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Table of Contents
Related Manuals for Watson-Marlow Bredel DuCoNite 25
Summary of Contents for Watson-Marlow Bredel DuCoNite 25
- Page 1 Disc ® The disc inserted in the front cover contains the user manual of the models DuCoNite ® 25 and DuCoNite 32. The disc also contains a replacement instruction for the pump hose. This replacement instruction is only for users that are familiar with the replacement procedures in the user manual.
- Page 3 Hose pump series ® ® DuCoNite 25 and DuCoNite Manual...
- Page 4 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.
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Page 5: Table Of Contents
CONTENTS GENERAL How to use this manual ................8 Original instructions ................8 Other supplied documentation ..............8 Service and support ................8 Environment and disposal of waste ............9 SAFETY Symbols ....................10 Intended use ..................10 Use in potentially explosive atmospheres ..........11 Use in corrosive atmosphere .............. - Page 6 INSTALLATION Unpacking .................... 21 Inspection ..................... 21 Installation conditions ................21 5.3.1 Ambient conditions ..............21 5.3.2 Set-up ..................21 5.3.3 Pipework ................... 22 5.3.4 Variable Frequency Drive ............23 5.3.5 High Level Control (HLC) ............24 Lifting and moving the pump ..............25 Placing the pump ..................
- Page 7 TROUBLESHOOTING SPECIFICATIONS 10.1 Pump head ................... 55 10.1.1 Performance ................55 10.1.2 Materials ..................56 10.1.3 Surface treatment ..............57 10.1.4 Chemical resistance chart DuCoNite® coating ......57 10.1.5 Lubricant table pump ..............58 10.1.6 Weights ..................58 10.1.7 Torque figures ................60 10.1.8 Shims specifications ..............
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Page 8: General
GENERAL GENERAL 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. Original instructions The original instructions for this manual have been written in English. -
Page 9: Environment And Disposal Of Waste
GENERAL Environment and disposal of waste CAUTION Always observe the local rules and regula- tions with respect to processing (non reus- able) parts of the hose pump. Inquire within your local government about the possibilities reuse environment-friendly processing of packaging materials, (contaminated) lubricant and oil. -
Page 10: Safety
SAFETY SAFETY 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. -
Page 11: Use In Potentially Explosive Atmospheres
SAFETY Only use the pump in accordance with the intended use described above. The manufacturer cannot be held responsible for damage or harm resulting from misuse. If you want to change the application of your hose pump, contact your Bredel representative first. Use in potentially explosive atmospheres The pump head and gearbox mentioned in this manual are suitable for use in a potentially explosive... -
Page 12: Qualification Of The User
SAFETY Immediately contact your Bredel representative, if you noticed a potential danger while using your hose pump. WARNING The user of the hose pump is always fully responsible for observing the local valid safety regulations and directives. Observe these safety regulations and directives when using the hose pump. -
Page 13: Warranties
This manufacturer's warranty is null and void for any user who has substituted the parts of an alternate manufacturer into a Watson-Marlow Bredel (hereafter called Bredel) hose pump. Damaged parts may be returned to the manufacturer for warranty analysis. If failure was determined caused by faulty workmanship, the manufacturer will repair or replace the faulty component. -
Page 14: Description
DESCRIPTION DESCRIPTION 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: Pump head Gearbox Electric motor Pump hose Frequency controller (option) 4.1.2 Identification of the pump The identification plate on the pump head contains the following data: Pump model... -
Page 15: Identification Of The Electric Motor
DESCRIPTION 4.1.4 Identification of the electric motor The identification plate on the electric motor contains the following data: Type number Serial number Article number Mains Frequency Speed Power Power factor Current 4.1.5 Identification of the frequency controller The identification of the Bredel Variable Frequency Drive (VFD) can be found inside the VFD. -
Page 16: Construction Of The Pump
DESCRIPTION Construction of the pump Cover Rotor Pressing shoes Pump hose Pump housing Support Gearbox Electric motor Frequency controller (option) Adapter without motor (option) Operation of the pump The heart of the pump head consists of a specially constructed pump hose (A) which lies contorted against the inside of the pump housing (B). - Page 17 DESCRIPTION hose are connected to the suction and discharge lines by means of a flange construction (C). A bearing- mounted rotor (D) with two facing pressing shoes (E) is in the center of the pump head. In phase 1 the lower pressing shoe compresses the pump hose by the rotational movement of the rotor, forcing the fluid through the hose.
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Page 18: Pump Hose
DESCRIPTION Pump hose 4.4.1 General Outer extruded layer made of natural rubber Four nylon reinforcement layers 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. -
Page 19: Hose Compression Force Adjustment (Shimming)
DESCRIPTION • When the compression is too low, this will result in loss of capacity and backflow. Backflow results in a reduction of the life of the pump hose. 4.4.2 Hose compression force adjustment (shimming) In order to achieve optimal life of the pump hose, the compression force of the pump hose can be adjusted by placing a number of shims under the pressing shoes. -
Page 20: Electric Motor
DESCRIPTION Electric motor If the electric motor has been standard supplied by the manufacturer, it is an integrated standardized squirrel- cage motor. Refer to § 10.4 for specifications. If the pump used potentially explosive atmospheres, contact your Bredel representative. Motor frequency controller Refer to the also supplied documentation of the supplier and §... -
Page 21: Installation
INSTALLATION INSTALLATION Unpacking When unpacking carefully follow the instructions as given on the packaging or on the hose pump. Inspection Check that your delivery is correct and check it for any transport damage. Refer to § 4.1.1. Report any damage immediately to your Bredel representative. -
Page 22: Pipework
INSTALLATION 5.3.3 Pipework When determining connecting suction 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. -
Page 23: Variable Frequency Drive
INSTALLATION Maximum permissible loads on the pump flange ® ® Force Unit DuCoNite DuCoNite CAUTION In case of hose failure, the product or a mixture of product and lubricant can leak by the breather cap. If this risk is not acceptable, drain piping can be connected, refer to §... -
Page 24: High Level Control (Hlc)
INSTALLATION In the event of a power or mechanical failure, the Bredel VFD controls the motor to stop. When the cause of the failure is removed, the motor can restart automatically. The automatic restart is dangerous to certain installations of the pump. -
Page 25: Lifting And Moving The Pump
INSTALLATION Where the floater is constructed to stop the equipment, operating has to be arranged so that the stop function locks-out, prevent- ing the equipment from being re-started without re-setting. Check if the floater is mounted with the NC sign at the top. Lifting and moving the pump For lifting and moving the pump head, it has been fitted with a lifting strip. -
Page 26: Commissioning
COMMISSIONING COMMISSIONING Preparations WARNING A Bredel VFD that is fitted without the con- trol switch starts automatically when power is applied. WARNING Disconnect and lock the power supply to the pump drive before any work is carried out. In case the motor is fitted with a frequency controller and has a single-phase power supply, wait two minutes to make sure that the capacitors have discharged. -
Page 27: Commissioning
COMMISSIONING Commissioning Connect the pipework. Make sure that there are no obstructions such as closed valves. 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 or consult your Bredel representative. -
Page 28: Maintenance
MAINTENANCE MAINTENANCE General WARNING Disconnect and lock the power supply to the pump drive before any work is carried out. In case the motor is fitted with a frequency controller and has a single-phase power supply, wait two minutes to make sure that the capacitors have discharged. - Page 29 MAINTENANCE Point Action To be carried out Remark Check the lubricant Before startup of the Make sure that the lubri- level. pump and on a sched- cant level is above the uled interval during oper- minimum level line in the ation.
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Page 30: Additional Maintenance In Potentially Explosive Environments
MAINTENANCE Point Action To be carried out Remark Check the wear ring. When the pump seal is For replacement, contact replaced, check the run- your Bredel representa- ning surface of the wear tive. ring for excessive wear. Replace the pressing Wear on the running sur- See §... -
Page 31: Changing Lubricant
MAINTENANCE Changing lubricant Place a tray (A) under the drain plug in the cover of the pump. Remove the drain plug (B). Catch the lubricant from the pump housing in the tray. Position the drain plug (A) and tighten it firmly. In order to facilitate the filling with lubricant the breather plug (B) on the front of the pump housing can be removed. -
Page 32: Changing Oil In Gearbox
MAINTENANCE Keep on pouring until the lubricant level has risen at least until just above the bottom level line in the inspection window. Position the breather plug (A) and tighten it firmly. For the required quantity of lubricant, refer to § 10.1.5. Changing oil in gearbox Isolate the pump from the electrical supply. -
Page 33: Replacing Pump Hose
MAINTENANCE Remove level plug (B) and filling plug (C) and position a funnel in the hole and fill the gearbox with oil until the oil just comes out of the level plug hole (B). Wait shortly to let out any entrapped air. - Page 34 MAINTENANCE Loosen the retaining bolts (A) of both the suction and discharge line (B). Disconnect the suction and discharge lines. Loosen hose clamp (A) of both the inlet and outlet ports by loosening retaining bolt (B). Pull the insert (B) from the hose and remove the flanges (A).
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Page 35: Cleaning The Pump Head
MAINTENANCE Slide off the sealing ring (A). Check that the sealing ring is not deformed or damaged and replace it if necessary. Carry out this procedure both for the inlet and outlet ports. Switch on the electrical supply. Power out the hose (A) from the pump chamber by jogging the drive motor. -
Page 36: Fitting The Pump Hose
MAINTENANCE Check the pressing shoes for wear or damage and replace them if necessary. Refer to § 7.8.1. Also see the maintenance scheme in § 7.2. CAUTION When the pressing shoes are worn the compression force of the hose decreases. If the compression force is too low, this results in a loss of capacity by the backflow of the liquid to be pumped. - Page 37 MAINTENANCE Fit the pump hose (A) via one of the ports – whichever is the suction based on rotation direction. Feed the hose into the port and allow the pressing shoe to draw the hose in the pump housing. The rotor will move the hose. WARNING During jogging the drive: Do not stand in front of the pump...
- Page 38 MAINTENANCE Slide insert (B) in flange (A) and press the insert in the hose. If necessary lubricate the insert with Bredel Genuine Hose Lubricant in order to simplify mounting. Make sure that the holes in flange (A) are aligned with the holes in flange bracket (C).
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Page 39: Exchanging Replacement Parts
MAINTENANCE Fit the suction and discharge lines (B) and the retaining bolts (A). Tighten the retaining bolts with the correct torque. Refer to § 10.1.7. Exchanging replacement parts 7.8.1 Replacing pressing shoes Jog the motor until the pressing shoe (B) is positioned between the inlet and outlet port (A). - Page 40 MAINTENANCE Remove the cover (A) by loosening the four retaining bolts (B). Loosen the retaining bolt (A) of the pressing shoe (B). Remove the shims (C) if present. Fit the removed shims (C) again. Position the (new) pressing shoe (B), check that the Nord- ®...
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Page 41: Replacing Seal Ring And Bearings
MAINTENANCE Isolate the pump from the electrical supply. Repeat the procedure for removing and fitting this second pressing shoe by repeating steps 4 through 8. Refill the lubricant. Refer to § 7.5. 7.8.2 Replacing seal ring and bearings Remove the pump hose. Refer to § 7.7.1. Isolate the pump from the electrical supply. - Page 42 MAINTENANCE Extract the rotor (A) from the hub. Position both crow bars behind the recesses (B) in the rotor. Dismount the retaining circlip (A) with the correct tool. Dismount the bearings (A) with the correct tool, the spacer ring (B) and the retaining circlip (C). Remove the seal (A).
- Page 43 MAINTENANCE Fit a new seal (A) using good engineering practises. The seal must be fitted in the correct orientation (B). Make sure that the open side points to the pump cover. Check that the hub is clean and free of grease. Fit the bearings and the rings now.
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Page 44: Adjusting Hose Compression Force (Shimming)
MAINTENANCE Fit the removed shims (C) again. Position the (new) pressing shoe (B), check that the Nord- ® Lock rings (D) have been positioned correctly and tighten the retaining bolt(s) (A) a few turns. Refer to § 10.1.7. Check the gasket (C) for damage and replace if necessary. - Page 45 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. Jog the motor until the pressing shoe (B) is positioned between the inlet and outlet port (A).
- Page 46 MAINTENANCE Loosen the retaining bolt (A) of the pressing shoe (B). Fit the shims (C) or remove them, until the correct number of shims is present. Refer to § 10.1.8. Fasten the retaining bolt of the pressing shoe with the correct torque. Refer to § 10.1.7. Refit the cover (B).
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Page 47: Options
MAINTENANCE 7.10 Options 7.10.1 Revolution counter For feedback of the pump revolutions to an "intelligent" system, the pump can be provided with an inductive sensor (A). This sensor is mounted at the backside of the pump. Connection of the revolution counter: The speed sensor can be connected via the 2 meter (6.5 foot) long PVC cable (3 x 0.34 mm , 3 x 22 AWG). -
Page 48: Drain Connection
MAINTENANCE 7.10.2 Drain connection Drain piping can be connected with an optional part (A) fitted at the breather. This is a 1" NPT threaded connection. CAUTION The drain piping must be connected to an open reservoir, to prevent pressure built up inside the pump housing. -
Page 49: Storage
STORAGE STORAGE Hose pump • Store the hose pump or pump parts in a dry area. Make sure that the hose pump or pump parts are not exposed to temperatures lower than -40 °F or higher than +140 °F. • Cover the openings of the inlet and outlet ports. -
Page 50: Troubleshooting
TROUBLESHOOTING 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. - Page 51 TROUBLESHOOTING Problem Possible cause Correction High pump temperature. Non standard hose lubri- Consult your Bredel repre- cant used. sentative for the correct lubricant. Low lubricant level. Add Bredel Genuine Hose Lubricant. For the required amount of lubricant refer to § 10.1.5. Product temperature too Consult your Bredel repre- high.
- Page 52 TROUBLESHOOTING Problem Possible cause Correction Low capacity / pressure. Shut-off valve in the suc- Fully open the shut-off tion line (partly) closed. valve. Under shimming of the Consult the diagram in pressing shoes. § 10.1.8. Fit the correct number of shims. Hose rupture or badly worn Replace hose.
- Page 53 TROUBLESHOOTING Problem Possible cause Correction Vibration of the pump Suction and discharge Check and secure pipe- and pipework. lines are not secured cor- work. rectly. High pump speed with long Reduce pump speed. suction and discharge lines Reduce the line lengths on or high relative density or a both suction and dis- combination of these fac-...
- Page 54 TROUBLESHOOTING Problem Possible cause Correction Hose pulled into the Insufficient or no hose Add extra lubricant. Refer pump. lubricant in the pump head. to § 7.5. Incorrect lubricant: no Consult the Bredel repre- Bredel Genuine Hose sentative for the correct Lubricant in the pump lubricant.
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Page 55: Specifications
SPECIFICATIONS SPECIFICATIONS 10.1 Pump head 10.1.1 Performance ® ® Description Unit DuCoNite DuCoNite Max. capacity, continuous 1.80 3.25 7.92 14.31 Max. capacity, intermittent 2.88 5.25 12.68 23.12 Capacity per revolution l/rev 0.300 0.625 gal/rev 0.079 0.165 Max. permissible working pressure kPa 1600 Permissible ambient temperature °C... -
Page 56: Materials
SPECIFICATIONS 10.1.2 Materials Description Material ® Pump housing Cast-iron with DuCoNite coating ® Cover Cast-iron with DuCoNite coating ® Pump rotor Cast-iron with DuCoNite coating Pressing shoe Epoxy Pump support AISI 316 Flange bracket AISI 316 Mounting material of pump cover AISI 316 Mounting material of drive system AISI 316... -
Page 57: Surface Treatment
SPECIFICATIONS 10.1.3 Surface treatment Pump head The main pump head parts (pump housing, cover and rotor) are provided with a special ® DuCoNite coating, which is both chemical and wear resistant. For the chemical resistance chart refer to § 10.1.4. Gearbox-electric motor After surface preparation, one layer of 2-component acrylate is used for surface protection. -
Page 58: Lubricant Table Pump
SPECIFICATIONS Chemical Concentration Chemical com- Hose material patibility with ® DuCoNite Phosporic Acid good EPDM Nitric Acid limited If the ambient temperature is above 104 °F consult your Bredel representative. 10.1.5 Lubricant table pump ® ® Unit DuCoNite DuCoNite Lubricant Bredel Genuine Bredel Genuine Hose Lubricant... - Page 59 SPECIFICATIONS Description Unit Weight ® ® DuCoNite DuCoNite Motor 11 - 17 11 - 23 24.2 - 37.4 24.2 - 50.6 Total unit: 81 - 87 113 - 125 178.2 - 191.4 248.6 - 275 Components: Hose Lubricant 12.1 Gearbox G0311... 14.5 31.9 Gearbox G0321...
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Page 60: Torque Figures
SPECIFICATIONS 10.1.7 Torque figures Description Unit Torques ® ® DuCoNite DuCoNite Pressing shoe lbf in Cover lbf in 442.5 442.5 Hose clamp lbf in Flange bracket lbf in 442.5 442.5 Support lbf in 221.2 752.2... - Page 61 SPECIFICATIONS Description Unit Torques ® ® DuCoNite DuCoNite Gearbox lbf in 221.2 442.5 Breather plug lbf in 26.5 26.5 Inspection Window lbf in 13.2 13.2 Drain plug lbf in 26.5 26.5...
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Page 62: Shims Specifications
SPECIFICATIONS 10.1.8 Shims specifications • When the product temperatures are above 140 °F always use one shim less than indicated in the diagrams. • Always round up the number of shims. DuCoNite 120 140 160 DuCoNite 100 120 140... -
Page 63: Lubricant Table Gearbox
SPECIFICATIONS 10.2 Lubricant table gearbox Below is an overview of some of the recommended lubricants for the co-axial gearbox. In the majority of the cases, a mineral oil ISO VG 220 is recommended. In case of extreme ambient temperatures or a relatively wide range of ambient temperatures, a synthetic oil is recommended. -
Page 64: Gearbox
SPECIFICATIONS Recommended lubricants for the Bredel co-axial gearboxes Oil type Synthetic oil Change oil 20,000 hours every Ambient tem- -30 °C to -10 °C -30 °C to +60 °C -30 °C to +40 °C perature -22 °F to 14 °F -22 °F to 140 °F -22 °F to 104 °F DIN (ISO) -
Page 65: Electric Motor
SPECIFICATIONS 10.4 Electric motor Standard electric motor design is an enclosed three-phase asynchronous motor. A thermal safety device to prevent motor overload is optional. In case of doubt about the local applicable regulations for the drive connec- tion, contact your Bredel representative. Protection class IP55/IK08 Insulation class... -
Page 66: Parts List
SPECIFICATIONS 10.6 Parts list 10.6.1 Overview Pos. Description Cover assembly. Refer to § 10.6.2. Rotor assembly. Refer to § 10.6.3. Pump housing assembly. Refer to § 10.6.4. Pump support assembly. Refer to § 10.6.5. Flange assembly. Refer to § 10.6.6. Revolution counter assembly. -
Page 67: Cover Assembly
SPECIFICATIONS 10.6.2 Cover assembly Pos. Qty. Description Product codes for parts of pump type ® ® DuCoNite DuCoNite Bolt, hex. head, M10X40 F502045 F502045 Washer, M10 F523013 F523013 ® DuCoNite sticker 225239 232239 ® Cover DuCoNite 225102N 232102N Quad ring 225123 232123 Gasket... -
Page 68: Rotor Assembly
SPECIFICATIONS 10.6.3 Rotor assembly Pos. Qty. Description Product codes for parts of pump type ® ® DuCoNite DuCoNite Pressing shoe 225109 232109 Pressing shoe with titanium 225109N 232109N inserts Shim 225107 232107 Shim, titanium 225107N 232107N Bolt, hex. head, M10X50 F502047 F502047 Bolt, hex. -
Page 69: Pump Housing Assembly
SPECIFICATIONS 10.6.4 Pump housing assembly Pos. Qty. Description Product codes for parts of pump type ® ® DuCoNite DuCoNite Circlip, A60 F343049 F343049 Bearing B141260 B141260 Spacer ring 29085201 29085201 Retaining circlip 29095297 29095297 Seal S312415 S312415 025020 032020 025040 032040 025070 032070... - Page 70 SPECIFICATIONS Pos. Qty. Description Product codes for parts of pump type ® ® DuCoNite DuCoNite Washer, Spring Lock, M10 F532010 F532010 Seal 225114 232114 Breather connection plug 29034451 29034451 O-ring S120183 S120183 Breather strip 29210222 29210222 Breather cap 29045221 29045221 O-ring S120263 S120263...
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Page 71: Support Assembly
SPECIFICATIONS 10.6.5 Support assembly Pos. Qty. Description Product codes for parts of pump type ® ® DuCoNite DuCoNite Bolt, hex. head, M8X35 F504057 Bolt, hex. head, M12x45 F502067 Washer, M8 F523012 Washer, M12 F523014 Pump support (standard) 225106A 232106A Washer, Spring Lock, M8 F532009 Washer, Spring Lock, M12 F532011... -
Page 72: Flange Assembly
SPECIFICATIONS 10.6.6 Flange assembly Pos. Qty. Description Product codes for parts of pump type ® ® DuCoNite DuCoNite O-ring S112233 S112273 Flange bracket 225197A 232197A Washer, Spring Lock, M10 F532010 F532010 Bolt, hex. head, M10X25 F504075 F504075 Hose clamp C101572 C101573 Flange, DIN SS 225199... -
Page 73: Revolution Counter Assembly
SPECIFICATIONS 10.6.7 Revolution counter assembly Pos. Qty. Description Product codes for parts of pump type ® ® DuCoNite DuCoNite Plug 29029457 29029457 O-ring S120183 S120183 29035458 29035458 Revolution counter shim 225107NS 232107NS Revolution counter 29050368 29050368 10.6.8 Lubricants Pos. Qty. Description Product codes for parts of pump type ®... -
Page 74: Safety Form
In compliance with the Health and Safety Regulations, the user is required to declare those substances that have been in contact with the item(s) you are returning to Watson-Marlow Bredel B.V. or any of its subsidiaries or distributors. Failure to do so will cause delays in servicing the item or in issuing a response. Therefore, please complete this form to make sure we have the information before receipt of the item(s) being returned. - Page 75 NOTES NOTES Notes...
- Page 76 Watson-Marlow Pumps Group 37 Upton Technology Park Wilmington, MA 01887 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.
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