Professional Documents
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The disc inserted in the front cover contains the user manual of the models Bredel 40,
Bredel 50, Bredel 65, Bredel 80 and Bredel 100. 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.
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 hyperlinks to chapters or paragraphs. These hyperlinks are linked
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
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2
Hose pump series
Bredel 40, Bredel 50, Bredel 65, Bredel 80 and
Bredel 100
Manual
3
© 2013 Watson-Marlow Bredel B.V.
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
2 SAFETY
2.1 Symbols ................................................................................................ 10
2.2 Intended use ......................................................................................... 10
2.3 Use in potentially explosive atmospheres ............................................. 11
2.4 Responsibility ........................................................................................ 11
2.5 Qualification of the user ........................................................................ 12
2.6 Regulations and instructions ................................................................. 12
3 WARRANTY CONDITIONS
4 DESCRIPTION
4.1 Identification of the product ................................................................... 14
4.1.1 Identification of the product ....................................................... 14
4.1.2 Identification of the pump .......................................................... 14
4.1.3 Identification of the gearbox ...................................................... 14
4.1.4 Identification of the electric motor .............................................. 15
4.1.5 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 Available options ................................................................................... 20
5 INSTALLATION
5.1 Unpacking ............................................................................................. 21
5.2 Inspection ............................................................................................. 21
5.3 Installation conditions ........................................................................... 21
5
5.3.1 Ambient conditions .................................................................... 21
5.3.2 Set-up ........................................................................................ 21
5.3.3 Pipework ................................................................................... 22
5.4 Lifting and moving the pump ................................................................ 23
5.5 Placing the pump .................................................................................. 24
6 COMMISSIONING
6.1 Preparations ......................................................................................... 25
6.2 Commissioning ..................................................................................... 25
7 MAINTENANCE
7.1 General ................................................................................................. 26
7.2 Maintenance and periodic inspections ................................................. 26
7.3 Cleaning the pump hose ...................................................................... 28
7.4 Changing lubricant ............................................................................... 28
7.5 Changing oil in gearbox ........................................................................ 29
7.6 Replacing pump hose ........................................................................... 30
7.6.1 Removing pump hose ............................................................... 30
7.6.2 Cleaning the pump head ........................................................... 32
7.6.3 Fitting the pump hose ................................................................ 33
7.7 Exchanging replacement parts ............................................................. 36
7.7.1 Replacing pressing shoes ......................................................... 36
7.7.2 Replacing seal and wear ring .................................................... 38
7.7.3 Replacing bearings ................................................................... 41
7.8 Adjusting hose compression force (shimming) ..................................... 42
7.9 Fitting options ....................................................................................... 45
7.9.1 Fitting a high-level float switch .................................................. 45
7.9.2 Fitting a low level float switch .................................................... 47
7.9.3 Fitting revolution counter ........................................................... 47
8 STORAGE
8.1 Hose pump ........................................................................................... 50
8.2 Pump hose ........................................................................................... 50
9 TROUBLESHOOTING
10 SPECIFICATIONS
10.1 Pump head ........................................................................................... 56
10.1.1 Performance .............................................................................. 56
10.1.2 Materials .................................................................................... 57
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10.1.3 Surface treatment ...................................................................... 58
10.1.4 Lubricant table pump ................................................................. 58
10.1.5 Weights ..................................................................................... 58
10.1.6 Torque figures ........................................................................... 59
10.1.7 Shims specifications .................................................................. 60
10.2 Lubricant table gearbox ........................................................................ 61
10.3 Electric motor ........................................................................................ 62
10.4 Parts list ................................................................................................ 63
10.4.1 Overview ................................................................................... 63
10.4.2 Cover assembly ......................................................................... 64
10.4.3 Rotor assembly ......................................................................... 65
10.4.4 Pump housing assembly ........................................................... 66
10.4.5 Support assembly ...................................................................... 68
10.4.6 Flange assembly ....................................................................... 69
10.4.7 Revolution counter assembly .................................................... 70
10.4.8 Lubricants .................................................................................. 71
7
GENERAL
1 GENERAL
8
GENERAL
CAUTION
Always observe the local rules and regula-
tions with respect to processing (non reus-
able) parts of the hose pump.
9
SAFETY
2 SAFETY
2.1 Symbols
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.
WARNING
Procedures, remarks, suggestions or
advice which refer to use in potentially
explosive atmospheres in accordance with
the ATEX Directive 94/9/EC.
10
SAFETY
2.4 Responsibility
11
SAFETY
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.
12
WARRANTY CONDITIONS
3 WARRANTY CONDITIONS
13
DESCRIPTION
4 DESCRIPTION
14
DESCRIPTION
15
DESCRIPTION
A: Pump hose
B: Pump housing
C: Rotor
D: Pressing shoes
E: Cover
F: Inspection window
G: Supports
H: Gearbox
I: Electric motor
16
DESCRIPTION
17
DESCRIPTION
4.4.1 General
A: Outer extruded layer made of natural rubber
B: Four nylon reinforcement layers
C: Inner extruded liner
18
DESCRIPTION
4.5 Gearbox
19
DESCRIPTION
20
INSTALLATION
5 INSTALLATION
5.1 Unpacking
5.2 Inspection
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.
21
INSTALLATION
5.3.3 Pipework
When determining and connecting suction and
discharge lines consider the following points:
• The bore size of the suction and discharge lines
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 Y-
connections instead of T-connections.
• Keep the piping at a minimum equal to or
greater than the bore size of the pump. Increase
the bore size of the pipe work when the duty
fluid has a high velocity or inertia. This will help
keep friction and impulse losses to a minimum.
Where critical velocities are a concern consult
your Bredel representative.
• For the flexible hoses select compatible
materials and ensure the installation is suited
for the design pressure of the system.
• 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.
Refer to § 10.1.1. If necessary fit a pressure
relief valve.
CAUTION
Consider the maximum permissible work-
ing pressure on the discharge side.
Exceeding the maximum working pressure
may lead to serious damage to the pump.
22
INSTALLATION
For lifting and moving the pump, it has been fitted with a
lifting point. This lifting point (A) is fitted on the upper
side of the cover. The maximum rating of the lifting point
depends on the pump model. Make sure that the total of
weight to be moved will not exceed this maximum
rating.
WARNING
If the pump is to be lifted ensure that all
standard lifting practices are adhered to
and carried out by qualified personnel only.
23
INSTALLATION
WARNING
Do not use the holes in the pump supports
to lift the hose pump.
24
COMMISSIONING
6 COMMISSIONING
6.1 Preparations
6.2 Commissioning
25
MAINTENANCE
7 MAINTENANCE
7.1 General
WARNING
Only use original Bredel parts when main-
taining the hose pump. Bredel cannot
guarantee a correct functioning and any
consequential damage that occurs from
the use of non-original Bredel components.
See also chapters 2 and 3.
WARNING
If the cover is removed when the pump
hose is still in the pump head, the com-
pression forces on the pump hose may
cause deformation of the pump housing.
The hose needs to be safely removed
before the cover can be replaced.
Normally the compression forces are par-
tially compensated by the cover.
26
MAINTENANCE
27
MAINTENANCE
28
MAINTENANCE
29
MAINTENANCE
30
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.
31
MAINTENANCE
10. Power out the hose (A) from the pump chamber
by jogging the drive motor.
WARNING
During jogging the drive:
- Do not stand in front of the pump
ports.
- Do not try to guide the hose by
hand.
WARNING
Never dismount the cover, when the pump
hose is in the pump head. The compres-
sion forces on the pump hose are partially
compensated by the cover. By removing
the cover, the pump housing may become
deformed.
32
MAINTENANCE
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 capacity by the backflow
of the liquid to be pumped.
Backflow results in a reduction of the life of
the pump hose.
WARNING
During jogging the drive:
- Do not stand in front of the pump
ports.
- Do not try to guide the hose by
hand.
33
MAINTENANCE
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.
34
MAINTENANCE
10. Now fit the other port. For this port proceed in
the same way as described above for the inlet
port.
35
MAINTENANCE
36
MAINTENANCE
37
MAINTENANCE
38
MAINTENANCE
WARNING
When removing the rotor a belt or similar
lifting aid must carry the weight of the rotor.
For the specific weight of the rotor, refer to
§ 10.1.5.
39
MAINTENANCE
10. Turn the rotor over. Make sure that the seats of
the new wear ring (A) and rotor are clean, dry
and free of grease. Apply Loctite® type 641 or
603 both on the rotor and the wear ring.
Position the new wear ring with the tapered
edge facing up. Use a plastic hammer to fit the
ring on the rotor until it touches the rotor
completely.
40
MAINTENANCE
41
MAINTENANCE
CAUTION
Too many shims, this means a too high
compression force on the pump hose, cre-
ate a too high load on the pump head and
pump hose, which results in a reduction of
the life of the pump hose and bearings.
42
MAINTENANCE
CAUTION
Too few shims, this means a too low com-
pression force on the pump hose, create a
loss of yield and slip or backflow. Backflow
results in a reduction of the life of the pump
hose.
43
MAINTENANCE
44
MAINTENANCE
45
MAINTENANCE
Specifications*
Voltage: Max. 230 V AC/DC
Current: Max. 2 A
Power: Max. 40 VA
* For use in non-explosive atmospheres
46
MAINTENANCE
47
MAINTENANCE
48
MAINTENANCE
Specifications
Voltage: 10...30 VDC
Current: Max. 150 mA
WARNING
Contact your Bredel representative for
proper connection of the sensor.
49
STORAGE
8 STORAGE
50
TROUBLESHOOTING
9 TROUBLESHOOTING
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.
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.
51
TROUBLESHOOTING
52
TROUBLESHOOTING
53
TROUBLESHOOTING
54
TROUBLESHOOTING
55
SPECIFICATIONS
10 SPECIFICATIONS
10.1.1 Performance
56
SPECIFICATIONS
10.1.2 Materials
57
SPECIFICATIONS
Should you require additional information with respect to the safety data
sheet, consult your Bredel representative.
10.1.5 Weights
58
SPECIFICATIONS
G I
F A C B D E H
59
SPECIFICATIONS
60
SPECIFICATIONS
Below is an overview of some of the recommended lubricants for the planetary gearbox.
In the majority of the cases a mineral oil ISO VG 150 or ISO VG 220 is recommended. In
case of very low or ambient temperatures a mineral ISO VG 100 is advised. In case of
high ambient temperatures or relatively wide range of ambient temperatures a synthetic
oil is recommended. Also in case of very high loads, resulting in high operating
temperatures a synthetic oil is to be preferred. Contact your Bredel representative for
advice.
61
SPECIFICATIONS
62
SPECIFICATIONS
10.4.1 Overview
Pos. Description
1 Cover assembly. Refer to § 10.4.2.
2 Rotor assembly. Refer to § 10.4.3.
3 Pump housing assembly. Refer to § 10.4.4.
4 Pump support assembly. Refer to § 10.4.5.
5 Flange assembly. Refer to § 10.4.6.
6 Lubricant. Refer to § 10.4.8.
63
SPECIFICATIONS
64
SPECIFICATIONS
65
SPECIFICATIONS
66
SPECIFICATIONS
67
SPECIFICATIONS
68
SPECIFICATIONS
69
SPECIFICATIONS
70
SPECIFICATIONS
10.4.8 Lubricants
Pos. Qty. Description Product codes for parts of pump type
Bredel Bredel Bredel Bredel Bredel
40 50 65 80 100
1 1 5 l can Bredel Genu- 903143 - - - -
ine Hose Lubricant
1 10 l can Bredel Gen- - 904143 - - -
uine Hose Lubricant
1 20 l can Bredel Gen- - - 905143 - -
2 uine Hose Lubricant - - - 905143 -
3 - - - - 905143
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ORIGINAL
We,
Watson-Marlow 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:
In addition, the machinery complies with the harmonised standard(s), other standards 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.
72
SAFETY FORM
SAFETY FORM
Safety form
Postal code...........................................................
Telephone ............................................................. Fax number ..........................................................
3 Details of substances pumped 4 I hereby confirm that the only substances(s) that
the equipment specified has pumped or come into
3.1 Chemical Names contact with are those named, that the information
a) .......................................................................... given is correct, and the carrier has been informed
b) .......................................................................... if the consignment is of a hazardous nature.
a) ......................................................................... .............................................................................
b) ......................................................................... .............................................................................
c) ......................................................................... .............................................................................
d) .........................................................................
73
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
29210301 TS 02-002-E
E-mail: bredel@wmpg.com
Internet: http://www.bredel.com
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