Disc
The disc inserted in the front cover contains the user manual of the models DuCoNite
25 and DuCoNite® 32. 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 hyperlink s to chapter s or para graphs . These hy perli nks are li nked
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:
• Disc drive
The following software must be installed on the PC:
• PDF reader program
• An Internet browser
1
2
Hose pump series
DuCoNite
®
25 and DuCoNite® 32
Manual
3
© 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 extensive 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 pa rties.
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.
4
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 ......................................................................................... 10
2.3 Use in potentially explosive atmospheres ............................................. 11
2.4 Use in corrosive atmosphere ................................................................ 11
2.5 Responsibility ........................................................................................ 11
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 mo tor .................... ...... ...... ..... ......... 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 .......................................................................... 16
4.4 Pump hose ............................................................................................ 18
4.4.1 General ...................................................................................... 18
4.4.2 Hose compression force adjustment (shimming) ...................... 19
4.4.3 Lubrication and cooling ............................................................. 19
4.5 Gearbox ................................................................................................ 19
4.6 Electric motor ........................................................................................ 20
4.7 Motor frequency controller .................................................................... 20
4.8 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 Set-up ........................................................................................ 21
5.3.3 Pipework ................................................................................... 22
5.3.4 Frequency controller ................................................................. 23
5.3.5 High Level Control (HLC) .......................................................... 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 Changing oil in gearbox ........................................................................ 32
7.7 Replacing pump hose ................................. .......................................... 33
7.7.1 Removing pump hose ............................................................... 33
7.7.2 Cleaning the pump head ........................................................... 35
7.7.3 Fitting the pump hose ...................... ..... ..................................... 35
7.8 Exchanging replacement parts ............................................................. 38
7.8.1 Replacing pressing sh oes ......................................................... 38
7.8.2 Replacing seal ring and bearings ................................ ...... ..... ... 40
7.9 Adjusting hose compression force (shimming) ..................................... 43
7.10 Options ................................................................................................. 46
7.10.1 Revolution counter .................................................................... 46
7.10.2 Drain connection ............................. ..... ...... ...... ..... .................... 47
8 STORAGE
8.1 Hose pump ........................................................................................... 48
8.2 Pump hose ........................................................................................... 48
6
9 TROUBLESHOOTING
10 SPECIFICATIONS
10.1 Pump head ........................................................................................... 54
10.1.1 Performance .............................................................................. 54
10.1.2 Materials .................................................................................... 55
10.1.3 Surface treatment ...................................................................... 56
10.1.4 Chemical r esistance chart DuCoNite
®
coating .......................... 56
10.1.5 Lubricant table pump ................................................................. 57
10.1.6 Weights ..................................................................................... 58
10.1.7 Torque figures ........................................................................... 59
10.1.8 Shims specifications .................................................................. 60
10.2 Lubricant table gearbox .......................................................... ..... ......... 61
10.3 Gearbox ................................................................................................ 62
10.4 Electric motor ........................................................................................ 62
10.5 Frequency controller ............................................................................. 63
10.6 Parts list ................................................................................................ 64
10.6.1 Overview ................................................................................... 64
10.6.2 Cover assembly ......................................................................... 65
10.6.3 Rotor assembly ......................................................................... 66
10.6.4 Pump housing assembly ....................................... ...... .............. 67
10.6.5 Support assembly ...................................................................... 69
10.6.6 Flange assembly ....................................................................... 70
10.6.7 Revolution counter assembly ................................ ...... ..... ...... ... 71
10.6.8 Lubricants .................................................................................. 71
EC DECLARATION OF CONFORMITY FOR MACHINERY
SAFETY FORM
NOTES
7
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 of components such as the motor and
the Variable Frequency Drive (VFD) is normally 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 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.
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 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.
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
10
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
The pump head and gearbox mentioned in this manual
are suitable for use in a potentially explosive
atmosphere. The pumps mentioned meet the
requirem ents as stated i n the Europ ean Direct ive 94/9/
EC (ATEX Directive).
The pumps belong to:
• Group II Appliances, category 2 GD ck T4
2.4 Use in corrosive atmosphere
®
The DuCoNite
externally) with a corrosion and wear resistant coating.
This coating withstands highly oxidising and reducing
media. Refer to § 10.1.4 for a specification.
pump head is coated (both in- and
SAFETY
2.5 Responsibility
The manufacturer does not accept any responsibility 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 specifi c worki ng cond itions or acce ssories used,
additional safety instructions can be required.
11
SAFETY
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.
2.6 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 car e.
• 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 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 specific 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.
13
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
C: ATEX code and document number, if applicable
D: 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
14
4.1.4 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
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
4.1.6 Identification of the pump hose
The identification stic ker on the pump hose cont ai ns 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
15
DESCRIPTION
4.2 Construction of the pump
A: Cover
B: Rotor
C: Pressing shoes
D: Pump hose
E: Pump housing
F: Support
G: Gearbox
H: Electric motor
I: Frequ enc y con trol ler (option)
J: Adapter without motor (option)
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
16
hose are c onnected to the suction and discha rge lines
by means of a flange construction (C). A bearingmounted rotor (D) with two facing pressing shoes (E) is
in the centre of the pump head.
In phase 1 the lower pressing shoe compresses the
pump hose by the rotational movement of the rotor,
forcing the fluid through the hose. As soon as the
pressing 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.
DESCRIPTION
In phase 3, the second 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 pressing shoe. When the first
pressing shoe runs from the pump hose, the second
pressing shoe has already closed the pump hose and
the product is prevented from flowing back. This
method of liquid displacement is also known as the
"positive displaceme nt principle".
17
DESCRIPTION
4.4 Pump hose
4.4.1 General A: Outer extruded layer made of natural rubber B: Four 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
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 correct
compression of the pump hose, because:
• When the compre ssion 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.
18
• 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
(shimming)
In order to achieve optimal life of the pump hose, the
compression force of the pump hose can be adjusted by
placing a number of shims under the pressing shoes.
The shims (A) are fitted between the rotor (B) and the
pressing shoe (C). The number of shims will vary for
each counterpressure situation.
The paragrap h 7.9 describes how to sele ct and install
the shims.
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.
DESCRIPTION
The lubricant is food grade. See § 10.1.5 for the
required quantity and 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 coaxial gearbox units.
The gearboxes are fitted with a foot rest. The outgoing
shaft has been fitted with a spline.
19
DESCRIPTION
4.6 Electric motor
If the electric motor has been standard supplied by the
manufacturer, it is an integrated standardized squirrelcage motor. Refer to § 10.4 for specifications. If the
pump is to be used in potentially explosive
atmospheres, contact your Bredel representative.
4.7 Motor frequency controller
Refer to the also s upp li ed documentation of the supplier
and § 10.5. If the pump is to be used in potentially
explosive atmospheres, contact your Bredel
representative.
4.8 Available options
The next options are available for the hose pump:
• Revolution counter
• Drain connection
• Epoxy / titanium pressing shoes and titanium
shims
• Frequency controller
• Pump support for non-standard gearbox types
• Special configuration for use in potentially
explosive atmospheres
20
WARNING
If the pump is to be used in potentially
explosive atmospheres, contact your
Bredel representative.
5 INSTALLATION
5.1 Unpacking
When unpacking carefully follow the instructions as
given on the packaging or on the hose pump.
5.2 Inspection
Check that your delivery is correct and check it 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.
5.3.2 Set-up
• The pump materials and protective layers are
suitable for indoor set-up and a protected
outdoor set-up. Under certain conditions the
pump is suitable for limited outdoor set-up or a
salty or aggressive atmosphere. Consult your
Bredel representative for more information.
• Make sure that the floor surface is horizontal
and 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 activities.
• Make sure that the room is sufficiently
ventilated, so that the heat developed by the
pump and drive can be discharged. Keep some
distance between the ventilation cover of the
electric motor and wall to enable the supply of
necessary cooling air.
INSTALLATION
21
INSTALLATION
5.3.3 Pipework
When determining and connecting suction and
discharge lines consider the following points:
• The bore size of the suction an d dis ch arge lin es
must be 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 the
bent discharge line is as large as possible
(preferably 5S). It is recommended to use Yconnections 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 lines
when changing a pump hose.
• Keep the delivery and suction lines as sh ort a nd
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.
• Prevent any possibilities of exceeding the
maximum working pressure of the hose pump.
Refer to § 10.1.1. 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
Maximum permissible loads [N] on the
pump flange
Force DuCoNite® 25 DuCoNite® 32
F1 600 600
F2 500 500
F3 200 200
CAUTION
In case of hose failure, the product or a
mixture of product and lubricant can leak
by the breather cap. If this risk is not
acceptable, dr ain piping can be connected,
refer to § 7.10.2.
WARNING
The maximum pump tem perature is 60°C.
Above this temperature the corrosion
speed can rise excessively, depending on
the product.
INSTALLATION
5.3.4 Frequency controller
WARNING
A Bredel VFD that is fitted without the control switch starts automatically when pow er
is applied.
If the hose pump is fitted with a Bredel Variable
Frequency Drive (VFD), consider the following points:
• Take precautions so the motor does not re-start
automatically after an unscheduled stop.
In the event of a power or mechanical failure,
the Bredel VFD controls the motor to stop.
When the cause of the failure is removed, the
motor can restart automatically. The automatic
restart is dangerous to certain installations of
the pump.
23
INSTALLATION
• All control cables outside the enclosure must be
shielded and have a cross sectional area
between 0.22 and 1 mm
be connected to earth at both ends.
5.3.5 High Level Control (HLC)
To sense the lubricant level inside the pump housi ng the
pump is provisioned with a floater. The HLC floater (A)
is positioned above the normal lubricant level of the
pump. When a hose fails, the product will be pressed
into the pump casing and causes a level rise of the
lubricant. The HLC shall detect this rise of lubricant.
After hose failure, the floater needs to be cleaned.
Connection of floaters:
The floater has to be connected to the auxiliary power
circuit via the 1 meter long PVC cable (2 x 0.24 mm
Specifications
Scope: For use in non-explosive environments
Voltage: Max. 230 V AC/DC
Current: Max. 1 A
Power: Max. 50 VA
2
. The shielding must
2
).
24
Where the floate r is co nstructed to stop th e
equipment, operating has to be arranged
so that the stop functio n lock s-out, prev enting the equipment from being re-st arte d
without re-setting. Check if the floater is
mounted with the NC sign at the top.
5.4 Lifting and moving the pump
For lifting and moving the pump head, it has been fitted
with a lifting strip. This lifting str ip (A) is fitted on the rear
of the pump head. For the weights, refer to § 10.1.6.
The complete hose pump, i.e. pump head, gearbox and
electric motor, must be lifted using the lifting strip of the
pump head plus additional support using suitably rated
straps or slings (A). For the weights, refer to §10.1.6.
WARNING
If the pump is to be lifted ensure that all
standard lifting practices are adhered to
and carried out by qualified personnel only.
INSTALLATION
5.5 Placing the pump
Position the pump on a horizontal surface. Use suitable
anchor bolts to attach the pump to the floor surface.
25
COMMISSIONING
6 COMMISSIONING
6.1 Preparations
WARNING
A Bredel VFD that is fitted without the control switch starts automatically when powe r
is applied.
WARNING
Disconnect and lock the power supply to
the pump drive before any work is carried
out.
In case the motor is fitted with a frequency
controller and has a single-phase power
supply, wait two minutes to make sure that
the capacitors have discharged.
1. Connect the electric motor and, if present, the
frequency controller in conformance with the
locally applicab le rules an d regulati ons. Refer to
§ 5.3.4. Have the electrical installation work be
carried out by qualified perso nne l.
2. Check that the lubricant level is above the
minimum leve l line in the inspec tion window. If
necessary refill Bredel Genuine Hose Lubricant
via the breather/vent plug. See also § 7.5.
3. Check the rotation of the rotor.
4. Check that the correct number of shims
corresponds with your application. Refer to
§ 10.1.8.
For adjusting the compression force of the
hose, refer to § 7.9.
6.2 Commissioning
1. Connect the pipework.
26
2. Make sure that there are no obstructions such
as closed valves.
3. Switch on the hose pump.
4. Check the rotation of the rotor.
5. Check the capacity of the hose pump. If the
capacity differs from your specification, follow
the instructions in chapter 9 or consult your
Bredel representative.
6. Check the capacity range of the frequency
controller. In case of any deviations consult the
documentation of the supplier.
7. Check the hose pump in acc orda nc e w it h po in ts
2 to 4 of the maintenance table from § 7.2.
COMMISSIONING
27
MAINTENANCE
7 MAINTENANCE
7.1 General
WARNING
Disconnect and lock the power supply to
the pump drive before any work is carried
out.
In case the motor is fitted with a frequency
controller and has a single-phase power
supply, wait two minutes to make sure that
the capacitors have discharged.
WARNING
Only use original Bredel parts when maintaining the hose pump. Bredel cannot
guarantee correct operation and any consequential damage that occurs from the
use of non-original Bredel components.
See also chapters 2 and 3.
7.2 Maintenance and periodic inspections
The following maintenance scheme shows the
maintenance and periodic inspections that need to be
carried out on the hose pump to guarantee optimal
safety, operation and life of the pump.
28
MAINTENANCE
Point Action To be carried out Remark
1 Check the lubricant
level.
Before startup of the
pump and on a scheduled interval duri ng o peration.
Make sure that the lubricant level is above the
minimum level lin e in the
inspection window.
If necessary refill the
lubricant. See also § 7.5.
2 Check the pump head
for any leakage of lubricant around the cover,
the flanges and the rear
Before startup of the
pump and on a scheduled interval duri ng o peration.
See § 9.
of the pump head.
3 Check the gearbox for
any leakage.
Before startup of the
pump and on a scheduled interval duri ng o per-
In case of leakage consult your Bredel representative.
ation.
4 Check the pump for
deviating temperature or
On a scheduled interval
during operation.
See § 9.
strange noises.
5 Check the pressing
shoes for excessive
When replacing the
pump hose.
See § 7.7.
damage.
6 Internal cleaning of the
pump hose.
7 Replace the pump hose. Preventive, this means
Cleaning of the system
or product change.
See § 7.4.
See § 7.7.
after 75% of the hose li fe
of the first hose.
8 Change lubricant. After every 2
nd
hose
See § 7.5
change or after 5,000
service hours, whic hever
comes first or after hose
rupture.
9 Change oil in the gear-
box.
Refer to the lubricant
table in § 10.2.
See § 7.6.
10 Replace the pump seal. If necessary. See § 7.8.2.
29
MAINTENANCE
Point Action To be carried out Remark
11 Check the wear ring. When the pump seal is
replaced, check the running surfac e of the wear
ring for excessive wear.
12 Replace the pressing
shoes.
13 Replace the bearings. If necessary. See § 7.8.2.
7.3 Additional maintenance in potentially explosive environments
The following maintenance scheme shows the
additional maintenance and periodic inspections that
need to be carried out on the hose pump to guarantee
an optimal safety, operation and life of the pump in a
potentially explosive environment.
Point Action To be carried out Remark
1 Replacing bearings. According to ATEX regu-
2 Cleaning the hose
pump.
Wear on the runni ng s urface.
lations after 40,000 hrs.
service or wh en damage is suspected.
In potentially explosive
(dust) atmospheres, the
dust must be removed
regularly.
For replacement, contact
your Bredel representative.
See § 7.8.1.
See § 7.8.2.
7.4 Cleaning the pump hose
The inside of the pump hose can be easily cleaned by
rinsing the pump with clean water. If a cleaning fluid is
added to the water, check if the hose liner material is
resistant to it. Also check if the pump hose can resist
the cleaning temperature. Special cleaning balls are
also available. Contact your Bredel representative for
more details.
30
7.5 Changing lubricant
1. Place a tray (A) under the drain plug in the
cover of the pu mp. Remove the dr ain plug (B) .
Catch the lubricant from the pump housing in
the tray.
2. Position the drain plug (A) and tighten it firmly.
In order to facilitate the filling with lubricant the
breather plug (B) on the front of the pump
housing can be removed.
3. The pump housing can be filled with lubricant
via the breather/vent (A) on the rear of the
pump housing. For this purpose remove the
breather cap (B) and position a funnel (C) in the
breather. Pour the lubricant in the pump
housing via the funnel.
MAINTENANCE
31
MAINTENANCE
4. Keep on pouring until the lubricant level has
risen at least until just above the bottom level
line in the inspection window. Position the
breather plug (A) and tighten it firmly.
For the required quantity of lubricant, refer
to § 10.1.5.
7.6 Changing oil in gearbox
1. Isolate the pump from the electrical supply.
2. Remove plug (A) and let the oil run out of the
gearbox.
3. The plug (A) is magnetically loaded. In this way
metal particles in the oil are pulled to the plug.
Clean the plu g and remove any metal particles
if necessary. Check that the sealing ring is not
damaged and replace it if necessary. Place the
plug back in the gearbox and tighten it firmly.
4. Re move level plug (B ) and filling pl ug (C) and
position a f unn el in the ho le a nd fi ll t he g earbo x
with oil until the oil just comes out of the level
plug hole (B). Wait shortly to let out any
entrapped air. Place plug (B) and filling plug (C)
back and tighten them firmly.
For the required lubricant, refer to § 10.2.
5. Switch on the electrical supply to the pump.
32
7.7 Replacing pump hose
7.7.1 Removing pump hose
1. Isolate the pump from the electrical supply.
2. Close any shut-off valves in both the suction
and discharge line to minimize product loss.
3. Place a tray (A) under the drain plug in the
bottom of the pump head. The tray must be
large enough to contain the lubricant, possibly
contaminated with product fluid, from the pump
head. Remove the drain plug (B). Catch the
lubricant from the pump housing in the tray.
Check that the breather/vent mounted on the
rear is not obscured. Position the drain plug and
tighten it firmly.
4. Loosen the retaining bolts (A) of both the
suction and discharge line (B). Disconnect the
suction and discharge lines.
MAINTENANCE
5. Loosen hose clamp (A) of both the inlet and
outlet ports by loosening retaining bolt (B).
33
MAINTENANCE
6. Pull the insert (B) from the hose and remove the
flanges (A). Carry out this procedure both for
the inlet and outlet ports.
7. Loosen the retaining bolts (A) of the flange
bracket (B) and remove the bolts. Slide the
flange bracket and the hose clip (C) off the
hose. Carry out this procedure both for the inlet
and outlet ports.
8. Slide off the sealing ring (A). Check that the
sealing ring is not deformed or damaged and
replace it if necessary. Carry out this procedure
both for the inlet and outlet ports.
9. Switch on the electrical supply.
10. Power out the hose (A) from the pump chamber
by jogging the drive mot or.
WARNING
During jogging the drive:
- Do not stand in front of the pump
ports.
- Do not try to guide the hose by
hand.
34
7.7.2 Cleaning the pump head
1. Isolate the pump from the electrical supply.
2. Remove the cover (B) by loosening the
retaining bolts (A).
3. Check the sealing ring (C) and replace it if
necessary.
4. Rinse the pump head with clean water and
remove all residues. Make sure that no rinsing
water remains in the pump head.
5. Check the pressing shoes for wear or damage
and replace them if necessary. Refer to § 7.8.1.
Also see the maintenance scheme in § 7.2.
CAUTION
When the pressing shoes are worn the
compression force of the hose decreases.
If the compression force is too low, this
results in a loss of cap acity by the backflow
of the liquid to be pumped.
Backflow result s in a reduct ion of the life of
the pump hose.
MAINTENANCE
6. Replace the cover and fasten the retaining bolts
with the correct torque. Refer to § 10.1.7.
7. Switch on the electrical supply to the pump.
7.7.3 Fitting the pump hose
1. Clean the (new) pump hose on the outside and
fully lubricate it with Bredel Genuine Hose
Lubricant.
35
MAINTENANCE
2. Fit the pump hose (A) via one of the ports.
3. Let the motor run to pull the hose in the pump
housing. The rotor will take up the hose. Stop
the motor when the hose stic ks out eq ual ly from
both sides of the pump housing.
WARNING
During jogging the drive:
- Do not stand in front of the pump
ports.
- Do not try to guide the hose by
hand.
4. First fit the inlet port. Fit the sealing ring.
Before mounting, check that the sealing ring (A)
is not deformed or damaged and replace it if
necessary.
5. Before fitting check that the hose clamp is not
damaged and replace it if necessary. Slide the
flange bracket (B) and the hose clamp (C) over
the hose together. Align the holes in the flange
bracket with the ones at the front of the port.
Position the two retaining bolts (A) and tighten
them until they are approx. 5 mm from the port,
so that the gap between the flange bracket and
the port remains.
36
6. Slide insert (B) in flange (A) a nd pre ss th e i ns ert
in the hose. If nec essary l ubrica te t he insert w ith
Bredel Genuine Hose Lubricant in order to
simplify mounting. Make sure that the holes in
flange (A) are aligned with the holes in flange
bracket (C). Check that the insert is in the
correct place. If the insert is not positioned
correctly the product to be pumped may leak or
the lubricant may leak.
7. Turn the rotor in such a way that the hose (A) is
pressed fi rmly against the flange surface (B).
8. Now fully tighten the retaining bolts (A) of the
flange bracket (B). Make sure the bolts are
tightened with the correct torque. Refer to
§ 10.1.7.
MAINTENANCE
9. Position hose clamp (A) against O-ring cham ber
of the flange bracket (B) and fasten the
retaining bolt. Make sure the bolts are tightened
with the correct torque. Refer to § 10.1.7.
10. Now fit the other port. For this port proceed in
the same way as described above for the inlet
port.
11. Fill the pump housing with Bredel Genuine
Hose Lubricant. Refer to §7.5.
37
MAINTENANCE
12. Connect the suction and discharge lines (B) and
fit the retaining bolts (A). Tighten the retaining
bolts with the correct torque. Refer to § 10.1.7.
7.8 Exchanging replacement parts
7.8.1 Replacing pressing shoes
1. Jog the motor until the pressing shoe (B) is
positioned between the inlet and outlet port (A).
2. Isolate the pump from the electrical supply.
3. Place a tray (A) under the drain plug in the
cover of the pump. Remove the drain plug (B).
Catch the lubricant from the pump housing in
the tray. Position the drain plug and tighten it
firmly.
38
4. Remove the cover (A) by loosening the four
retaining bolts (B).
5. Loosen the retaining bolt (A) of the pressing
shoe (B). Remove the shims (C) if present.
6. Fit the removed shims (C) again. Position the
(new) pressi ng shoe (B), check t hat the Nord-
®
Lock
rings (D) have been positioned correctly
and tighten the retaining bolt(s) (A) a few turns.
Refer to § 10.1.7.
MAINTENANCE
7. Check the gasket (C) for damage and replace if
necessary. Refit the cover (B ). Make sure that
the 4 bolts (A) are refitted and that they are
tightened in the correct order, diagonally
opposite each other. Refer to § 10.1.7.
8. Switch on the electrical supply.
9. Jog the motor until the second pressing shoe is
positioned between the inlet and outlet port.
39
MAINTENANCE
10. Isolate the pump from the electrical supply.
11. Repeat the procedure for removing and fitting
this second pressing shoe by repeating steps 4
through 8.
12. Refill the lubricant. Refer to § 7.5.
7.8.2 Replacing seal ring and bearings
1. Remove the pump hose. Refer to § 7.7.1.
2. Isolate the pump from the electrical supply.
3. Remove the cover (B) by loosening the
retaining bolts (A).
4. Check the sealing ring (C) and replace it if
necessary.
5. Loosen the retaining bolt (A) of both pressing
shoes (B). Remove the shims (C) if present.
40
6. Extract the rotor (A) from the hub. Position both
crow bars behind the recesses (B) in the rotor.
7. Dismount the retaining circlip (A) with the
correct tool.
8. Dismount the bearings (A) with the correct tool,
the spacer ring (B) and the retaining circlip (C).
MAINTENANCE
9. Remove the seal (A). Clean and degrease the
bore.
41
MAINTENANCE
10. Fit a new seal (A) using good engineering
practises. The seal must be fitted in the correct
orientation (B). Make sure that the open side
points to the pump cover.
11. Check that the hub is clean and free of grease.
Fit the bearings and the rings now.
The bearings are pl ac ed on th e hub with a slight
interference fit. Use a pressing tool to press the
bearings on the hub.
12. Mount the retaining circlip (A).
13. Fit rotor (A). The rotor is placed on the bearings
with a loose fit. Press the rotor on t he hub unt il it
sticks.
42
14. Fit the removed shims (C) again. Position the
(new) pressi ng shoe (B), check t hat the Nord-
®
Lock
rings (D) have been positioned correctly
and tighten the retaining bolt(s) (A) a few turns.
Refer to § 10.1.7.
15. Check the gasket (C) for damage and replace if
necessary. Refit the cover (B ). Make sure that
the 4 bolts (A) are refitted and that they are
tightened in the correct order, diagonally
opposite each other. Refer to § 10.1.7.
16. Switch on the electrical supply to the pump.
17. Fit the (new) pump hose. Refer to § 7.7.3.
7.9 Adjusting hose compression force (shimming)
MAINTENANCE
Remove the pump cover before fitting and removing
shims. In order to determine the correct number of
shims for your specific application refer to § 10.1.8.
CAUTION
Too many shims, this means a too high
compression force on the pump hose, will
create a too high load on the pump head
and pump hose, which may result in a
reduction of the life of the pump hose and
bearings.
43
MAINTENANCE
CAUTION
Too few shims, this means a too low compression force on the pump hos e, cre ate a
loss of yield and sl ip or backflow. Backflow
results in a reduction of the life of the pump
hose.
1. Jog the motor until the pressing shoe (B) is
positioned between the inlet and outlet port (A).
2. Isolate the pump from the electrical supply.
3. Place a tray (A) under the drain plug in the
cover of the pump. Remove the drain plug (B).
Catch the lubricant from the pump housing in
the tray. Position the drain plug and tighten it
firmly.
4. Remove the cover (B) by loosening the
retaining bolts (A).
44
5. Loosen the retaining bolt (A) of the pressing
shoe (B). Fit the shims (C) or remov e them , until
the correct number of shims is present. Refer to
§ 10.1.8.
Fasten the retaining bolt of the pressing shoe
with the correct torque. Refer to § 10.1.7.
6. Refit the cover (B). Check the gasket (C) for
damage and replace if necessary. Make sure
that all bolts (A) are refitted and that they are
tightened in the correct order, diagonally
opposite each other. Refer to § 10.1.7.
7. Switch on the electrical supply.
8. Jog the rotor until t he second pressi ng shoe is
positioned between the inlet and outlet port.
9. Isolate the pump from the electrical supply.
MAINTENANCE
10. Repeat the procedure for this pressing shoe by
repeating steps 4, 5, 6 and 7.
11. Refill the lubricant via the breather. Refer to
§ 7.5.
45
MAINTENANCE
7.10 Options
7.10.1 Revolution counter
For feedback of the pump revolutions to an "intelligent"
system, the pump can be provided with an inductive
sensor (A). This sensor is mounted at the backside of
the pump.
Connection of the revolution counter:
The speed sensor can be connected via the 2 meter
long PVC cable (3x 0.34 mm
2
).
Specifications
Scope: For use in non-explosive environment s
Volt ag e: 10...30 VDC
Current: Max. 200 mA
Adjustment sensor:
The sensor (A) must be adjusted at an offset of 1-2 mm
to the special shim (B).
46
7.10.2 Drain connection
Drain piping can be connected with an optional part (A)
fitted at the breather. This is a 1" NPT threaded
connection.
CAUTION
The drain piping must be connected to an
open reservoir, to prevent pressure built u p
inside the pump housing.
MAINTENANCE
47
STORAGE
8 STORAGE
8.1 Hose pump
• Store the hose pump or pump parts in a dry
area. Make sure that the hose pump or pump
parts are not exposed to temperatures lower
than -40 °C or higher than +60 °C.
• Cover the openings of the inlet and outlet ports.
• Prevent corrosion of untreated parts. For this
purpose use the correct protection or packaging
means.
• After a long period of standstill or storage, the
static load on the pump hose may have caused
permanent deformation, which will reduce the
life of the pump hose. To prevent this, remove a
pressing shoe. Jog the rotor until the second
pressing shoe is positioned between the inlet
and outlet port. In this way there is no load put
on the pump hose.
8.2 Pump hose
• Store the pump hose in a cool and dark room.
After two years the h ose m aterial will age , which
will reduce the life of the hose.
48
TROUBLESHOOTING
9 TROUBLESHOOTING
WARNING
Disconnect and loc k the powe r suppl y to the pu mp drive be fore any work is
carried out.
In case the motor is fitted with a frequency controller and has a singlephase power supply, wait two minutes to make sure that the capacitors
have discharged.
If the hose pump does not function (correctly), consult the following checklist to see if
you can remedy the error yourself. If this is not the case, contact your Bredel
representative.
Problem Possible cause Correction
Failure to operate. No voltage. Check that the supply
power switch is on.
Check the el ectrical su p-
ply is available at the
pump.
Stalled rotor. Check if the pump is
stalled by inc orrect fitting of
the hose.
Lubricant level monitoring
system has been ac tivate d.
Check that the lubricant
level monitoring system
has stalled the pump.
Check the functioning of
the lubricant level monitoring system, or check the
lubricant level.
49
TROUBLESHOOTING
Problem Possible cause Correction
High pump temperature. Non standard hose lubri-
cant used.
Low lubricant level. Add Bredel Genuine Hose
Consult your Bredel representative for the correct
lubricant.
Lubricant. For the required
amount of lubricant refer to
§ 10.1.5.
Product temperature too
high.
Internal friction on the hose
caused by blocked or poor
suction characteristics.
Over-shimming of the
pump rotor shoes.
High pump speed. Reduce pump speed to a
Consult your Bredel representative about the maximum temperature range of
the product.
Check pipework/valves for
blockages. Ensu re that th e
suction pipework is as
short as possible and that
the diameter is large
enough.
Consult the diagra m. Refer
to § 10.1.8. Remove
excess shims.
minimum. Consult with
your Bredel pump representative for advice on
optimum pump speeds.
50
TROUBLESHOOTING
Problem Possible cause Correction
Low capacity / pressure. Shut-off valve in the suc-
tion line (partly) closed.
Fully open the shut-off
valve.
Under shimming of the
pressing shoes.
Hose rupture or badly worn
hose.
(Partial) blockage of the
suction line or too little
product on the suction
side.
Connections and hose
clamps not correctly
mounted, which makes the
pump suck air.
The filling degree of the
pump hose is too low,
because the speed is too
high in relation to the viscosity of the product to be
pumped and the inlet pressure.
The suction line can be too
long or too narrow or a
combination of these factors.
Consult the diagram in
§ 10.1.8. Fit the correct
number of shims.
Replace hose. Refer to
§ 7.7.
Ensure that the suction line
is clear of blockages and
that sufficient product is
available.
Tighten co nne cti ons and
hose clamps.
Consult your Bredel representative for a recommendation.
51
TROUBLESHOOTING
Problem Possible cause Correction
Vibration of the pump
and pipework.
Suction and discharge
lines are not secured correctly.
Check and secure pipework.
High pump speed with long
suction and discharge lines
or high relative d ensity or a
combination of these factors.
Too narrow diameter of
suction and/or discharge
line.
Short hose life. Chemical attack of the
hose.
High pump speed. Reduce pump speed.
High discharge pressures. Maximum working pres-
Reduce pump speed.
Reduce the line lengths on
both suction and discharge where possible.
Consult your Bredel representative for a recommendation.
Increase the diameter of
the suction/discharge lin es .
Check the compatibil ity of
the hose material with the
product to be pumped.
Consult your Watson-Marlow Bredel representative
for correct hose selection.
sure 1600 kPa. Check that
the discharge line is not
blocked, the shut-of f valves
are fully opened and the
pressure relief valve functions properly (if present in
the discharge line).
52
High product temperature. Consult your Bredel repre-
sentative for correct hose
selection.
High pulsations. Restructure the discharge
and inlet conditions.
TROUBLESHOOTING
Problem Possible cause Correction
Hose pulled into the
pump.
Insufficient or no hose
lubricant in the pump head.
Add extra lubricant. Refer
to § 7.5.
Lubricant leakage at
flange bracket.
Leakage from the rear of
the pump housing
"Buffer zone".
Motor functions, but
rotor does not.
Incorrect lubricant: no
Bredel Genuine Hose
Lubricant in the pump
head.
Extremely high inlet pressure - larger than 300 kPa.
Hose blocked by an incompressible object in the
hose. The hose cannot be
compressed and will be
pulled into the pump housing.
Bolts of flange bracket
loose.
Bolts of hose clam ps loos e. Tighten to the specified
Damaged sealing ring. Replace sealing ring.
Broken fracture surface on
rotor.
Consult your Bredel representative for the correct
lubricant.
Reduce the inlet pressure.
Remove hose, check for
blockages and replace if
necessary.
Tighten to the specified
torque settings. Refer to
§ 10.1.7.
torque settings. Refer to
§ 10.1.7.
Replace the rotor.
Extreme corrosion inside
the pump.
When the pump temperature goes above 60°C, the
corrosion speed can rise
excessively, depending on
the product.
Lower the pump temperature, by using the pump
intermittently. Or mount a
temperature switch, to prevent the pump temperature
from rising above 60 °C.
53
SPECIFICATIONS
10 SPECIFICATIONS
10.1 Pump head
10.1.1 Performance
Description DuCoNite® 25 DuCoNite® 32
3
Max. capacity, continuous [m
Max. capacity, intermittent [m
/h] 1.80 3.25
3
*
/h]
2.88 5.25
Capacity per revolution [l/rev] 0.300 0.625
Max. permissible working pressure [kPa] 1600
Permissible ambient temperature [°C] -20 to +45
Permissible product te m per at ur e [ °C] -10 to +60
Sound level at 1 m [dB(A)] 70
* Intermittent duty: "Let the pump stand still to cool down for at least 1 hour after 2 hours of
operation".
54
10.1.2 Materials
SPECIFICATIONS
Pos Description Material
1 Pump housing Cast-iron with DuCoNite
2 Cover Cast-iron with DuCoNite
3 Pump rotor Cast-iron with DuCoNite
4 Pressing sh oe Epoxy
5 Pump support AISI 316
6 Flange bracket AISI 316
7 Mounting material of pum p cover AISI 316
8 Mounting material of dr ive system AISI 316
9 Mounting material of pum p support AISI 316
10 Seal VITON
11 Seals, gaskets EPDM
12 Fitting PVC
13 Inspection cover PVC
®
coating
®
coating
®
coating
55
SPECIFICATIONS
10.1.3 Surface treatment
Pump head
The main pump head parts (pump housing, cover and rotor) are provided with a special
DuCoNite
®
coating, which is both chemical and wear resistant. For the chemical
resistance chart refer to § 10.1.4.
Gearbox-electric motor
After surface preparation, one layer of 2 component acrylate is used for surface
protection. The standard colour is RAL 9005. Contact your Bredel representative for
details on surface treatment.
10.1.4 Chemical resistance chart DuCoNite
®
coating
Chemical Concentration Chemical com-
Hose mater ial
patibility with
DuCoNite
®
Sodium Hypochlorite up to 18% good EPDM
Sodium Bisulphate 38% good EPDM
Ferric Chloride up to 50% good EPDM
Ferrous Chloride 35% good EPDM
Alum 50% good EPDM
Polymer good EPDM
Fluoride (Hydrofluorosi licic
18-24% limited EPDM
Acid)
Sodium Hydroxide 20-50% good EPDM
Potassium Permangana te 50 % good EPDM
Potassium Hydroxi de up to 70% good EPDM
Aqueous Ammonia 20% limited EPDM
Methanol good EPDM
Sulfuric Acid 93-97% good CSM
Peroxide 50% good CSM
Citric Acid 50% good EPDM
Zinc Orthophosphate 25% good EPDM
56
SPECIFICATIONS
Chemical Concentration Chemical com-
Hose mater ial
patibility with
DuCoNite
®
Phosporic Acid 50% good EPDM
Nitric Acid 25% limited CSM
If the ambient temperature is above 40°C consult your
Bredel representative.
10.1.5 Lubricant table pump
DuCoNite® 25 DuCoNite® 32
Lubricant Bredel Genuine
Hose Lubricant
Bredel Genuine
Hose Lubricant
Required quantity [litres] 2.5 4.5
Bredel Genuine Hose Lubricant is registered at NSF: NSF Registration N
o
Category Code H1. See also: www.NSF.org/USDA.
Should you require additional information with respect to the safety data
sheet, consult your Bredel representative.
123204;
57
SPECIFICATIONS
10.1.6 Weights
Description Weight [kg]
DuCoNite® 25 DuCoNite® 32
Main components:
Pump head 55 82
Gearbox 14.5 20
Motor 11 - 17 11 - 23
Total unit: 81 - 87 113 - 125
Components:
Hose 2 3
Lubricant 3 5.5
Gearbox G031 1. .. 14.5
Gearbox G0321... 14.5
Gearbox G0361... 20
Gearbox G0371... 20
Motor 0.55 kW, E013201 11
Motor 0.75 kW, E015211 11
Motor 1.1 kW, E015221 15
Motor 1.5 kW, E015231 17
Motor 2.2 kW, E015241 23
58
10.1.7 Torque figures
SPECIFICATIONS
Pos Description Torques [Nm]
DuCoNite® 25 DuCoNite® 32
A Pr essing shoe 50 50
B C over 50 50
C Hose clam p 40 40
D Flange bracket 50 50
E Support 25 85
F Gearbox 25 50
G Breather plug 3 3
H Inspection window 1.5 1.5
I Drain plug 3 3
59
SPECIFICATIONS
6
7
0
0
120 140 16010080604020
5
4
3
2
1
25DuCoNite
R
1600kPa - 16bar - 232psi
1250kPa - 12.5bar - 181psi
1000kPa - 10bar - 145psi
750kPa - 7.5bar - 109psi
500kPa - 5bar - 72.5psi
250kPa - 2.5bar - 36psi
0kPa - 0bar
10.1.8 Shims specifications
• When the product temperatures are above 60 °C always use one shim less than
indicated in the diagrams.
• Always round up the number of shims.
R
32DuCoNite
5
1600kPa - 16bar - 232psi
4
1250kPa - 12.5bar - 181psi
60
1000kPa - 10bar - 145psi
3
750kPa - 7.5bar - 109psi
2
500kPa - 5bar - 72.5psi
250kPa - 2.5bar - 36psi
1
0kPa - 0bar
0
0 20 40 60 80 100 120 140
SPECIFICATIONS
10.2 Lubricant table gearbox
Below is an overview of some of the recommended lubricants for the co-axial gearbox.
In the majority of the cases, a mineral oil ISO VG 220 is recommended. In case of
extreme ambient temperatures or a relatively wide range of ambient temperatures, a
synthetic oil is recommended. Contact your Bredel representative for advice.
Recommended lubri ca n ts for the B re del co-axial gearboxes
*
Oil type Mineral oil Synthetic oil
Change oil
5000 hours 20,000 hours
every
Ambient tem-
-10 °C to +40 °C -40 °C to +80 °C -30 °C to +60 °C
perature
DIN (ISO) CLP (CC) CLP HC CLP HC
ISO, NLGI VG22 0 VG220 VG150
Mobil Mobilgear 630 Mobil SHC 630 Mobil SHC 629
Shell Shell Om a la 220 Shell Omala 220 HD
Klüber Klüberoil GEM 1-220 Klübersynth GH4-220 Klübersynth EG 4-150
Aral Aral Degol BG 220 Aral Degol PAS220
BP BP Energol GR-XP 220
Tribol Tribol 1100/220 Tribol 1510/220
Texa co Meropa 220 P in na cl e EP2 20 Pinnacle EP150
Optimol Optigear BM 220 Optigear Synthetic
A220
Fuchs Renolin CLP 220 Renolin Unisyn CLP220
Recommended lubri ca n ts for the B re del co-axial gearboxes
*
Oil type Synthetic oil
Change oil
20,000 hours
every
Ambient tem-
-30 °C to -10 °C -30 °C to +60 °C -30 °C to +40 °C
perature
DIN (ISO) CLP HC HCE E
ISO, NLGI VG32 VG460 VG460
Foodgrade
**
Biology
***
Mobil Mobil SHC 624
61
SPECIFICATIONS
Recommended lubri ca n ts for the Bre d el co-axial gearboxes
Shell Shell Cassida Fluid GL
460
Klüber Klüber-Summit HySyn
FG32
Aral Aral Eural Gear 460 Aral Dego l BA B 460
Texaco Cetu s PAO 46
Optimol Optileb GT 460 Optisy nt BS 460
* For a complete overview of the recommended lubricants contact your Bredel representa-
tive.
** For use in the foodstuffs industry. Meets the requirements of the USDA (United States
Department of Agriculture): lubricant is suited for unforeseen contact with foodstuffs.
*** Lubricant for use in agricultural areas and nature reserves.
Klüber oil 4UH1-460 Klüberbio CA2-460
*
10.3 Gearbox
Co-axial gearbox with helical gears. Standard as a 2 and 3 stage version.
Mounting position IM 2001 (IM B35) foot flange gearbox with splined shaft in
horizontal position.
Motor adapter Electric mo to r h as be en integrated in the gearbox housing,
by which the smallest possible dimension is achi ev ed.
Optional motor adapter Adapters in conformance with IEC-B5 or NEMA TC.
10.4 Electric motor
Standard electric motor design is an enclosed three-phase asynchronous motor. A
thermal safety device to prevent motor overload is optional.
In case of doubt ab out the local applicable re gu lati on s fo r the driv e c on nec tion, contact your Bredel representative.
Protection class IP55/IK08
Insulation class F
Increase in temperat ure Within cla ss B
Voltage/frequency 230/400 V - 3 phases - 50 Hz
62
SPECIFICATIONS
10.5 Frequency controller
The frequency controller has been preprogrammed and only needs to be connected to
the mains.
RFI filter Integrated RFI filt er B (ind ust r ia l appl i ca tions).
Control Rotary knob for setting the speed and the key s f or starting
forward, stop and starting reverse.
Protection class IP65
Mains power supply There are 3 t ype s avai labl e; the cho ice de pends on the l ocal
electricity grid:
• 200-240 V ± 10%; 50/60 Hz ± 5%; 1 ph
• 200-240 V ± 10%; 50/60 Hz ± 5%; 3 ph
• 400-480 V ± 10%; 50/60 Hz ± 5%; 3 ph
63
SPECIFICATIONS
10.6 Parts list
10.6.1 Overview
Pos. Description
1 Cover assembly. Refer to § 10.6.2.
2 Rotor assembly. Refer to § 10.6.3.
3 Pump housing assembly. Refer to § 10.6.4.
4 Pump support assembly. Refer to § 10.6.5.
5 Flange assembly. Refer to § 10.6.6.
6 Revolution counter assembly. Refer to § 10.6.7.
7 Lubricant. Refer to §10.6.8.
64
SPECIFICATIONS
10.6.2 Cover assembly
Pos. Qty. Description Product codes for parts of pump type
DuCoNite® 25 DuCoNite® 32
1 4 Bolt, hex. head, M10X40 F502045 F502045
2 4 Washer, M10 F523013 F523013
®
31DuCoNite
41Cover DuCoNite
sticker 225239 232239
®
225102N 232102N
5 1 Quad ring 225123 232123
6 1 Gasket 29017349 29017349
7 1 Drain plug 29025348 29025348
8 5 Round head screw, M6X16 F552536 -
6 - F552536
9 1 Breather plug 29017463 29017463
10 1 O-ring S120113 S 120113
11 1 Inspection window 225155N 232155N
12 1 Gasket 225156 232156
65
SPECIFICATIONS
10.6.3 Rotor assembly
Pos. Qty. Description Product codes for parts of pump type
DuCoNite® 25 DuCoNite® 32
1 2 Pressing shoe 225109 232109
Pressing shoe with titanium
inserts
2 14 Shim 225107 -
10 - 2321 07
14 Shim, titanium 225107N 10 - 232107N
3 2 Bolt, hex. head, M10X50 F502047 F502047
Bolt, hex. head, M10X50 titanium
4 2 Nord-Lock ring, M10 F349506 F34950 6
Washer, M10 titanium F523013-1 F523013-1
5 1 O-ring S120263 S120263
6 1 Sealing cap 29035456 29035456
71Rotor DuCoNite
®
225109N 232109N
F504080-1 F504080-1
225103N 232103N
66
10.6.4 Pump housing assembly
SPECIFICATIONS
Pos. Qty. Description Product codes for parts of pump type
DuCoNite® 25 DuCoNite® 32
1 1 Circlip, A60 F343049 F343049
2 2 Bearing B141260 B141260
3 1 Spacer ring 29085201 2908 5201
4 1 Retaining circlip 29095297 29 09 5297
5 1 Seal S312415 S312415
6 1 NR 025020 032020
1 NBR 025040 032040
1 CSM 025070 032070
1 EPDM 025075 032075
7 1 Pump housing DuCoNite
8 1 Lifting strip 29065361 29065361
9 1 Bolt, hex. head, M10X25 F504075 F504075
®
225101N 232101N
67
SPECIFICATIONS
Pos. Qty. Description Product codes for parts of pump type
DuCoNite® 25 DuCoNite® 32
10 1 Washer, Spring Lock, M10 F532010 F532010
11 1 Seal 225114 232114
12 1 Breather connec t ion pl ug 29034451 2903445 1
13 5 O-ring S120183 S120183
14 1 Breather strip 29210222 29210222
15 1 Breather cap 29045221 29045221
16 1 O-ring S120263 S120263
17 1 Breather pipe 29060453 29060453
18 1 Gasket 29038352 29038352
19 1 Breather housing 29086450 29086450
20 1 High level switch 900610 900610
21 3 Plug 29029455 29029455
22 3 O-ring S122113 S122113
23 1 Drain pipe 29060454 29060454
68
SPECIFICATIONS
10.6.5 Support assembly
Pos. Qty. Description Product codes for parts of pump type
DuCoNite® 25 DuCoNite® 32
1 4 Bolt, hex. head, M8X35 F504057 -
Bolt, hex. head, M12x45 - F502067
2 4 Washer, M8 F523012 -
Washer, M12 - F523014
3 1 Pump support (standard) 2251 06 A 232106A
4 4 Washer, Spring Lock, M8 F532009 -
Washer, Spr i ng Lock, M12 - F 532011
5 4 Nut, M8 F516012 -
Nut, M12 - F516014
69
SPECIFICATIONS
10.6.6 Flange assembly
Pos. Qty. Description Product codes for parts of pump type
DuCoNite® 25 DuCoNite® 32
1 2 O-ring S112233 S112273
2 2 Flange bracket 225197A 232197A
3 4 Washer, Spring Lock, M10 F5 32010 F532010
4 4 Bolt, hex. head, M10X25 F504075 F504075
5 2 Hose clamp C101572 C101573
6 2 Fl ange, DIN SS 225199 232199
Flange, ANSI SS 225199A 232199A
7 2 Insert, Stainless steel 025186 032186
Insert, PVC 02 518 7 032187
Insert, PP 025189 032189
Insert, PVDF 025190 032190
70
SPECIFICATIONS
10.6.7 Revolution counter assembly
Pos. Qty. Description Product codes for parts of pump type
DuCoNite® 25 DuCoNite® 32
1 1 Plug 29029457 29029457
2 1 O-ring S120183 S12 0183
3 1 Nut 29035458 29035458
4 1 Revolution counter shim 225107NS 232107NS
5 1 Revolution counter 29050368 29050368
10.6.8 Lubricants
Pos. Qty. Description Product codes for parts of pump type
DuCoNite® 25 DuCoNite® 32
1 1 3 l can Bredel Genuine Hose
Lubricant
1 5 l can Bredel Genuine Hose
Lubricant
908143 -
- 9 03143
71
ORIGINAL
Original
EC DECLARATION OF CONFORMITY FOR MACHINERY
(according to Annex II.1.A. of Directive 2006/42/EC on machinery)
We,
Watson -Ma rlow Bredel B.V.
Sluisstraat 7
P.O. Box 47
7490 AA Delden
The Netherlands,
herewith declare, on our own responsibility, that the following machinery fulfils all the
relevant provisions of Directive 2006/42/EC:
Peristaltic hose pum p: DuCoNite
®
25-32 series,
for the transportation of various kinds of fluids.
In addition, the machi nery co mplie s with the h armoni sed s tan dard(s ), other st and ards or
technical specifications, applicable requirements of these standards and/or
specifications as listed below:
NEN-EN 809
NEN-EN-ISO 12100-2
NEN-EN-IEC 60204-1
The undersigned is responsible for compilation of the technical file and makes this
declaration on behalf of the manufacturer.
J. van den Heuvel
Managing Director
The Netherlands, Delden
1 June 2013
72
SAFETY FORM
Safety form
SAFETY FORM
Product Use and Decontamination Declaratio n
In compliance with the Health and Safety Regulations, t he user is required to declare those substances that
have been in contact with the item(s) you are returning to Watson-Marlow Bredel B.V. or any of its subsidiaries or
distributors. Failure to do so will cause delays in servicing the item or in issuing a response. Therefore, please
complete this form to make sure we have the information before receipt of the item(s) being returned. A completed copy must be attached to the outside of the packaging containing the item(s). You, the user, are responsible for cleaning and decontaminating the item(s) before returning them.
Please complete a separate Decontamination Certificate for each item returned. RGA/KBR no...................
1 Company ............................................................. .........................................................................................
Address ................. ........... .......... ........... .......... ..... ............... ..... ........... .......... ........... .....................................
Postal code...........................................................
Telephone .............................................................
2 Product ................................................................ 3.4 Cleaning fluid to be used if residue of chemical is
2.1 Serial Number ......................................................
2.2 Has the Product been used?
YES NO
If yes, please complete all the following para-
graphs.
If no, please complete paragraph 5 only
3 Details of substances pumped 4 I hereby confirm that the only substances(s) that
3.1 Chemical Names
a) ...................... ................ ............... ................ .....
b) ...................... ................ ............... ................ .....
c) ...................... ............................... .....................
d) ...................... ................ ............... ................ .....
3.2 Precautions to be taken in handling these substances:
a) ...................... ................ ............... ................ .....
b) ...................... ................ ............... ................ .....
c) ...................... ............................... .....................
d) ...................... ................ ............... ................ .....
3.3 Action to be taken in the event of human contact:
a) .........................................................................
b) .........................................................................
c) .........................................................................
d) .........................................................................
Fax number ..........................................................
found during servicing;
a) ........................................................................
b) ........................................................................
c) ......................... ..... ...... ..... ..... ..... .....................
d) ........................................................................
the equipment specified has pumped or come into
contact w it h a r e t h ose na me d , th at t h e in f or ma t ion
given is correct, and the carrier has been informed
if the consignment is of a hazardous nature.
5 Signed .................................................. ...............
Name ......................... ........................... ...............
Position ...................... ...... ..... ..... ..... .....................
Date ...................... .......................... .....................
Note:
To assist us in our servicing please describe
any fault condition you ha ve witn essed.
.............................................................................
.............................................................................
.............................................................................
.............................................................................
.............................................................................
NOTES
Notes
NOTES
74
NOTES
75
Watson-Marlow Bredel B.V.
P.O. Box 47
NL-7490 AA Delden
The Netherlands
Telephone: +31 (0)74 3770000
Fax: +31 (0)74 3761175
E-mail: bredel@wmpg.com
Internet: http://www.bredel.com
76
29210313 TS05-028-C
© 2013 Watson-Marlow Bredel B.V.
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