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MAINTENANCE

MAINTENANCE

8.1

General

WARNING

Make sure that during maintenance the
power supply is disconnected.

CAUTION

Only use original Bredel parts when main-
taining the hose pump. Bredel cannot
guarantee a correct functioning pump and
any consequential damage that occurs
from the use of non-original Bredel compo-
nents. See also chapters

and

CAUTION

Check that your delivery of original parts is
correct and check it for any transport dam-
age. When in doubt, consult your Bredel
representative

WARNING

Do not remove the pump cover if the power
cable is connected to the motor. Do not
connect the power cable to the motor if the
pump cover is removed.

Содержание Bredel 2100

Страница 1: ...ith 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...

Страница 2: ...2...

Страница 3: ...3 Hose pump series Bredel 265 Bredel 280 and Bredel 2100 Manual Hose Pumps TYPE EL CLASS I AUGUST 2012 Environmental Management ISO 14001 Quality Management ISO 9001...

Страница 4: ...s 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 Marl...

Страница 5: ...ification of the product 14 4 1 1 Identification of the product 14 4 1 2 Identification of the pump 14 4 1 3 Identification of the gearbox 14 4 1 4 Identification of the electric motor 15 4 1 5 Identi...

Страница 6: ...Dry running 37 7 4 Hose failure 37 7 5 Fluid leakage 38 8 MAINTENANCE 8 1 General 40 8 2 Maintenance and periodic inspections 41 8 3 Cleaning the pump hose 43 8 4 Changing lubricant 43 8 5 Changing oi...

Страница 7: ...75 11 1 1 Performance 75 11 1 2 Materials 76 11 1 3 Surface treatment 77 11 1 4 Lubricant table pump 77 11 1 5 Weights 78 11 1 6 Torque figures 79 11 1 7 Shims specifications 80 11 2 Lubricant for gea...

Страница 8: ...inverters 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 informa...

Страница 9: ...our local government about the possibilities for reuse or environment friendly processing of packaging materials contaminated lubricant and oil CAUTION Always observe the local rules and regula tions...

Страница 10: ...usive 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 ins...

Страница 11: ...e 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...

Страница 12: ...with the hose pump must be aware of the contents of this manual and observe the instructions with great care Never change the order of the actions to be carried out Always store the manual and the man...

Страница 13: ...ed 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...

Страница 14: ...the following data A Pump model B Serial number 4 1 3 Identification of the gearbox The identification plate on the gearbox contains the following data A Type number B Batch number C Motor power D Ge...

Страница 15: ...in temperature I Bredel article or order number 4 1 5 Identification of the pump hose The identification sticker on the pump hose contains the following data A Pump type B Reorder number C Internal d...

Страница 16: ...Inspection window G Frame H Gearbox I Electric motor 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...

Страница 17: ...he 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 continuo...

Страница 18: ...of the pump hose determines the hose type Each hose type is marked by a unique color code Natural Rubber Always the first choice hose A highly dynamic material which has excellent abrasion resistance...

Страница 19: ...using CSM The Bredel pump hoses have been carefully machined therefore there are minimum tolerances in wall thickness This is very important to guarantee the correct compression of the pump hose beca...

Страница 20: ...an 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 c...

Страница 21: ...earboxes which are not particularly loaded and that have an intermittent operating cycle without considerable temperature ranges can be lubricated with mineral oil When the gearboxes are heavily loade...

Страница 22: ...lubricant level float switch Low lubricant level float switch Revolution counter Cover lifting device CLD Heavy duty bearings Epoxy pressing shoes Stainless steel 316 flanges flange brackets hose cla...

Страница 23: ...nstallation conditions 5 3 1 Ambient conditions Temperature 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...

Страница 24: ...fficiently 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 necessa...

Страница 25: ...velocity or inertia This will help keep friction and impulse losses to a minimum Where critical velocities are a concerned consult your Bredel representative For the flexible hoses select compatible m...

Страница 26: ...suppression it is recommended to use a segment of flexible hose between the pump flange and hard piping of the suction and or discharge line A segment of three quarters 3 4 of the pump hose length for...

Страница 27: ...pipe diameter when joining both discharge lines or both suction lines Flange sizes Pump EN ANSI D d6 b k Number d2 Bredel 265 EN1092 1 mm 185 81 20 145 4 18 ANSI inches 7 2 94 7 8 5 1 2 4 3 4 Bredel...

Страница 28: ...is properly balanced and provide hooks lifting systems and cables suitable for the total mass of the pump unit The illustrations show the proper way to lift the units The maximum ratings are shown in...

Страница 29: ...pump cover 1 The cover B can be lifted by using the lifting hole C on the top of the pump cover For weights of the pump cover see 11 1 5 The cover can also be lifted by means of a cover lifting device...

Страница 30: ...es 3 Use a hammer to drive the anchor into the bore 4 Tighten the bolt to the applicable moment setting MD da Min material thickness t Min drill depth hs Min hole depth d Foundation depth l Anchor bol...

Страница 31: ...ll depth t 4 33 4 33 4 33 Mounting depth hs 3 94 3 94 3 94 Torque setting MD lbf in 445 885 885 Bredel 265 Bredel 280 Bredel 2100 CAUTION Install the pump unit before drilling the holes Then mark the...

Страница 32: ...r vent plug See also 8 4 3 Connect the electric motor in conformance with the locally applicable rules and regulations See the manual of the electric motor Ensure that the electrical installation work...

Страница 33: ...Switch on the hose pump 4 Check the rotation direction of the pump rotor 5 Check the capacity of the hose pump If the capacity differs from your specification follow the instructions in chapter 11 or...

Страница 34: ...a person should not be in direct contact with the pump surface to avoid injury by burning 7 2 Power rating The pump requires a certain amount of power for the specified operating condition s The gear...

Страница 35: ...r rating of the gearbox Check the rated powers of the motor and gearbox as indicated on the name plate and check these with the power ratings required for your operating condition 0 5 11 16 21 27 0 10...

Страница 36: ...in gal min Required Motor Power HP Intermittent Duty Continuous Duty 104 122 140 158 176 Product Temperature F 72 5 psi 109 psi 1 4 5 p s i 2 3 2 p s i 42 0 48 0 36 0 30 0 24 0 18 0 12 0 6 0 0 0 0 5 1...

Страница 37: ...ed on the rotor To minimize the extra wear it is advised to minimize the dry running periods 7 4 Hose failure The hose in a peristaltic pump has to withstand many load cycles of considerable magnitude...

Страница 38: ...ration This lubricant is contained in the pump housing by the cover on the front side and by a dynamic seal on the back side The gearbox is also filled with lubricant Seal damage can occur due to norm...

Страница 39: ...leakage this can be detected at the back side of the pump When drops of lubricant are visible it indicates upcoming seal failure To avoid consequential damage the pump must be stopped and lubricant l...

Страница 40: ...ing pump and any consequential damage that occurs from the use of non original Bredel compo nents See also chapters 2 and 3 CAUTION Check that your delivery of original parts is correct and check it f...

Страница 41: ...e cover can be replaced Normally the compression forces are par tially compensated by the cover The following steps must be taken 1 Remove pump hose from the pump 2 Isolate the motor from the electric...

Страница 42: ...se of leakage con sult your Bredel repre sentative 4 Check pump for deviat ing temperature or strange noises On a scheduled interval during operation See 11 5 Check pressing shoes for excessive damage...

Страница 43: ...hose that can cause damage upon restart 8 4 Changing lubricant 1 Place a tray A under the drain plug in the bottom of the pump Remove the drain plug B Catch the lubricant from the pump housing in the...

Страница 44: ...e lubricant level has reached above the minimum level line 8 5 Changing oil in gearbox 1 Isolate the pump from the electrical supply 2 Position a tray under the gearbox 3 See the gearbox manual for pr...

Страница 45: ...vent mounted on the rear is not obscured Check that the sealing ring C is not damaged and replace it if necessary Position the drain plug and tighten it firmly 4 Loosen the retaining bolts A of both t...

Страница 46: ...ed and replace it if necessary Carry out this procedure both for the inlet and outlet ports 9 Connect the pump to the electrical supply 10 Power out the hose A from the pump chamber by jogging the mot...

Страница 47: ...water remains in the pumphead WARNING Never remove the cover when the pump hose is in the pumphead The compression forces on the pump hose are partially compensated by the cover By removing the cover...

Страница 48: ...on the pump and note the direction of the pump rotation 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...

Страница 49: ...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 four retaining bolts A and t...

Страница 50: ...A against O ring chamber of the flange bracket B and fasten the retaining bolt Make sure the bolts are tightened with the correct torque See 11 1 6 11 Now fit the other port For this port proceed in t...

Страница 51: ...n plug B in the bottom of the pumphead Remove the drain plug Drain as much Bredel Genuine Hose Lubricant until the level has lowered just below the inspection window D Check that the sealing ring C is...

Страница 52: ...ssing shoe B a few turns Remove the shims C if present Loosen the retaining bolt s A of pressing shoe B completely and remove the pressing shoe 6 Position the new pressing shoe A check that the NordLo...

Страница 53: ...pump from the electrical supply 12 Repeat the procedure for removing and fitting this second pressing shoe by repeating steps 4 through 9 13 Refill the lubricant See 8 4 8 7 3 Replacing seal and wear...

Страница 54: ...s will ensure that the angle between the two rotors will be 90 degrees 5 Remove the retaining bolts A of the drive shaft B and remove the drive shaft Check the sealing ring C for damage 6 Remove the r...

Страница 55: ...al crosswise and with equal strength in the bore until it touches the hub The seal must be fitted in the correct orientation C Make sure that the open side points to the pump cover 10 Support the roto...

Страница 56: ...The bearings have been placed on the hub with a slight interference fit Use a pressing tool to press the rotor on the hub 13 Check rotor retaining circlip A for any signs of damage and replace if nece...

Страница 57: ...orque See 11 1 6 16 Switch on the electrical supply to the pump 17 Fit the new pump hose See 8 6 3 8 7 4 Replacing bearings 1 Dismount the pump hose the cover and rotor by following steps 1 through 7...

Страница 58: ...through 16 from 8 7 3 8 8 Adjusting hose compression force shimming Fitting and removing shims is a simple action which can be carried out via the inspection window on the front of the pump housing Th...

Страница 59: ...just below the inspection window D Check that the sealing ring C is not damaged and replace it if necessary Position the drain plug and tighten it firmly 4 Loosen the retaining bolts A of the inspect...

Страница 60: ...sary Refit the inspection window B Make sure that all bolts A are refitted and that they are tightened in the correct order diagonally opposite each other to the specified torque limits See 11 1 7 7 S...

Страница 61: ...ismount the standard breather A on the rear of the pump by dismounting it from crimp connector B 2 Slide the standard breather cap A from breather B 3 Replace the standard breather cap with the breath...

Страница 62: ...t the electrical contact of the float switch is normally closed NC When the lubricant level is too high the contact will open 6 The floater has to be connected to the auxiliary power circuit via the 2...

Страница 63: ...connector A 3 Connect the low level float switch to the electrical supply Bear in mind that the electrical contact of the float switch is normally closed NC When the lubricant level is too low the co...

Страница 64: ...the special pressing shoe with a magnet A by following the steps 6 through 8 of 8 7 2 3 Fit the inductive sensor A in plug B and adjust it to dimension X as indicated in the table below Use sealant L...

Страница 65: ...6 Fit the plug with the inductive sensor A together with sealing ring B on the pump housing 7 Refill the pump housing to the proper level with Bredel lubricant 8 Connect the sensor electrically via t...

Страница 66: ...ed by a ring E which is placed in the hole of the bracket 8 9 5 Installing the cover lifting device CLD on a vertical configuration 1 Define the position The cover lifting device CLD must be mounted w...

Страница 67: ...bottom side of the bracket with a bolt D Furthermore the lifting pole is supported by a ring E which is placed in the hole of the bracket Bolt size Torque M16 210 Nm 1860 lbf in M20 400 Nm 3540 lbf in...

Страница 68: ...permanent deformation which will reduce the life of the pump hose and may cause difficulty in starting To prevent deformation of the hose pump motor should be jogged on a monthly basis to allow reposi...

Страница 69: ...period of time especially in humid conditions fill the gearbox completely with oil and protect the machined parts with rust inhibitors For further requirements regarding storage of the electric motor...

Страница 70: ...ssary when the motor is fitted with a Variable Frequency Drive VFD and has single phase power supply Problem Possible cause Correction Failure to operate No voltage Check that the supply power switch...

Страница 71: ...the maximum temperature range of the product Internal friction on the hose caused by blocked or poor suction characteristics Check pipework valves for block ages Ensure that the suction pipe work is a...

Страница 72: ...n side Ensure that the suction line is clear of blockages and that sufficient product is available Connections and hose clamps not correctly mounted which makes the pump suck air Tighten connections a...

Страница 73: ...of 90 degrees Broken front cover bolts Pump cover dis mounted with the hose in the pump Never dis mount the pump cover when the hose is still in the pump Short hose life Chemical attack of the hose C...

Страница 74: ...he hose cannot be compressed and will be pulled into the pump hous ing Remove hose check for block ages and replace if necessary Bolts of flange bracket loose Tighten to the specified torque set tings...

Страница 75: ...17 0 Max capacity intermittent GPM Intermittent duty Let the pump stand still to cool down for at least 1 hour after 2 hours of operation 283 4 344 3 475 5 Capacity per revolution gal rev 3 6 6 2 10 6...

Страница 76: ...nium Epoxy optional 5 Frame Mild steel galvanised available in Stainless Steel upon request 6 Hose flange brackets Mild steel galvanised 7 Cover fixings Mild steel galvanised 8 Motor fixings Mild stee...

Страница 77: ...been provided with an electrolytic zinc layer of 15 20 microns 0 6 0 8 mil 11 1 4 Lubricant table pump The relative density of Bredel Genuine Hose Lubricant is 1 245 Bredel 265 Bredel 280 Bredel 2100...

Страница 78: ...e gearbox and electric motor 2780 4295 5985 Pumphead complete Weight of a completely mounted pumphead hose lubricant included 795 1270 2019 Pumphead assembly Pumphead without cover hose lubricant flan...

Страница 79: ...1 M8x35 71 M8x45 C Cover 1860 M16x35 1860 M16x35 3540 M20x55 D Hose clamp 354 M10 354 M10 354 M10 E Flange bracket 440 M10x25 750 M12x25 750 M12x30 F Drive shaft 750 M12x35 1860 M16x45 1860 M16x45 G H...

Страница 80: ...ally reduces in time If leak age starts re tighten the hose clamp to the specified torque level The listed torque values apply to a new and properly greased hose clamp See also 8 6 3 point 10 for extr...

Страница 81: ...ing conditions and ambient conditions Special features might be required to keep the gearbox temperatures within limits Please check the gearbox manual In case of doubt consult your Bredel representat...

Страница 82: ...CATIONS 82 11 3 2 Overview pump head Pos Description 1 Cover assembly See 11 3 3 2 Rotor assembly See 11 3 4 3 Pump housing assembly See 11 3 5 4 Flange assembly See 11 3 6 5 Lubricants See 11 3 7 5 1...

Страница 83: ...29265238 29280238 29200238 2 8 Bolt hex head F101038 F101038 F101040 3 8 Washer plain F322012 F322012 F322012 4 1 Inspection window 265155 280155 200155 5 1 Gasket 265156 280156 200156 6 14 Bolt hex...

Страница 84: ...22611 S122611 5 4 Bolt hex head F101085 F101131 F101132 6 4 NordLock ring F349007 F349009 F349009 7 1 Rotor 265103 280103 200103 8 20 Pos 8 Bredel 265 Bredel 280 20 pieces and Bredel 2100 14 pieces Sh...

Страница 85: ...3 29089223 29089223 5 1 Breather 29110146 29125146 29125146 6 1 Coupling straight F602006 F602008 F602008 7 2 Plug ext hex hd F911006 F911008 F911008 8 1 O ring S122711 S122771 S122801 9 1 Dowel pin F...

Страница 86: ...280197A 200197 2 Flange bracket ANSI SS 265197E 280197F 200197E 3 8 Washer spring lock F336012 F336013 F336013 4 8 Bolt hex head F111096 F111128 F111130 5 2 Hose clamp C101048 C101051 C101054 6 2 Fla...

Страница 87: ...S 87 11 3 7 Lubricants per pumphead Pos Qty Description Product codes 1 1 gallon Bredel Genuine Hose Lubricant 911143 5 gallons Bredel Genuine Hose Lubricant 912143 55 gallons Bredel Genuine Hose Lubr...

Страница 88: ...2 29350480 Adaption flange 180H 2 29350365 2 29350380 Adaption flange 200V 2 29400480 Adaption flange 200H 2 29400380 Adaption flange 225V Adaption flange 225H 2 Bolt hex socket head 20 F201106 20 F1...

Страница 89: ...ange 180H 2 29355300 Adaption flange 200V 2 29400300 Adaption flange 200H 2 29400300 Adaption flange 225V 2 29450300 Adaption flange 225H 2 29450300 2 Bolt hex socket head 24 F111164 24 F111164 24 F20...

Страница 90: ...345765 1 29345766 Frame 160H 1 29345665 1 29345666 Frame 180V 1 29345765 1 29345766 1 29440780 Frame 180H 1 29345665 1 29345666 1 29440680 Frame 200V 1 29395780 Frame 200H 1 29395680 Frame 225V Frame...

Страница 91: ...4 Spring washer 4 F532015 4 F532017 4 F336017 5 Hex nut 4 F516018 4 F516020 4 F301012 Pos Description Product codes for parts of pump type Bredel 2100 AISI 316 Bredel 2100 Steel Galv Bredel 2100 AISI...

Страница 92: ...redel 265 Bredel 280 Bredel 280 Qty Code Qty Code Qty Code Qty Code 1 Shaft 160V H 1 29475565 Shaft 180V H 1 29485565 1 29490580 Shaft 200V H 1 29650580 Shaft 225V H 2 Parallel key 1 F436908 1 F436909...

Страница 93: ...9525500 Shaft 200V H 1 29650500 Shaft 225V H 1 29600500 2 Parallel key 1 F436909 1 F436906 1 F436906 3 Retaining ring 2 F343066 2 F343071 2 F343073 4 Spline sleeve 2 29110500 Pos Qty Description Produ...

Страница 94: ...a separate Decontamination Certificate for each item returned RGA KBR no 1 Company Address Telephone Postal code Fax number 2 Product 3 4 Cleaning fluid to be used if residue of chemical is found dur...

Страница 95: ...NOTES 95 Notes NOTES...

Страница 96: ...roup 37 Upton Technology Park Wilmington MA 01887 USA Telephone 800 282 8823 978 658 6168 Fax 978 658 0041 Internet www wmpg com E mail support wmpg us 2013 Watson Marlow Bredel B V Environmental Mana...

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