Watson-Marlow SP User Manual

Hose Pump Series

SP/10, SP/15, SP/20, SP/25, SP/32,

SP/40, SP/50, SP/65, SP/80 and SP/100

Manual

Contents

1 GENERAL.........................................................................................................................6

1.1 How to use this manual..............................................................................................6

1.2 Other supplied documentation ...................................................................................6

1.3 Service and support ...................................................................................................6

1.4 Used products and the environment ..........................................................................6

2 SAFETY ............................................................................................................................7

2.1 Pictograms .................................................................................................................7

2.2 Intended use ..............................................................................................................7

2.3 Responsibility.............................................................................................................7

2.4 Qualification of the user .............................................................................................8

2.5 Regulations and instructions......................................................................................8

3 WARRANTY CONDITIONS..............................................................................................9

4 DESCRIPTION................................................................................................................10

4.1 Identification of the product......................................................................................10

4.2 Construction of the pump.........................................................................................10

4.3 Operation of the pump .............................................................................................11

4.4 Pump hose...............................................................................................................12

4.4.1 General .............................................................................................................12

4.4.2 Hose compression force adjustment (shimming). (not applicable for series

SP/10, SP/15 and SP/20). ................................................................................12

4.4.3 Lubrication and cooling.....................................................................................12

4.4.4 Gearbox ............................................................................................................12

4.4.5 Electric motor....................................................................................................13

4.4.6 Available options...............................................................................................13

5 INSTALLATION..............................................................................................................14

5.1 Unpacking ................................................................................................................14

5.2 Inspections...............................................................................................................14

5.3 Installation conditions...............................................................................................14

5.3.1 Ambient conditions ...........................................................................................14

5.3.2 Set-up ...............................................................................................................14

5.3.3 Pipework ...........................................................................................................14

5.3.4 Pulsating flow....................................................................................................15

5.3.5 Pumping pressure (counter pressure) ..............................................................15

5.4 Lifting and moving the pump....................................................................................15

5.5 Placing the pump .....................................................................................................16

6 COMMISSIONING ..........................................................................................................17

6.1 Preparations.............................................................................................................17

6.2 Commissioning ........................................................................................................ 17

7 MAINTENANCE..............................................................................................................18

7.1 Maintenance and periodic inspections.....................................................................18

7.2 Cleaning pump hose ................................................................................................19

7.3 Changing lubricant ...................................................................................................19

7.4 Changing oil in gearbox ...........................................................................................19

7.5 Replacing pump hose ..............................................................................................19

7.5.1 Hose removal....................................................................................................19

7.5.2 Removal of lubricant .........................................................................................19

7.5.3 Removal of piping .............................................................................................19

7.5.4 Loosening of hose clamps ................................................................................19

7.5.5 Removal of flanges and/or inserts ....................................................................19

7.5.6 Removal of flange brackets ..............................................................................20

7.5.7 Removal of the hose.........................................................................................20

7.5.8 Cleaning of pump casing ..................................................................................20

7.5.9 Tighten drain plug (not applicable for SP/10, SP/15 and SP/20)......................20

7.5.10 Preparation of pump hose ................................................................................20

7.5.11 Insertion of the hose .........................................................................................20

7.5.12 Place hose clamps............................................................................................20

7.6 Hose connection ......................................................................................................20

7.6.1 Mount flange brackets (SP/25 to SP/100) ........................................................21

7.6.2 Positioning of pump hose .................................................................................21

7.6.3 Tighten hose clamps.........................................................................................21

7.6.4 Tighten bolts of all flange brackets ...................................................................21

7.6.5 Filling with lubricant ..........................................................................................21

7.6.6 Finally ...............................................................................................................21

7.7 Exchanging replacement parts ................................................................................22

7.7.1 Replacing pressing shoes (not applicable for SP/10, SP/15 and SP/20) .........22

7.7.2 Replacing seal and bearings ............................................................................22

7.8 Hose compression force adjustment (shimming) (not applicable for SP/10, SP/15

and SP/20). ..............................................................................................................23

7.9 Fitting options...........................................................................................................24

7.9.1 Fitting a high-level float switch..........................................................................24

7.9.2 Fitting a low level float switch (not applicable for SP/10, SP/15 and SP/20) ....24

8 STORAGE ......................................................................................................................25

8.1 Hose pump...............................................................................................................25

8.2 Pump hose...............................................................................................................25

9 TROUBLESHOOTING....................................................................................................26

10 SPECIFICATIONS ......................................................................................................28

10.1 Pumphead................................................................................................................28

10.1.1 Performance .....................................................................................................28

10.1.2 Materials ...........................................................................................................28

10.1.3 Lubricant ...........................................................................................................28

10.1.4 Surface treatment .............................................................................................29

10.1.5 Weights and dimensions...................................................................................29

10.1.6 Torques.............................................................................................................30

10.1.7 Shimming..........................................................................................................31

10.1.8 Parts list: SP/10-SP/15 .....................................................................................32

10.1.9 Parts list: SP/20 H-L .........................................................................................34

10.1.10 Parts list: SP/25, SP/32, SP/40 and SP/50 ...................................................36

10.1.11 Parts list: SP/65, SP/80 and SP/100 .............................................................39

10.1.12 Dimensional drawings...................................................................................43

10.1.13 EG-Declaration of Conformity .......................................................................46

10.1.14 Manufacturer’s Declaration ........................................................................... 47

10.1.15 Product Use and Decontamination Declaration ............................................48

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 Other supplied documentation

In this manual the documentation of pump components i.e. engines, etc. is not included. But if the documentation of a certain component is part of this manual, you must respect and act according the instructions as given in the supplied documentation.

1.3 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

You will find these data on the identification plates or stickers of the pumphead and the pump hose. See “Description”: “Identification of the product”, § 4.1.

1.4 Used products and the environment

ENVIRONMENT

Enquire with your local government about the possibilities for reuse or environment friendly processing of packaging materials, (contaminated) lubricant and oil. Always observe the local rules and regulations with respect to processing (non reusable) parts of the hose pump.

2 SAFETY

2.1 Pictograms

In this manual the following symbols are used:

WARNING

Procedures which, if not carried out with the necessary care, may result in serious damage to the hose pump or in serious bodily harm.

CAUTION

Procedures which, if not carried out with the necessary care, may result in serious damage to the hose pump, the surrounding area or the environment.

Remarks, suggestions and advice.

2.2 Intended use

The hose pump is exclusively designed for pumping suitable products. Every other or further

(1)

use is not in conformance with the intended use.

The manufacturer cannot be held responsible for damage or harm resulting from this. The hose pump is designed in conformance with the valid standards and directives.

Only use the pump in conformance with the intended use described above. If you want to change the application of your hose pump, contact your Bredel representative first.

c 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 instructions in the user’s documentation also belongs to intended use.

2.3 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 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 regulations and directives when using the hose pump.

2.4 Qualification of the user

The installation, use and maintenance of the hose pump is only reserved for well trained and qualified users. Temporary staff and persons in training may only use the hose pump under the supervision and responsibility of well trained and qualified users.

2.5 Regulations and instructions

• Everyone who will work with the hose pump must know the content of this manual and observe the instructions with great care.

• Never change the order of the actions to be carried out.

• Always store the manual near the hose pump.

3 WARRANTY CONDITIONS

The manufacturer offers a one–year warranty on proper workmanship of all parts of the hose pump. Exclusion is made for normal wear and tear of consumables, such as pump hoses, lubricant, hose clamps, pressing shoes, ball bearings, wear ring, an seals, or parts which have been misused or damaged through negligence. This manufacturer’s warranty is null and void for any user who has substituted the parts of an alternate manufacturer into a Bredel hose pump.

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.

Warranties purporting to be on behalf of Bredel Hose Pumps B.V. made by any person, including representatives of Bredel Hose Pumps B.V., its subsidiaries, or its distributors, which do not accord with the terms of this warranty shall not be binding upon Bredel Hose Pumps B.V. unless expressly approved in writing by a Director or Manager of Bredel Hose Pumps B.V.

4 DESCRIPTION

4.1 Identification of the product

The hose pump can be identified based on the identification plates or stickers on:

A. Pump hose B. Pumphead C. Gearbox D. Electric motor E. Pump hose

The identification plate on the pumphead contains the following data:

A. Type number B. Serial number

If applicable: the identification plate on the gearbox contains (depending on the brand) the following data:

A. Article number B. Serial number C. Type number D. Reduction E. Number of rounds per minute F. Oil type upon delivery

If applicable: the identification plate on the electric motor contains (depending on the brand) 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

The identification sticker on the pump hose contains the following data:

A. Order number B. Internal diameter C. Type of material of inner liner D. Maximum permissible working pressure

4.2 Construction of the pump

A. Pump hose B. Pump housing C. Rotor D. Pressing shoes E. Cover F. Support G. Gearbox H. Electric motor

4.3 Operation of the pump

The heart of the pumphead consists of a specially constructed pump hose which lies contorted against the inside of the pump housing. Both ends of the hose are connected to the suction and discharge lines by means of a flange construction. A bearing-mounted rotor with two facing pressing shoes is in the center of the pumphead.

In phase 1 the lower pressing shoe compressed 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.

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 displacement principle”.

4.4 Pump hose

4.4.1 General

The pump hose is made of special rubbers, reinforced with nylon cords and is constructed as follows:

A. Outer extruded layer made of natural rubber B. 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.

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 compression is too high, it creates a too high load of the pump and pump

hose, which will result in a reduction of the life of the pump hose and bearings.

• 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). (not applicable for series SP/10,

SP/15 and SP/20).

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 are fitted between the rotor and the pressing shoe. The number of shims will vary for each counter-pressure situation. See “Hose compression force adjustment” § 7.8 and “Shimming table” §10.1.7. Caution: insufficient shimming reduces hose life.

4.4.3 Lubrication and cooling

The pumphead, in which the rotor and pump hose can be found are filled with a special lubricant.The lubricant lubricates the movement between the hose and the pressing shoes and transfers the generated heat from the hose to the pump housing and the cover.

4.4.4 Gearbox

The hose pump types described in this manual use various types of gearbox units. The gearboxes are fitted with a foot rest.

4.4.5 Electric motor

The hose pump type described in this manual use various types of motors. If the pump is to be used in potentially explosive atmospheres, please contact your Bredel representative, as these type of pumps are not

in compliance with ATEX.

4.4.6 Available options

The following options are available for the hose pump:

• High (lubricant) level float switch

• Low (lubricant) level float switch (not applicable for SP/10, SP/15 and SP/20)

• Epoxy pressing shoes (not applicable for SP/10, SP/15 and SP/20)

• Stainless steel 316 flanges, flange brackets, hose clamps, supporting and mounting

articles

5 INSTALLATION

5.1 Unpacking

When unpacking carefully follow the instructions as given on the packaging or on the hose pump.

5.2 Inspections

Check that your delivery is correct and check it for any transport damage, see “Description: “Identification of the product”, § 4.1. 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° 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 1 mm per

meter.

• 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.

5.3.3 Pipework

When determining and connecting suction and discharge lines consider the following points:

• The bore size of the suction line must be larger than the bore size of the pump hose.

The bore size of the discharge line must be minimal or larger than the bore size of the pump hose. For more information consult your Bredel representative.

• Limit the presence of sharp bends. Make sure that the radius of the bends are as

large as possible (preferably 5S). It is recommended to use Y-connections instead of T-connections.

• It is recommended to use a minimum of three quarter (3/4) of the hose length as

flexible hose in the suction or discharge line. In this way you prevent that connection lines must be removed when changing a pump hose.

• Keep the delivery and suction lines as short and direct as possible.

• Prevent any possibilities of exceeding the maximum working pressure of the hose

pump, see “Specifications”: “Performance”, § 10.1.1. If necessary fit an overpressure 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 maximum

permissible loads on the pump flange are given in the table below:

Force

F1 [N] SP/10 SP/15 SP/20 SP25 SP/32 SP/40 SP/50 SP/65 SP/80 SP/100

F1 600 600 600 1000 1000 1000 1400 1400 2000 2000 F2 120 120 120 200 200 200 300 300 400 400 F3 300 300 300 500 500 500 700 700 1000 1000

5.3.4 Pulsating flow

Hose pumps have a pulsating flow that can result in vibrations of pump and lines under the following circumstances:

• suction and discharge lines are not fixed correctly

• high pump speed in combination with long suction and discharge lines or high specific

gravity of the product

• diameter of suction and/or discharge line too small

In case of unacceptable pulsations, dampeners for suction and/or discharge line can be supplied for the pump series SP/25 to SP/100. Please consult your Bredel representative for literature on Inlet Pulsation Accumulators (IPA) or Pulsation Dampeners (PD). These accumulators and dampeners are not available for SP/10, SP15 and SP/20.

5.3.5 Pumping pressure (counter pressure)

Should not go over maximum allowance (7,5 bar for SP/10, SP/15 and SP/20; 16 bar for bigger models). If hose failure looks like explosion, check system for blocked lines, closed valves or failing pressure relief valves.

5.4 Lifting and moving the pump

For lifting and moving the pumphead, it has been fitted with a lifting strip. This lifting strip is fitted on the rear of the pumphead. For the weights of the pump, see “Specifications”: “Weights”, § 10.1.5.

The complete hose pump, i.e. pumphead, gearbox and electric motor, must be lifted using the lifting eyes in the pump support plus additional support on gearbox and motor using suitably rated straps or slings, see “Specifications”: Weights, § 10.1.5.

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