Bredel 10
Table of contents
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Disc
The disc inserted in the front cover contains the user manual of the models Bredel 10,
Bredel 15 and Bredel 20. 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.
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Hose pump series
Bredel 10, Bredel 15 and Bredel 20
Manual
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© 2013 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 extens ive limitation of the liability which
applies to all damage, inclusive of (without limitation) compensating, direct, indirect 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 or 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.
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CONTENTS
1 GENERAL
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 ......................................................................................... 11
2.3 Use in potentially explosive atmospheres ............................................. 11
2.4 Responsibility ........................................................................................ 12
2.5 Qualification of the user ........................................................................ 12
2.6 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 rotor ............................................................ 14
4.1.4 Identification of the gearbox ...................................................... 15
4.1.5 Identification of the electric mo tor .................... ...... ...... ..... ......... 15
4.1.6 Identification of the frequency controller .................................... 16
4.1.7 Identification of the pump hose ................................................. 16
4.2 Construction of the pump ...................................................................... 17
4.3 Operation of the pump .......................................................................... 17
4.4 Pump hose ............................................................................................ 19
4.4.1 General ...................................................................................... 19
4.4.2 Hose compression force adjustment ......................................... 20
4.4.3 Lubrication and cooling ............................................................. 20
4.5 Gearbox ................................................................................................ 20
4.6 Electric motor ........................................................................................ 21
4.7 Frequency controller ............................................................................. 21
4.8 Available options ................................................................................... 21
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5 INSTALLATION
5.1 Unpacking ............................................................................................ 22
5.2 Inspection ............................................................................................. 22
5.3 Installation conditions ........................................................................... 22
5.3.1 Ambient conditions .................................................................... 22
5.3.2 Set-up ........................................................................................ 22
5.3.3 Pipework ................................................................................... 23
5.3.4 Frequency controller ................................................................. 24
5.4 Lifting and moving the pump ................................................................ 25
5.5 Placing the pump .................................................................................. 25
6 COMMISSIONING
6.1 Preparations ......................................................................................... 26
6.2 Commissioning ..................................................................................... 26
7 MAINTENANCE
7.1 General ................................................................................................. 28
7.2 Maintenance and periodic inspections ................................................. 28
7.3 Additional maintenance in potentially explosive environments ............ 30
7.4 Cleaning the pump hose ...................................................................... 30
7.5 Changing lubricant ............................................................................... 31
7.6 Replacing pump hose ................................. .......................................... 31
7.6.1 Removing pump hose ............................................................... 31
7.6.2 Cleaning the pump head ........................................................... 33
7.6.3 Fitting the pump hose ...................... ..... ..................................... 33
7.7 Exchanging replacement parts ............................................................. 35
7.7.1 Replacing rotor, bearings and seal ring .................................... 35
7.8 Fitting options ....................................................................................... 39
7.8.1 Fitting a high-level float switch .................................................. 39
7.8.2 Revolution counter .................................................................... 40
8 STORAGE
8.1 Hose pump ........................................................................................... 41
8.2 Pump hose ........................................................................................... 41
9 TROUBLESHOOTING
10 HAZARDOUS ENVIRONMENTS (ATEX)
10.1 ATEX compliance ................................................................................. 47
10.2 Identification ......................................................................................... 47
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10.2.1 Pump head ................................................................................ 47
10.2.2 Gearbox ..................................................................................... 48
10.2.3 Electric motor ............................................................................ 48
10.2.4 Frequency controller ....................... ...... ...... ..... ...... .................... 48
11 SPECIFICATIONS
11.1 Pump head ........................................................................................... 49
11.1.1 Performance .............................................................................. 49
11.1.2 Materials .................................................................................... 50
11.1.3 Surface treatment ...................................................................... 51
11.1.4 Lubricant table pump ................................................................. 51
11.1.5 Weights ..................................................................................... 51
11.1.6 Torque figures ........................................................................... 52
11.2 Gearbox ................................................................................................ 52
11.3 Electric motor ........................................................................................ 53
11.4 Variable Frequency Drive (VFD) (optional) ........................................... 53
11.5 Parts list ................................................................................................ 54
11.5.1 Overview ................................................................................... 54
11.5.2 Cover assembly .......................................... ............................... 55
11.5.3 Pump head assembly ................................................................ 56
11.5.4 Support assembly ...................................................................... 57
11.5.5 Barbed nipple assembly (PTFE/PDVF) ..................................... 58
11.5.6 Barbed or threaded nipple assembly (stainless steel) ............... 59
11.5.7 Flange assembly (1) .................................................................. 60
11.5.8 Flange assembly (2) .................................................................. 61
11.5.9 Revolution counter assembly ................................ ...... .............. 62
11.5.10Lubricants ................................................................................. 62
EC DECLARATION OF CONFORMITY OF THE MACHINERY
SAFETY FORM
NOTES
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GENERAL
1 GENERAL
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 o f co mpone nt s su ch as th e gearb ox, the
motor and the frequency co ntrolle r is not inc luded in this
manual. However, if additional documentation is
supplied, you must follow the instructions in this
additional documen t ati on.
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 hose pump
• Article number pump hose
• Article number gearbox
• Article number electric motor
• Article number frequency controller
You will find these data on the identification plates or
stickers of the pumphead, the pump hose, the gearbox
and the electric motor. Refer to § 4.1.1.
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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
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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 resu lt in serious
damage to the hose pump or in serious
bodily harm.
CAUTION
Procedures which, if not carried out with
the necessary care, may resu lt in serious
damage to the hose pum p, the surrounding
area or the environment.
Remarks, suggestions and advice.
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WARNING
Procedures, remarks, suggestions or
advice which refer to use in potentially
explosive atmos phe res in a ccordance with
the ATEX Directive 94/9/EC.
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.
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 . Observing the i nstructions
in the user's documentation also belongs to intended
use.
Only use the pump in conformance with the intended
use described above. The manufacturer cannot be held
responsible for damage or harm resulting from use that
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
SAFETY
Refer to chapter 10 for a description of pump
configurations th at are suitable in a potentially exp losiv e
atmosphere. Such configurations are suitable for use in
a potentially explosive atmosphere. For use in Europe,
the pump complie s with the European Directi ve 94 /9/EC
(ATEX).
The pumps belong to:
• Group II Appliances, category 2 GD bck T5
Use in Potentially explosive atmospheres
requires special configuration of the pump
unit. Contact y our Bredel rep resentativ e for
use in explosive atmosphe res .
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SAFETY
2.4 Responsibility
The manufacturer does not ac ce pt any resp ons ib ili ty for
damage or harm caused by not (strictly) observing the
safety regulations and instructions in this manual and
the also 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
noticed a potential danger while using your hose pump.
WARNING
The user of the hose pump is always fully
responsible for observing the local valid
safety regulations and directives. Observe
these safety regulation s and directives
when using the hose pump.
2.5 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.
2.6 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 car e.
• Never change the order of the actions to be
carried out.
• Always store the manual near the hose pump.
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3 WARRANTY CONDITIONS
The manufacturer offers a two-year warranty on all
parts of the hose pum p. Thi s m ean s th at al l parts will be
repaired or replaced free of charge, with the exception
of consumables, such as pump hoses, hose clamps,
ball bearings, wear rings, and seals, or parts which
have been misused or have been intentionally
damaged.
If parts are used that are not Watson-Marlow Bredel
B.V. (hereafter called Bredel) parts, every warranty
becomes 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 spec ific cleaning procedure has
been followed, and it should be indicated that the
equipment has been decontaminated. The safety form
is required at all items, 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.
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DESCRIPTION
4 DESCRIPTION
4.1 Identification of the product
4.1.1 Identification of the product
The hose pump can be identified based on the
identification plates or stickers on:
A: Pump head
B: Gearbox
C: Electric motor
D: Pump hose
E: Frequency controller (option)
4.1.2 Identification of the pump
The identification plate on the pump head contains the
following data:
A: Pump type
B: Serial number and rotor identification letter
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C: Year of manufacture
4.1.3 Identification of the rotor
The rotor identification letter identifies which type of
rotor is mounted to the pump. The table below shows
the rotor identification letter and the article number of
the mounted rotor. Also refer to 11.5.3.
Letter Bredel 10 Bredel 15-20
blank no rotor no rotor
A 210103L 215103L
1 For information on the rotor identification letter, refer
to 4.1.3.
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Letter Bredel 10 Bredel 15-20
B 210103H 215103H
C - 220103L
D - 220103H
E 210103X 215103X
F - 220103X
4.1.4 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
4.1.5 Identification of the electric motor
The identification plate on the electric motor contains
the following data:
A: Type number
B: Serial number
C: Article number
D: Mains
E: Frequency
F: Speed
G: Power
H: Power factor
I: Current
DESCRIPTION
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DESCRIPTION
4.1.6 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
4.1.7 Identification of the pump hose
The identification st icker on the pump hose contains the
following data:
A: Pump type
B: Reorder number
C: Internal diameter
D: Type of material of inner liner
E: Remarks, if applicable
F: Maximum permissible working pressure
G: Production code
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4.2 Construction of the pump
DESCRIPTION
A: Cover
B: Rotor
C: Pump hose
D: Pump housing
E: Support
F: Gearbox
G: Electric motor
H: Frequency controller
4.3 Operation of the pump
The heart of the pump head consists of a specially
constructed pump hose (A) which lies contorted against
the inside of the pump housing (B). Both ends of the
hose are c onnected to the suction and discha rge lines
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DESCRIPTION
(C). A bearing-mounted rotor (D) with two facing
integral pressing shoes (E) is in the centre of the pump
head.
In phase 1 the lower shoe compresses the pump hose
by the rotational movement of the rotor, forcing the 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.
In phase 2 the product is drawn into the hose by the
(continuous) turning motion of the rotor.
In phase 3, the second integral pressing shoe will
subsequently compress the pump hose. Due to the
continuous rotating movement of the rotor not only new
product is sucked in, but also the already present
product is pressed out by the shoe. When the first shoe
runs from the pump hose, the second shoe has already
closed the pump hose and the product is prevented
from flowing back . T his m ethod of liquid displacement is
also known as the "positive displacement principle".
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4.4 Pump hose
4.4.1 General A: Outer extruded layer made of natural rubber B: Two nylon reinforcement layers C: Inner extruded liner
The pump hose liner material should be chemically
resistant with the product to be pumped. Dependent on
the specific requirements of your application a
corresponding pump hose must be selected. For each
pump model various hose types are available.
The material of the inner liner of the pump hose
determines the hose type. Each hose type is marked by
a unique colour code.
Hose type Material Colour code
NR Natural rubber Purple
NBR Nitrile rubber Yell ow
EPDM EPDM Red
CSM CSM Blue
DESCRIPTION
Consult your Bredel representative for
more detailed information about the chemical and temperature resistance of pump
hoses.
The Bredel pump hoses have been carefully machined,
therefore there are minimum tolerances in wall
thickness. It is very important to guarantee the cor rect
compression of the pump hose, because:
• When the compression is too high, it creates a
too high load of the pump and pump hose,
which may result in a reduction of the life of the
pump hose and bearings.
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DESCRIPTION
• When the compression is too low, this will result
in loss of capacity and backflow. Backflow
results in a reduction of the life of the pump
hose.
4.4.2 Hose compression force adjustment
The compression force of 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 us e of th e hos e pu mp . If yo u w ant
to change the application of your hose pump, contact
your Bredel representative .
4.4.3 Lubrication and cooling
The pumphead, in which the rotor and pump hose can
be found, is filled with Bredel Genuine Hose Lubricant.
This lubricant lubricates the movement between the
hose and the pressing shoes and dissipates the
generated heat via the pump housing and the cover.
The lubricant is food grade. See §11.1.4 for the
required quantity an d NSF registration.
Consult your Bredel representative for
lubrication recommendations when operating the hose pump below 2 rpm.
4.5 Gearbox
The hose pump types described in this manual use
helical gearbox units. The gearboxes are fitted with a
flange connection. Refer to § 11.2 for specifications. If
the pump is to be used in potentially explosive
atmospheres, refer to chapter 10.
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4.6 Electric motor
If the electric motor has been standard supplied by the
manufacturer, it is a standardized squirrel-cage motor.
Refer to § 11.3 for specifications. If the pump is to be
used in potentially explosive atmospheres, refer to
chapter 10.
4.7 Frequency controller
Refer to the also s upp lie d documentation of the supplier
and § 11.4. If the pump is to be used in potentially
explosive atmospheres, refer to chapter 10.
4.8 Available options
The following options are available for the hose pump:
• High (lubricant) level float switch
• Revolution counter
• Low, medium, or high pressure rotor
• Rotor and coupling for heavy duty
• Frequency controller
• Special configuration for use in explosive
atmospheres
DESCRIPTION
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