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Disc The disc, which is inserted in the cover, contains the user manual(s) of the Bredel 265, Bredel 280 and Bredel 2100 hose pumps in the following languages: English (UK) Nederlands English (US) Polski Svenska Español Portiguês Suomi Français The disc also contains quick-reference instructions for the replacement of the pump hose.
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Hose pump series Bredel 265, Bredel 280 and Bredel 2100 Manual 9001 14001 Quality Environmental Management Management TYPE EL - CLASS I AUGUST 2012...
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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.
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 Responsibility ..................11 Qualification of the user ................
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Installation conditions ................23 5.3.1 Ambient conditions ..............23 5.3.2 Set-up ..................24 5.3.3 Pipework ................... 25 5.3.4 Flange sizes of the pipework ............. 27 Lifting and moving the pump ..............28 5.4.1 Lifting the complete unit ............28 5.4.2 Lifting the pumphead ..............29 5.4.3 Lifting the pump cover ...............
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8.9.2 Fitting a low level float switch ............ 63 8.9.3 Fitting revolution counter ............64 8.9.4 Installing the cover lifting device (CLD) on a horizontal configuration ................66 8.9.5 Installing the cover lifting device (CLD) on a vertical configuration ................66 STORAGE Hose pump ...................
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.
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.
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.
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. Responsibility The manufacturer does not accept any responsibility for damage or harm caused by not (strictly) observing the...
SAFETY Regulations and instructions • Everyone who works 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. •...
If genuine Watson-Marlow Bredel (hereafter called Bredel) parts are not used, any warranty claim is void. Damaged parts which are covered by the applicable...
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: Pumphead Gearbox Electric motor Pump hose Frame 4.1.2 Identification of the pump The identification plate on the pump head contains the following data: Pump model Serial number...
DESCRIPTION 4.1.4 Identification of the electric motor The identification plate on the electric motor contains the following data: Serial number Type number As. mot. Power Voltage Isol. cosj Frequency Pole no./Speed Insulation class Rise in temperature Bredel article or order number 4.1.5 Identification of the pump hose The identification sticker on the pump hose contains the...
DESCRIPTION Construction of the pump Pump hose Pump housing Rotor Pressing shoes Cover Inspection window Frame Gearbox Electric motor 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).
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DESCRIPTION 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.
DESCRIPTION Pump hose 4.4.1 General The pump hose is made of special rubbers, reinforced with nylon cords and is constructed as follows: 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.
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DESCRIPTION EPDM* Good chemical resistance especially to concentrated acids, ketones, and alcohols. Max. liquid temperature 90 °C (195 °F). Min. temperature -10 °C (15 °F). Consult Bredel technical services for details on higher temperature operation, up to 90 °C (195 °F) with EPDM.
DESCRIPTION 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. The shims (A) are fitted between the rotor (B) and the pressing shoe (C).
DESCRIPTION 4.5.2 Maintenance For all information on maintenance and lubrications, see the manual of the gearbox. Check the oil level regularly. If necessary, refill the oil level. Avoid mixing oils of different types. In case of doubt, change the oil completely. Also check that there are no metallic parts with unusual dimensions in the oil.
DESCRIPTION Available options The following options are available for the hose pump: • High (lubricant) level float switch • Low (lubricant) level float switch • Revolution counter • Cover lifting device (CLD) • Heavy duty bearings • Epoxy pressing shoes •...
INSTALLATION INSTALLATION Unpacking When unpacking, carefully follow the instructions as given on the packaging or on the hose pump. This also applies to the unpacking of the geabox and the electric motor. Inspection Check that your delivery is correct and check it for any transport damage.
INSTALLATION For extreme conditions, special precautions must be taken. Contact your local Bredel representative for additional information. 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.
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.
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• Make sure that the maximum forces on the flanges are not exceeded. The permissible loads are given in the following table. Maximum permissible loads [lbf] on the pump flange Force Bredel 265 Bredel 280 Bredel 2100...
INSTALLATION 5.3.4 Flange sizes of the pipework The table below shows the flange sizes on the pumphead for external connection. øk CAUTION Apply a sufficiently large pipe diameter when joining both discharge lines or both suction lines. Flange sizes Pump EN-ANSI Number Bredel...
INSTALLATION Lifting and moving the pump 5.4.1 Lifting the complete unit The pump can be delivered in several mounting positions. The gear motor unit can be placed in a vertical and horizontal position. Applicable for both configurations, use the through holes or tapped holes of the gear reducer casing when lifting and transporting the pump unit.
INSTALLATION 5.4.2 Lifting the pumphead Lift the pumphead by using the lifting hole on the top of the pump cover, see §5.4.3. During the (dis)assembly of the pumphead from the adaption ring, use the special-made lifting tool (A). The lifting tool makes sure that the pumphead is positioned vertically in front of the adaption ring.
INSTALLATION Placing the pump Follow the next steps to make sure the anchor bolts are used properly. Drill the holes. Clean the bore holes. Use a hammer to drive the anchor into the bore. Tighten the bolt to the applicable moment setting (M Min.
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INSTALLATION Bredel Bredel Bredel 2100 Bredel part no. F550041 F550048 F550048 Bolt thread Bolt length l [“] 5.71 5.71 5.71 Foundation height d [“] 9.84 9.84 9.84 Drill diameter Ø [“] 0.62 0.79 0.79 Min. drill depth t [“] 4.33 4.33 4.33 Mounting depth...
COMMISSIONING COMMISSIONING Preparations Check that the correct number of shims corresponds with your application. See § 11.1.7. For adjusting the compression force of the hose, see § 8.8. Check that the lubricant level is above the minimum level line in the inspection window. If necessary add Bredel Genuine Hose Lubricant via the breather/vent plug.
COMMISSIONING Commissioning Connect the pipework. Make sure that there are no obstructions such as closed valves. Switch on the hose pump. Check the rotation direction of the pump 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.
OPERATION OPERATION Temperature The pump will heat up during normal operation. Heat is generated in the contact zone between the pressing shoe and the hose. The heat is removed by the lubricant and transported to the pump casing and cover. Under conditions of high pressure and running speed, casing and cover temperatures can reach values of over 65 °C (+149 °F).
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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. 7.2.1 Performance graph Bredel 265: Required Motor Power [HP] Intermittent Duty Product Temperature [ °F] Continuous duty rev.
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OPERATION 7.2.2 Performance graph Bredel 280: Required Motor Power [HP] 40.0 Intermittent Duty 35.0 Product 30.0 Temperature [ °F] 25.0 20.0 15.0 10.0 Continuous Duty rev. /min gal. /min 7.2.3 Performance graph Bredel 2100: Required Motor Power [HP] 48.0 Intermittent Duty 42.0 Product Temperature [ °F]...
OPERATION Dry running Dry running is a running condition of the pump when no process flow (pumped product) is flowing through the pump. The Bredel peristaltic pumps are very suitable for dry running. Dry running does impose an additional thermal load on the pump hose, because the internal heat associated with repetitive hose compression is normally removed by convection of the process fluid.
OPERATION Genuine Hose Lubricant is harmless (FDA approved), but it will result in additional downtime since the pump needs to be cleaned prior to new hose installation. WARNING Exceptions to this general rule are when the pumped product is either a strong oxi- dizer or a strong acid.
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OPERATION Both the pumphead and gearbox are directly coupled to each other. A special feature is included in the pumphead to enable early detection of seal damage of the pump or gearbox. This feature is called the leakage zone. When a seal starts to show increased leakage, this can be detected at the back side of the pump.
MAINTENANCE MAINTENANCE 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.
MAINTENANCE WARNING If the cover is removed when the pump hose is still in the pumphead, the compres- sion 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.
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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.
MAINTENANCE Point Action To be carried out Remark Replacing wear ring. If necessary. See § 8.7.3. Replacing pressing Wear on the running sur- See § 8.7.2. shoes. face. Replacing bearings. If necessary. See § 8.7.4. Maintenance and peri- Before start-up of the Check the manuals of odic inspection of the pump and on a sched-...
MAINTENANCE The pump housing can be filled with lubricant via the breather/vent (A) on the rear of the pump housing. For this purpose remove the breather cap (B) and position a funnel (C) in the breather. In order to facilitate the filling with lubricant the plug (D) on the front of the pump housing can be removed.
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MAINTENANCE Place a tray (A) under the drain plug in the bottom of the pumphead. The tray must be large enough to contain the lubricant, possibly contaminated with product fluid, from the pumphead. Remove the drain plug (B). Catch the lubricant from the pump housing in the tray. Check that the breather vent mounted on the rear is not obscured.
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MAINTENANCE Loosen the retaining bolts (A) of the flange bracket (B) and remove the bolts. Slide the flange bracket and the hose clip (C) off the hose. Carry out this procedure both for the inlet and outlet ports. Slide off the sealing ring (A). Check that the sealing ring is not deformed or damaged and replace it if necessary.
MAINTENANCE 8.6.2 Cleaning the pump head 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 with the hose installed, subsequent damage can occur.
MAINTENANCE Check the pressing shoes for wear or damage and replace them if necessary. See § 8.7.2. Also see the maintenance scheme in § 8.2. 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.
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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. Stop the motor when the hose sticks out equally from both sides of the pump housing.
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MAINTENANCE Turn the rotor in such a way that the hose (A) is pressed firmly against the flange surface (B). Now fully tighten the retaining bolts (A) of the flange bracket (B). Make sure the bolts are tightened with the correct torque. See § 11.1.6. Position hose clamp (A) against O-ring chamber of the flange bracket (B) and fasten the retaining bolt.
MAINTENANCE Exchanging replacement parts 8.7.1 General CAUTION Items may be heavy. For all weight and torque adjustments for replacement proce- dures under this section, please see the technical information in chapter 11. 8.7.2 Replacing pressing shoes Jog the motor until the pressing shoe (B) is positioned in view of the inspection window (A).
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MAINTENANCE Loosen the retaining bolts (A) of the inspection window (B) and remove the bolts. Remove the inspection window. Care must be taken not to damage the gasket (C). Loosen the retaining bolt(s) (A) of pressing shoe (B) a few turns. Remove the shims (C) if present.
MAINTENANCE Refit the inspection window (B). Check the inspection window gasket (C) for damage and replace if necessary. Make sure that all bolts (A) are refitted and that they are tightened in the correct order, diagonally opposite each other. Switch on the electrical supply. Jog the motor until the second pressing shoe is positioned in front of the inspection window.
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MAINTENANCE Mark the position of the drive shaft in relation to the rotor before removing the drive shaft. Also, mark the position of the rotor in relation to the pump house before removing the retaining bolts. This will ensure that the angle between the two rotors will be 90 degrees.
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MAINTENANCE necessary lifting means before dismounting the rotor. Extract the rotor (A) from the hub. A suitable puller or similar extraction tool will be required during this stage of the disassembly. WARNING When removing the rotor a belt or similar lifting aid must carry the weight of the rotor.
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MAINTENANCE 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.
MAINTENANCE the bolt holes in the drive shaft correspond with the threaded holes in the rotor. Mount the retaining bolts (A) of the drive shaft. Tighten the bolts finger-tight. Tighten them diagonally opposite to each other to the specified torque limits.
MAINTENANCE Turn the rotor over. Check that the hub is clean and dry. Press using the pressing tool the first bearing (C) in its place. Position the spacer ring (B). Subsequently press the second bearing (A) in its place. Refit the retaining circlip (A) in the rotor. Use the correct tools for this purpose.
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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 in view of the inspection window (A).
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MAINTENANCE Loosen the retaining bolt(s) (A) of pressing shoe (B) a few turns. Fit the shims (C) or remove them, until the correct number of shims is present. See § 11.1.7. Tighten the retaining bolt(s) of the pressing shoe with the correct torque.
MAINTENANCE Fitting options 8.9.1 Fitting a high-level float switch Dismount the standard breather (A) on the rear of the pump, by dismounting it from crimp connector (B). Slide the standard breather cap (A) from breather (B). Replace the standard breather cap with the breather cap with high level float switch (A) and slide it over breather (B).
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MAINTENANCE Fit the breather (A) on the rear of the pump, by mounting it to crimp connector (B). Connect the high-level float switch to the electrical supply. Bear in mind that the electrical contact of the float switch is normally closed (NC).
MAINTENANCE 8.9.2 Fitting a low level float switch If the pump is filled with lubricant this must be removed first. Place a clean 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 tray.
"X" as indicated in the table below. Use sealant Loctite 572 or similar to prevent leakage. Pump type Dimension “X” [inch] Bredel 265 1.26 +0 /-0.04 Bredel 280 1.77 +0 /-0.04 Bredel 2100 1.77 +0 /-0.04...
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MAINTENANCE Remove a plug (A) and the sealing ring (B) on the back side of the pump housing. Check that the sealing ring (B) is not damage and replace it if necessary. Fit the plug with the inductive sensor (A) together with sealing ring (B) on the pump housing.
MAINTENANCE 8.9.4 Installing the cover lifting device (CLD) on a horizontal configuration Define the position. The cover lifting device (CLD) must be mounted on the frame on the opposite position of the motor side. See the illustration. Fit the bracket. Fit the bracket (A) with the supplied fasteners (B) on the frame of the unit.
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MAINTENANCE The torque on the bolts should be as given in the table below. Bolt size Torque 210 Nm (1860 lbf in.) 400 Nm (3540 lbf in.) Insert the lifting pole. The lifting pole (C) is fastened on the bottom side of the bracket with a bolt (D).
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 °C (-104 °F) or higher than +70 °C (158 °F).
STORAGE Electric motor and gearbox • When the unit must be stored for a long 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 and the gearbox, see the supplied documentation of the electric motor and gearbox.
TROUBLESHOOTING TROUBLESHOOTING WARNING Disconnect and lock the power supply to the pump drive before any work is carried out. Wait two minutes to make sure that the capacitors have discharged. This is necessary when the motor is fitted with a Variable Frequency Drive (VFD) and has single phase power supply.
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TROUBLESHOOTING Problem Possible cause Correction High pump tem- Non standard hose lubri- Consult the Bredel representative perature. cant used. for the correct lubricant. Low lubricant level. Add Bredel Genuine Hose Lubri- cant. For the required amount of lubricant see § 11.1.4. Product temperature too Consult the Bredel representative high.
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TROUBLESHOOTING Problem Possible cause Correction Low capacity / Shut-off valve in the suc- Fully open the shut-off valve. pressure. tion line (partly) closed. Under shimming of the Consult the diagram in § 11.1.7. Fit pressing shoes. the correct number of shims. Hose rupture or badly worn Replace hose.
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TROUBLESHOOTING Problem Possible cause Correction Vibration of the Suction and discharge Check and secure pipework. pump and pipe- lines are not secured cor- work. rectly. High pump speed with long Reduce pump speed. suction and discharge lines Reduce the line lengths on both or high relative density or a suction and discharge where pos- combination of these fac-...
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TROUBLESHOOTING Problem Possible cause Correction Hose pulled into Insufficient or no hose Add extra lubricant. See § 8.4. the pump. lubricant in the pumphead. Incorrect lubricant: no Consult the Bredel representative for the correct lubricant. Bredel Genuine Hose Lubricant in the pumphead. Extremely high inlet pres- Reduce the inlet pressure.
Contact your Bredel representative for details on surface treatment. • All galvanized parts, exclusive of mounting articles, have been provided with an electrolytic zinc layer of 15 - 20 microns (0.6 - 0.8 mil). 11.1.4 Lubricant table pump Bredel 265 Bredel 280 Bredel 2100 Lubricant Bredel Bredel*...
When the product temperatures are above 60 °C (+140 °F) always use one shim less than indicated in the diagrams. • Always round up the number of shims. • Each diagram gives the number of shims per pressing shoe. • Shim both pressing shoes identically. Bredel 265 Bredel 280 Bredel 2100...
SPECIFICATIONS 11.2 Lubricant for gearbox Please check the documentation that is supplied with the gearbox for specified lubricants. Please be aware that the type of lubricant depends on running conditions and ambient conditions. Special features might be required to keep the gearbox temperatures within limits. Please check the gearbox manual.
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.
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Questions and answers
I can’t get the rotor off, used a puller amongst other things and I did remove the retaining. Any ideas of what else I can do? Thanks
Fit the necessary lifting means before dismounting the rotor. Then, extract the rotor from its position.
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