pump hose ..................................................................... 37
8.5.1 Removing the pump hose ......................................................... 37
8.5.2 Cleaning the pumphead ............................................................ 38
8.5.3 Fitting the pump hose ................................................................ 39
8.6 Exchanging replacement parts ............................................................. 41
8.6.1 Replacing rotor, bearings and seal ring .................................... 41
8.7 Fitting options ....................................................................................... 44
8.7.1 Fitting a high-level float switch .................................................. 44
8.7.2 Replacing the revolution counter ............................................... 46
6
9 STORAGE
9.1 Hose pump ........................................................................................... 48
9.2 Pump hose ...................................... .. ..................................... ... ............ 48
10 TROUBLESHOOTING
11 SPECIFICATIONS
11.1 Pumphead ............................................................................................ 54
11.1.1 Performance .............................................................................. 54
11.1.2 Materials .................................................................................... 55
11.1.3 Surface treatment ...................................................................... 56
11.1.4 Lubricant table pump ................................................................. 56
11.1.5 Weights ..................................................................................... 57
11.1.6 Torque figures ........................................................................... 58
11.2 Gearbox ................................................................................................ 59
11.3 Electric motor ........................................................................................ 59
11.4 Variable Frequency Drive (VFD) (optional) ........................................... 60
11.5 Parts list ................................................................................................ 60
11.5.1 Ordering parts .................................................................... ... ... . 60
11.5.2 Overview ................................................................................... 61
11.5.3 Cover assembly ......................................................................... 62
11.5.4 Pumphead assembly ................................................................. 63
11.5.5 Support assembly ...................................................................... 64
11.5.6 Barbed nipple assembly (PTFE/PDVF) ..................................... 65
11.5.7 Barbed or threaded nipple assembly
(stainless steel/PP/PVC) ........................................................... 66
11.5.8 Flange assembly with insert with collar ..................................... 67
11.5.9 Flange assembly with threaded nipple ...................................... 68
11.5.10Lubricant ................................................................................... 68
EC DECLARATION OF CONFORMITY OF THE MACHINERY
SAFETY FORM
NOTES
7
GENERAL
1GENERAL
1.1 How to use this manual
This manual is intended as a reference book by means
of which qualified users are able to install, commission
and maintain the hose pumps mentioned on the front
cover.
1.2 Original instructions
The original instructions for this manual have been
written in English. Other language versions of this
manual are a translation of the original instructions.
1.3 Other supplied documentation
Documentation of components such as the gearbox, the
motor and the frequency controller is not included in this
manual. However, if additional documentation is
supplied, you must follow the instructions in this
additional documentation.
1.4 Service and support
For information with respect to specific adjustments,
installation, maintenance or repair jobs which fall
beyond the scope of this manual, contact your Bredel
representative. Make sure you have the following data
at hand:
• Serial number of the hose pump
• Article number of the pump hose
• Article number of the gearbox
• Article number of the electric motor
• Article number of the frequency controller
You will find these data on the identification plates or
stickers on the pumphead, the pump hose, the gearbox
and the electric motor. Refer to § 4.1.1.
8
1.5 Environment and disposal of waste
CAUTION
Always observe the local rules and
regulations with respect to processing (non
reusable) parts of the hose pump.
Enquire within your local government about the
possibilities for reuse or environment-friendly
processing of packaging materials, (contaminated)
lubricant and oil.
GENERAL
9
SAFETY
2SAFETY
2.1 Symbols
In this manual the following symbols are used:
WARNING
Procedures which, if not carried out with
the necessary care, may result in serious
bodily harm.
CAUTION
Procedures which, if not carried out with
the necessary care, may result in serious
damage to the hose pump, the surrounding
area or the environment.
Remarks, suggestions and advice.
2.2 Intended use
The hose pump is exclusively designed for pumping
suitable products. Every other or further use is not in
conformance with the intended use.
Flammable fluids are not suitable products to be
pumped by this hose pump. This pump is not intended
to operate in potentially explosive atmospheres.
The "Intended use" as laid down in EN 292-1 is "... the
use for which the technical product is intended in
accordance with the specifications of the manufacturer,
inclusive of his indications in the sales brochure". In
case of doubt it is the use, which appears to be its
intended use judging from the construction, execution
and function of the product, and its description in the
user's documentation.
Only use the pump in conformance with the intended
use described above. The manufacturer cannot be h eld
responsible for damage or harm resulting from use that
10
is not in conformance with the intended use. If you want
to change the application of your hose pump, contact
your Bredel representative first.
2.3 Use in potentially explosive atmospheres
The pumphead and drive mentioned in this manual may
be configured to be suitable for use in a potentially
explosive atmosphere. Such a pump meets the
requirements as stated in the European Directive 94/9/
EC (ATEX Directive). Such a pump belongs to: Group II
appliances, category 2 GD bck T5.
Use in potentially explosive atmospheres
requires special configuration of the pump
unit. Contact your Bredel representative for
use in explosive atmospheres.
See Bredel’s ATEX Instruction manual which is supplied
with pumps configured as mentioned above.
2.4 EHEDG compliance
SAFETY
The hose connections of the pumphead described in
this manual are EHEDG compliant when stainless steel
nipples are applied and the connections are properly
created. This only concerns the connection between
nipple and pump hose.
WARNING
The user is responsible for the EHEDG
compliance of the connection between
nipple and suction or discharge line if
compliance is needed.
See the user guide “NBR Hoses For Food Contact”
supplied with F-NBR hoses for a description of a proper
hose connection.
11
SAFETY
2.5 Responsibility
The manufacturer does not accept any responsibility for
damage or harm caused by not observing the safety
regulations and instructions in this manual and other
supplied documentation, or by negligence during
installation, use, maintenance and repair of the hose
pumps mentioned on the front cover. Depending on the
specific working conditions or accessories used,
additional safety instructions can be required.
Immediately contact your Bredel representative if you
notice a potential danger while using your hose pump.
WARNING
The user of the hose pump is fully
responsible for observing local safety
regulations and directives. Observe these
safety regulations and directives when
using the hose pump.
2.6 Qualification of the user
The installation, use and maintenance of the hose
pump should only be performed by well-trained and
qualified users. Temporary staff and persons in training
may use the hose pump only under the supervision and
responsibility of trained and qualified users.
2.7 Regulations and instructions
• Everyone who works with the hose pump must
be aware of the contents of this manual and
observe the instructions with great care.
• Never change the order of the actions to be
carried out.
• Always store the manual near the hose pump.
12
3 WARRANTY CONDITIONS
The manufacturer offers a two-year warranty on all
parts of the hose pump. This means that all parts will be
repaired or replaced free of charge, with the exception
of consumables such as pump hoses, hose clamps, ball
bearings, wear rings, seals and rubber bushes, or parts
which have been used wrongly, misused, whether or
not they have been intentionally damaged. If genuine
Watson-Marlow Bredel B.V. (hereafter called Bredel)
parts are not used, any warranty claim is void.
Damaged parts which are covered by the applicable
warranty conditions can be returned to the
manufacturer. The parts must be accompanied by a
fully filled in and signed safety form, as present in the
back of this manual. The safety form must be applied to
the outside of the shipping carton. Parts which have
been contaminated or which have been corroded by
chemicals or other substances which can pose a health
risk must be cleaned before they are returned to the
manufacturer. Furthermore, it should be indicated on
the safety form which specific cleaning procedure has
been followed, and that the equipment has been
decontaminated. The safety form is required even if the
parts have not been used.
WARRANTY CONDITIONS
Warranties purporting to be on behalf of Bredel made
by any person, including representatives of Bredel, its
subsidiaries, or its distributors, which do not accord with
the terms of this warranty shall not be binding upon
Bredel unless expressly approved in writing by a
Director or Manager of Bredel.
13
DESCRIPTION
min-1
N
o
i
D A
B
E
C
4 DESCRIPTION
4.1 Identification of the product
4.1.1 Identification of the product
The hose pump can be identified by identification plates
or stickers on:
A Pumphead
B Gearbox
C Electric motor
D Pump hose
E Frequency controller (option)
E
C
B
4.1.2 Identificati on of the pump
The identification plate on the pumphead contains the
following data:
A Pump type, hose diameter and rotor type (low
or medium pressure)
B Serial number
C Year of manufacture
4.1.3 Identification of the gearbox
The identification plate on the gearbox contains the
following data:
A Article number
B Serial number
C Type number
D Reduction ratio
E Number of revolutions per minute
A
A C
APEX
Serial No:.
YEAR:
Watson-Marlow Bredel B.V.
Sluisstraat 7-Delden-NL
www.bredel.com
B
10 15 20
LOW
D
MED.
14
4.1.4 Identification of the electric motor
V
S
IP IK
Hz min-1 kW A
COS
C/h%
N
o
U
N
V
P
Mf
Nm
CF
o
D E F
GH I
C
B
The identification plate on the electric motor contains
the following data:
B Serial number
C Article number
D Mains
E Frequency
F Speed
G Power
H Power factor
I Current
4.1.5 Identification of the frequency controller
The identification of the Bredel Variable Frequency
Drive (VFD) can be found inside the VFD. Remove the
cover by loosening the two screws. The identification
sticker contains the following data:
A Article number
B Serial number
DESCRIPTION
B
LS serial number
sn20837003969
Bredel article number E384083
A
4.1.6 Identif ication of the pump hose
The identification sticker on the pump hose contains the
following data:
A: Pump type
B: Part code
C: Internal diameter
D: Type of material of inner liner
E: Remarks, if applicable
F: Maximum permissible working pressure
G: Production code
A
B
C
D
E
F
G
15
DESCRIPTION
4.2 Construction of the pump
C
B
A
H
F
E
D
G
A Cover
B Rotor
C Pump hose
D Pump housing
E Support
F Gearbox
G Electric motor
H Frequency controller
16
4.3 Operation of the pump
The heart of the pumphead consists of a specially
constructed pump hose (A) which lies against the inside
of the pump housing (B). The ends of the hose are
connected to the suction and discharge lines (C). A
bearing-mounted rotor (D) with two facing integral
pressing shoes (E) is in the centre of the pumphead. It
rotates clockwise.
In phase 1 the lower shoe compresses the pump hose
by the rotational movement of the rotor, forcing fluid
through the hose. As soon as the shoe has passed, the
hose recovers to its original shape due to the
mechanical properties of the material and fluid is drawn
into the hose.
In phase 2 fluid is drawn through the hose by the
(continuous) turning motion of the rotor.
DESCRIPTION
AB E CD
In phase 3, the second integral pressing shoe
compresses the pump hose. Due to the continuous
rotating movement of the rotor new fluid is sucked in
and fluid that is previously drawn in is pressed out by
the shoe. When the first shoe leaves the pu mp hose,
the second shoe has already occluded the pump hose
and fluid is prevented from flowing back. This method of
liquid displacement is known as the "positive
displacement principle".
17
DESCRIPTION
4.4 Pump hose
4.4.1 General A Extruded outer layer made of natural rubber B Two nylon reinforcement layers C Extruded inner liner
The pump hose liner material should be chemically
resistant to the product being pumped. For each pump
model various hose types are available. Choose the
most appropriate for your application.
The material of the inner liner of the pump hose
determines the hose type. Each hos e ty pe i s marked by
a unique colour code.
Hose type Material Colour code
NR Natural rubber Purple
NBR Nitrile rubber Yellow
F-NBR Nitrile rubber Yellow
EPDM EPDM Red
CSM CSM Blue
A
B C
Consult your Bredel representative for
more detailed information about the
chemical and temperature resistance of
pump hoses.
Bredel pump hoses have been carefully machined to
achieve minimum tolerances in wall thickness. It is very
important to guarantee the correct compression of the
pump hose, because:
• When the compression is too high, it creates an
excessive load on the pump and pump hose,
which may reduce the life of the pump hose and
bearings.
• When the compression is too low, it cuts
capacity and causes backflow. Backflow
reduces the life of the pump hose.
18
4.4.2 Hose compress ion force adjustment
The compression force on the pump hose can be
adjusted by installing a rotor with a different dimension
between the tips of the integral pressing shoes. The
rotor is chosen to achieve an optimal life of the pump
hose for the intended use of the hose pump. Each hose
size (10, 15 or 20 mm inner diameter) has its own lowpressure and medium-pressure rotors. This means
there are six types of rotors available. If you want to
change the application of your hose pump or if you want
to change the hose size, contact your Bredel
representative.
Low-pressure and medium-pressure rotors can be
recognized by a marked hole near the “L” for “Lowpressure” (B) or near the “M” for “Medium-pressure” (A)
on the rotor.
DESCRIPTION
A
B
4.4.3 Lubrication and cooling
The pumphead is filled with Bredel Genuine Hose
Lubricant. This lubricant lubricates the shoes and
dissipates the heat generated by the movement of the
pressing shoes against the pump hose.
The lubricant is food grade. The user is responsible to
ensure the chemical compatibility of the lubricant with
the fluid to be pumped. Refer to § 11.1.4 for the
required quantity and NSF registration.
Refer to § 7.5 for the consequences of a hose failure.
Consult your Bredel representative for
lubrication recommendations when
operating the hose pump below 2 rpm.
19
DESCRIPTION
4.5 Gearbox
The hose pump types described in this manual use
helical gearbox units. Other gearbox types are available
as option. The gearboxes are fitted with a flange
connection. Refer to § 11.2 for specifications. Refer to
the documentation supplied with the gearbox for
installation and maintenance information. In case of
doubt, consult your Bredel representative.
4.6 Electric motor
The standard electric motor is a completely enclosed
three-phase asynchronous motor. The motor
connection must meet the local applicable regulations.
Refer to the documentation supplied with the electric
motor for installation and maintenance information. In
case of doubt consult your Bredel representative. Refer
to § 5.3.4 and § 6.1 for installation and connection
information.
4.7 Available options
The following options are available for the hose pump:
• High (lubricant) level float switch
• Revolution counter
• Medium- or low-pressure rotor (depending on
the discharge pressure)
• Frequency controller
1
• Three hose sizes
• Five hose types
• Various types of hose connection
• Worm gear drive
• Special configuration for use in explosive
atmospheres
1 Refer to the supplier’s documentation and § 11.4.
20
5INSTALLATION
5.1 Unpacking
Follow the unpacking instructions on the packaging or
on the hose pump, the gearbox and the electric motor.
5.2 Inspection
Check that your delivery is correct and check it for any
transport damage. When replacing parts, check that the
delivery is correct and check these parts for any
transport damage. Refer to § 4.1.1. Report any damage
immediately to your Bredel representative.
5.3 Installation conditions
5.3.1 Ambient conditions
Make sure that the hose pump is in an area where the
ambient temperature during operation is not lower than
-20 °C and not higher than +45 °C.
INSTALLATION
5.3.2 Setup
• The pump materials and protective layers are
suitable for indoor setup and a protected
outdoor setup. Under certain conditions the
pump is suitable for limited outdoor setup or a
salty or aggressive atmosphere. Consult your
Bredel representative for more information.
• Make sure that the floor surface has a
maximum slope of 10 mm per metre.
• Make sure that there is sufficient room around
the pump to carry out the necessary
maintenance.
• Make sure that the room is sufficiently
ventilated, so that the heat developed by the
pump and drive can be dissipated. Keep some
distance between the ventilation cover of the
electric motor and the wall to allow the supply of
cooling air.
21
INSTALLATION
5.3.3 Pipework
When determining and connecting suction and
discharge lines consider the following points:
• It is recommended that the bore size of the
suction and discharge lines is larger than the
bore size of the pump hose. For more
information consult your Bredel representative.
• Limit the presence of sharp bends in the
discharge line. Make sure that the radius of any
bend is as large as possible. Use Y-connections
instead of T-connections.
• It is recommended to use a minimum of three
quarters (3/4) of the hose length as flexible
hose in the suction or discharge line. This
avoids the need to remove the connection l ines
when changing a pump hose.
• Keep the delivery and suction lines as short and
direct as possible.
• Select the correct mounting material for flexible
hoses and make sure that the installation is
suited for the design pressure of the system.
• Do not exceed the maximum working pressure
of the hose pump. Refer to § 11.1.1. If
necessary fit a pressure relief valve.
CAUTION
Consider the maximum permissible
working pressure on the discharge side.
Exceeding the maximum working pressure
may lead to serious damage to the pump.
• Make sure that the maximum forces on the
flanges are not exceeded. The permissible
loads are given in the following table.
22
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