Watson-Marlow SP40 User Manual
Bredel PUMP SerieS
Installation, Operating and Maintenance Manual
Hose Pump Series
Bredel CIP 40, Bredel CIP 50
Manual
Original Instructions
© 2014 Watson-Marlow Bredel B.V.
All rights reserved.
The information provided herein may not be reproduced and/or published in any form,
by print, photoprint, microfilm or any other means whatsoever (electronically or
mechanically) without the prior written authorisation of Watson-Marlow Bredel B.V.
The information provided can be changed without prior notification. Watson-Marlow
Bredel B.V. or one of its representatives cannot be held liable for possible damage
resulting from use of this manual. This is an extensive limitation of the liability which
applies to all damage, inclusive of (without limitation) compensating, direct, indirect or
consequential damage, loss of data, income or profit, loss or damage to possessions
and claims of third parties.
Watson-Marlow Bredel B.V. provides the information in this manual "as is" and does not
take any responsibility and does not give any guarantee on this manual or its content.
Watson-Marlow Bredel B.V. rejects all responsibilities and guarantees. Furthermore,
Watson-Marlow Bredel B.V. does not take responsibility for and does not guarantee that
the information in this manual is accurate, complete or up to date.
Names, trade names, brands, etc. used by Watson-Marlow Bredel B.V. may not, as per
the legislation concerning the protection of trade names, be considered as available.
CONTENTS
1 GENERAL
1.1 How to use this manual .......................................................................... 4
1.2 Other supplied documentation ................................................................ 4
1.3 Service and support ................................................................................ 4
1.4 Used products and the environment ....................................................... 4
2 SAFETY
2.1 Symbols .................................................................................................. 5
2.2 Intended use ........................................................................................... 5
2.3 Responsibility .......................................................................................... 6
2.4 Qualification of the user .......................................................................... 6
2.5 Regulations and instructions ................................................................... 7
3 WARRANTY CONDITIONS
4 DESCRIPTION
4.1 Identification of the product ..................................................................... 9
4.1.1 Identification of the product ......................................................... 9
4.1.2 Identification of the pump ............................................................ 9
4.1.3 Identification of the gearbox ........................................................ 9
4.1.4 Identification of the electric motor .............................................. 10
4.1.5 Identification of the pump hose ................................................. 10
4.2 Construction of the pump ...................................................................... 11
4.3 Operation of a hose pump .................................................................... 12
4.4 Description of Bredel hose pump with special rotor construction for
CIP cleaning ......................................................................................... 13
4.5 Application information & cleaning ........................................................ 15
4.6 Pump hose ............................................................................................ 16
4.6.1 General ...................................................................................... 16
4.6.2 Hose compression force adjustment (shimming) ...................... 17
4.6.3 Lubrication and cooling ............................................................. 17
4.6.4 Gearbox ..................................................................................... 17
4.6.5 Electric motor ............................................................................ 18
4.6.6 Available options ....................................................................... 18
5 INSTALLATION
5.1 Unpacking ............................................................................................. 19
5.2 Inspections ............................................................................................ 19
1
5.3 Installation conditions ........................................................................... 19
5.3.1 Ambient conditions .................................................................... 19
5.3.2 Set-up ........................................................................................ 19
5.3.3 Pipework ................................................................................... 20
5.3.4 Pulsating flow ............................................................................ 21
5.4 Lifting and moving the pump ................................................................ 22
6 COMMISSIONING
6.1 Preparations ......................................................................................... 23
6.2 Start-up ................................................................................................. 23
7 GENERAL MAINTENANCE
7.1 Maintenance and periodic inspections ................................................. 24
7.2 Cleaning pump hose ............................................................................ 25
7.3 Changing lubricant ............................................................................... 25
7.4 Changing oil in gearbox ........................................................................ 26
7.5 Replacing pump hose ........................................................................... 26
7.5.1 Remove the lubricant ................................................................ 26
7.5.2 Remove the pump hose ............................................................ 26
7.5.3 Install the pump hose ................................................................ 27
7.5.4 Fasten the pump hose .............................................................. 28
7.5.5 Fill the pump with lubricant ........................................................ 29
7.5.6 Finish the pump hose replacement ........................................... 29
7.6 Remove the cover ................................................................................ 29
7.7 Exchanging replacement parts ............................................................. 30
7.7.1 Replacing pressing shoes ......................................................... 30
7.7.2 Replacing seal and bearings ..................................................... 30
7.8 Hose compression force adjustment (shimming) ................................. 33
7.9 Fitting options ....................................................................................... 34
7.9.1 Fitting a high-level float switch .................................................. 34
7.9.2 Fitting a low level float switch .................................................... 34
7.9.3 Float switch power specification ................................................ 34
8 MAINTENANCE OF CAM AND ACTUATORS
8.1 Cam assembly ...................................................................................... 35
8.2 Manually operated actuator .................................................................. 36
8.3 Positioning of the electrical actuator ..................................................... 37
8.4 Positioning of the pneumatic actuator .................................................. 41
8.5 Direct pneumatic connection ................................................................ 43
8.5.1 Clockwise pump operation ........................................................ 43
2
8.5.2 Counter clockwise pump operation ........................................... 43
8.6 5/2 valve controlles connection ............................................................ 44
8.6.1 Clockwise pump operation ........................................................ 45
8.6.2 Counter clockwise pump operation ........................................... 46
8.6.3 Setting the valve controlled pneumatic actuator response ........ 47
9 STORAGE
9.1 Hose pump ........................................................................................... 50
9.2 Pump hose ............................................................................................ 50
10 TROUBLESHOOTING
11 SPECIFICATIONS
11.1 Pumphead ............................................................................................ 57
11.1.1 Performance .............................................................................. 57
11.1.2 Materials .................................................................................... 57
11.1.3 Actuator ..................................................................................... 58
11.1.4 Lubricant .................................................................................... 58
11.1.5 Surface treatment ...................................................................... 59
11.1.6 Weights and dimensions ........................................................... 59
11.1.7 Torques ..................................................................................... 60
11.1.8 Shimming .................................................................................. 60
11.1.9 Parts list for Bredel CIP 40 and CIP 50 pump ........................... 61
11.1.10Parts list air operation for CIP pumps ....................................... 68
11.1.11Parts list electrical operation for CIP pumps ............................. 71
11.1.12Parts list manual operation for CIP pumps ............................... 74
EG-DECLARATION OF CONFORMITY
SAFETY FORM
3
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 Bredel CIP 40 and Bredel
CIP 50.
1.2 Other supplied documentation
Documentation of components such as the gearbox, the
motor and the actuator is not included in this manual.
However, if additional documentation is supplied, you
must follow the instructions in this additional
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 (refer to
section 4.1.1).
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.
4
2 SAFETY
2.1 Symbols
In this manual the following symbols are used:
WARNING
Procedures which, if not carried out with
the necessary care, may result in serious
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.
SAFETY
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. (1)
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.
1. 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
5
SAFETY
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.
6
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.
SAFETY
7
WARRANTY CONDITIONS
3 WARRANTY CONDITIONS
The manufacturer offers a 2 year warranty on all parts
of the hose pump. This means that all parts will be
repaired or replaced free of charge, with the exception
of consumables, such as pump hoses, hose clamps,
ball bearings, wear rings, and seals, or parts which
have been used wrongly, misused, and whether or not
they have been intentionally damaged. If no original
Watson-Marlow Bredel parts are used, every claim to
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.
Warranties purporting to be on behalf of Watson-Marlow
Bredel B.V. made by any person, including
representatives of Watson-Marlow Bredel B.V., its
subsidiaries, or its distributors, which do not accord with
the terms of this warranty shall not be binding upon
Watson-Marlow Bredel B.V. unless expressly approved
in writing by a Director or Manager of Watson-Marlow
Bredel B.V.
8
4 DESCRIPTION
D
A
C
B
D
A
C
B
Bredel
Hose Pumps
Watson-Marlow Bredel B.V.
Suisstraat 7 -Delden-NL
www.bredel.com
YEAR:
Bredel CIP 40 - no.
Patent applied
A B
C
min-1
N
o
i
C
D E BA
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: Pumphead
B: Gearbox
C: Electric motor
D: Pump hose
4.1.2 Identification of the pump
The identification plate on the pumphead contains the
following data:
A: Pump type
B: Serial number
C: Year of manufacture
DESCRIPTION
4.1.3 Identification of the gearbox
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 ratio
E: Revolutions per minute
9
DESCRIPTION
V
S
IP
IK
Hz AkWmin-1
COS
C/h%
N
o
U
N
V
P
Mf
Nm
C F
o
C B
D E F IHG
Bredel
Hose Pumps
High precision pump
element machined for
A
B
C
D
E
F
G
4.1.4 Identification of the electric motor
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
4.1.5 Identification of the pump hose
The identification sticker on the pump hose contains the
following data:
A: Pump type
B: Part code
C: Internal diameter
D: Type of material of inner layer
E: Remarks, if applicable
F: Maximum permissible working pressure
G: Production code
10
4.2 Construction of the pump
G
F
E
C
D
B
A
G
F
E
C
D
B
A
DESCRIPTION
A: Cover
B: Rotor
C: Pump hose
D: Pump housing
E: Support
F: Gearbox
G: Electric motor
11
DESCRIPTION
4.3 Operation of a hose 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".
12
4.4 Description of Bredel hose pump with
ABA
B
POSITION 1
120°
POSITION 2
R1
special rotor construction for CIP cleaning
The pump has a special rotor that contains 2 standard
pressing shoes. These pressing shoes can be adjusted
by shims, same as with standard pumps. Every
pressing shoe is, at one side, connected to the rotor by
a pivot-arm Construction. In the centre of this pivot-arm
is a roller (A).
Attached to the inside of the special pump cover is a
shaft with a cam (B), that can be moved manually or by
an actuator (electrically or pneumatically) that is
mounted at the outside of the pump cover.
When the cam (B) is in neutral position, it does not
touch the roller (A) of the pivot-arm inside the pump.
When the cam (B) is turned over about 120° (position
1), the roller (A) will follow the cam (B), thus pushing the
pivot-arm outwards (position 2).
DESCRIPTION
Resulting from this movement, the pressing shoe is
retracted from the pump hose. Once retracted the shoe
rests on the hose (position 3). Now the pump hose is
and remains fully opened. The pump can be stopped
and the hose can be flushed/cleaned. When the
retracted shoe is leaving the compression area (in
between the ports) the attached spring will force it back
into normal position.
13
DESCRIPTION
POSITION 3
A
B
With rotation in CIP mode the pressing shoes are
retracted one at a time during one full rotation in the
pumping direction.
The pump is not intended to keep running in CIP mode.
Caution
Stop the pump after one revolution when
the pump is in CIP mode. Continuous
rotation may cause excessive wear and
damage of the cam mechanism.
When the cleaning procedure is finished, first the cam
(B) has to be repositioned to neutral. After the cam is in
this position, the pump can be started in normal
direction of rotation. The springs will pull the pressing
shoe back to the normal (pumping) position.
Caution
Do not start the pump before the cam is in
neutral position;
Do not reverse rotation when actuator
(cam) is in active position, this will
seriously damage the cam mechanism.
When the actuator (cam) is in neutral
position, the pump can be reversed as
normal.
Additional remarks:
• The construction of the rotor and cam
mechanism depends on the rotation direction of
the pump. Refer to section 7.9.
• After initial assembly, the pump cover cannot be
mounted in another position.
• To avoid wear to all vital parts, we recommend
14
following speed limits:
Bredel CIP 40 : 60 rpm
Bredel CIP 50 : 50 rpm
4.5 Application information & cleaning
Possible fields of application:
• Food industry
• Pharmaceutical industry
• Paint industry
• Others
For FOOD INDUSTRY applications (dairies, breweries,
etc.) the pumps preferably can be supplied with nitrile
(F-NBR) food grade hoses or Bioprene hoses, and
stainless steel sanitary connectors.
Carefully read the additional user
information supplied with the food hoses.
Cleaning of the F-NBR pump hose can be done by
using aqueous ALKALINE solutions, such as CAUSTIC
SODA or SODIUM CHLORIDE (max. concentration
20%).
In case of cleaning with saturated steam (SIP) use one
of the following combinations of temperature and
duration of cleaning.
• 120 °C. (248 °F) : maximum 30 minutes
• 100 °C. (212 °F) : maximum 60 minutes
• 80 °C. (176 °F) : unlimited
It is recommended to flush (cool) the pump hose with
cold water after high temperature cleaning, unless the
pump is going back to normal duty again.
For OTHER INDUSTRIES the pumps can be supplied
with other hose types like NR (natural rubber) or EPDM
rubber hoses and with standard flange + Insert
connections.
Flanges can be galvanized steel or stainless steel to
EN, ASA or JIS.
Inserts available in stainless steel, PVC, PP and PVDF.
Cleaning to be done by using liquids that do not attack
the used pump hose material. In case of doubt contact
your Bredel representative.
DESCRIPTION
15
DESCRIPTION
A
CB
4.6 Pump hose
4.6.1 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 color code.
Hose type Material Colour code
NR Natural rubber Purple
NBR Nitrile rubber Yellow
F-NBR Nitrile rubber Yellow
EPDM EPDM Red
CSM CSM Blue
Bioprene Bioprene Light green
Consult your Bredel representative for
more detailed information about the
chemical and temperature resistance of
pump hoses.
16
The Bredel pump hoses have been carefully machined,
with minimum tolerances in wall thickness. To ensure
the correct compression of the pump hose, because:
• When the compression is too high it creates an
excessive load on the pump and pump element,
resulting in reduced hose life and bearing life.
• When the compression is too low, this will result
in loss of capacity due to backflow. Backflow
results in a reduction of hose life.
4.6.2 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 are fitted between the rotor and the pressing
shoe. The number of shims will vary depending on the
operating speed and pressure. Refer to section 11.1.8.
Caution
Always apply the advised amount of
shimming for optimum hose performance.
Shim both shoes identically.
DESCRIPTION
4.6.3 Lubrication and cooling
The pumphead is 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.
The Bredel CIP pump needs to be filled with twice as
much lubricant compared to a standard pump of this
size. The lubricant is food grade. The user is
responsible to ensure chemical compatibility with the
fluid to be pumped (refer to section 11.1.4).
4.6.4 Gearbox
The hose pump types described in this manual use
various types of gearbox units. The gearboxes are fitted
with a foot rest.
17
DESCRIPTION
4.6.5 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 by default.
4.6.6 Available options
The following options are available for the hose pump:
• High (lubricant) level float switch.
• Low (lubricant) level float switch.
• Epoxy pressing shoes.
• Stainless steel 316 flanges, flange brackets,
hose clamps, supporting parts and fasteners.
The following options are available for CIP control:
• Pneumatic actuator with solenoid 5/2 control
valve
• Electric actuator
• Manual actuator
18
5 INSTALLATION
5.1 Unpacking
When unpacking carefully follow the instructions as
given on the packaging or on the hose pump. Dispose
of the package material through the appropriate
channels.
5.2 Inspections
Check that your delivery is correct and check it for any
transport damage, refer to section 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°C (-4°F) and not higher than +45°C (113°F).
INSTALLATION
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 meter.
Use suitable anchor bolts to attach the pump to
the floor surface.
• Make sure that there is sufficient room around
the pump to carry out the necessary
maintenance activities.
19
INSTALLATION
• Make sure that the room is sufficiently
ventilated, for convection of the heat generated
by the pump and drive. Keep some distance
between the ventilation cover of the electric
motor and wall to enable cooling.
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.
• Avoid sharp bends and make the radiuses of
the bends are as large as possible. 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. This way
connection lines do not have to be removed
when changing a pump hose.
• Keep the delivery and suction lines as short and
direct as possible.
• Do not exceed the maximum working pressure
of the hose pump, refer to section 11.1.1. If
necessary fit a pressure release valve.
20
Caution
Consider the maximum permissible
working pressure on the discharge side.
Exceeding the maximum working pressure
can cause to serious damage to the pump.
• Make sure that the maximum forces on the
flanges are not exceeded. The maximum flange
loads are given in the table below:
Force Bredel CIP 40 Bredel CIP 50
F1 [N] 1000 1400
F2 [N] 200 300
F3 [N] 500 700
5.3.4 Pulsating flow
Hose pumps have a pulsating flow that can result in
vibrations of pump and flow lines under the following
circumstances:
• suction and discharge lines are not fixed
correctly
• high pump speed in combination with long
suction and discharge lines and/or high density
of the product
• diameter of suction and/or discharge line too
small
INSTALLATION
In case of unacceptable pulsations, dampeners for
suction and/or discharge line can be supplied. Please
consult your Bredel representative for information on
Inlet Pulsation Accumulators (IPA) or Pulsation
Dampeners (PD). These accumulators and dampeners
are not suitable for food applications.
21
INSTALLATION
AA
B
5.4 Lifting and moving the pump
For lifting and moving the pumphead, use the lifting lug
(A). This lifting lug is fitted on the rear of the pumphead.
The complete hose pump, i.e. pumphead, gearbox and
electric motor, must be lifted using the lifting lug (A) plus
additional support on gearbox and motor using suitable
straps or slings (B).
For the weights of the pump, refer to section 11.1.6.
Warning
If the pump is to be lifted ensure that all
standard lifting practices are adhered to
and carried out by qualified personnel only.
Never lift the complete pump unit by only
using the lifting lug.
22
6 COMMISSIONING
6.1 Preparations
• Connect the electric motor in conformance with
the locally applicable rules and regulations.
Have the electrical installation work carried out
by qualified personnel.
• The pump casing is filled with a Bredel Genuine
Hose Lubricant. If necessary refill lubricant via
the breather/vent plug (refer to section 7.3).
• Set the actuator switch in the pumping position.
• In case of pneumatic actuator check if the
actuator response is good (refer to section
8.6.3).
• Check the rotation of the rotor.
• Check that the number of shims corresponds
with your application, refer to section 11.1.8.
• For adjusting the compression force of the
hose, refer to section 7.8.
• Make sure that there are no obstructions such
as closed valves.
COMMISSIONING
6.2 Start-up
• Switch on the hose pump.
• Check the rotation of the rotor.
• Check the capacity of the hose pump. If the
capacity differs from your specification, follow
the instructions in chapter 10 or consult your
Bredel representative.
• Check the hose pump in accordance with points
1 to 4 of the maintenance table from section
7.1.
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