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Bredel CIP20 Operating Manual

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Bredel CIP20 Operating Manual
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Summary of Contents for Bredel CIP20

  • Page 1 Bredel CIP20 Operating Manual m-bredel-cip20-en-01...

  • Page 2: Table Of Contents

    4.4 Pump installation positions 4.5 Hose 4.6 Gearbox 4.7 Electric motor 4.8 Frequency controller 4.9 Available options 5 Installation 5.1 Unpacking and inspection 5.2 Installation conditions Set-up 5.3 Lifting and moving the pump 5.4 Placing the pump 6 Commissioning 6.1 Preparations m-bredel-cip20-en-01...
  • Page 3 8.6 Exchanging replacement parts 8.7 Fitting options 9 Storage 9.1 Hose pump 9.2 Hose 9.3 Lubricant 10 Troubleshooting 11 Specifications 11.1 Pumphead 11.2 Gearbox 11.3 Electric motor 11.4 Bredel Variable Frequency Drive (VFD) (optional) 11.5 Parts list 12 Safety form m-bredel-cip20-en-01...
  • Page 4 (electronically or mechanically) without the prior written authorisation of Watson-Marlow Bredel B.V.. 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.

  • Page 5: General

    Service and support Some specific adjustments, installation and maintenance or repair jobs fall beyond the scope of this manual. In case of doubt, consult your Bredel representative. Make sure that you have the following data at hand: •...

  • Page 6: Environment And Disposal Of Waste

    Procedures which, if not carried out with the necessary care, may result 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 Information on environmentally-friendly disposal or recycling of materials. m-bredel-cip20-en-01...

  • Page 7: Intended Use

    A list of certified products and relevant chemicals can be found at http://www.nsf.org/certified- products-systems. For further details refer to the Bredel User Guide NSF 61 certified hose pumps supplied with such a pump, which can also be found on the website, or contact your Bredel representative for advice.

  • Page 8: Responsibility

    Depending on the specific working conditions or accessories used, additional safety instructions can be required. Immediately contact your Bredel representative for advice if you notice a potential danger while using your hose pump. WARNING The user of the hose pump is fully responsible for observing local safety regulations and directives.

  • Page 9: Warranty Conditions

    Warranties purporting to be on behalf of Bredel made by any person, including representatives of Bredel, its subsidiaries, or its distributors, which do not accord with the terms of this warranty shall not be binding upon Bredel unless expressly approved in writing by a Director or Manager of Bredel.

  • Page 10: Description

    Pumphead Pump hose Gearbox Frequency controller (option) Electric motor Identification of the pump The identification plate on the pumphead contains the following data: Serial No:. YEAR: Watson-Marlow Bredel B.V. Sluisstraat 7-Delden-NL www.bredel.com Pump type Serial number Year of manufacture m-bredel-cip20-en-01...
  • Page 11 Identification of the hose compression Letter Pressure range Bredel CIP20 ≤ 400 kPa 28-1008816 400 to 800 kPa 28-1008817 > 800 kPa 28-1008818 Identification of the actuation disc for the hose compression (L, M or H) See also Refer to "Maximum working pressure" on page 63.
  • Page 12 Identification of the electric motor The identification plate on the electric motor contains the following data: C D E F G H IP55 IK08 cl.F 40°C kg 9 min -1 kW cos Part number Speed Serial number Power Mains Power factor Frequency Current m-bredel-cip20-en-01...
  • Page 13 Identification of the frequency controller The identification of the Bredel Variable Frequency Drive (VFD) can be found inside the VFD. Remove the cover by loosening the two screws. The identification sticker contains the following data: Serial number sn20837003969 E384083 Bredel article number Part number Manufacturer’s serial number...

  • Page 14: Construction Of The Pump

    Construction of the pump CIP cover Support Drive shaft Coupling bush CIP rotor Gearbox Hose Frequency controller Pump housing Electric motor m-bredel-cip20-en-01...

  • Page 15: Operation Of The Pump

    When the first pressing shoe leaves the pump hose, the second pressing shoe has already occluded the hose and fluid is prevented from flowing back. This method of liquid displacement is known as the "positive displacement principle". m-bredel-cip20-en-01...

  • Page 16: Pump Installation Positions

    An accurate reading of the lubricant level through the inspection window is possible at every pump position. The pump operational direction is determined by the configuration of the CIP rotor. By flipping the actuator disc the operation direction can be changed. m-bredel-cip20-en-01...

  • Page 17: Hose

    Note: Contact your Bredel representative for advice about the chemical and temperature resistance of the hoses. The Bredel hoses are carefully manufactured and quality checked to achieve minimum tolerances in wall thickness. It is very important to guarantee the correct compression of the hose, because: •...

  • Page 18: Gearbox

    Refer to "Pumphead assembly" on page 73. Lubrication and cooling The pumphead is filled with Bredel Genuine Hose Lubricant. This lubricant lubricates the pressing shoes and dissipates the generated heat via the pump and the cover. The user is responsible to ensure the chemical compatibility of the lubricant with the fluid to be pumped.

  • Page 19: Electric Motor

    See also Refer to "Specifications" on page 62 Use of electric and electronic devices like electric motor and frequency controller require special configurations. Sometimes use is limited to non-ATEX only. In case of doubt, consult your Bredel representative.. Available options The following options are available for the hose pump: •...

  • Page 20: Installation

    Unpack all parts carefully. Retaining packaging until inspection is complete. Inspection Check all components present Inspect components for damage in transit Report missing components or damage to your local Bredel representative immediately Packaging disposal Dispose of packaging materials: Safely Responsibly...

  • Page 21: Set-Up

    Do not exceed ambient operating air temperature range (°C) -20 °C to +45 °C Maximum floor slope (mm per metre) Note: Pump is suitable for indoor use. In case of outdoor use contact your Bredel representative for advice. Set-up Installation site requirements: •...
  • Page 22 A segment of three quarters (3/4) of the pump hose length for the flexible pipe work is recommended. Bredel also recommends installing an isolation valve and pipedrain in the suction and discharge pipework to allow fluid isolation and drainage from the pump during maintenance.

  • Page 23: Lifting And Moving The Pump

    All control cables outside the enclosure must be shielded and have a cross sectional area of at least 0.22mm . The shielding must be connected to earth at one end. In case of doubt, contact your Bredel representative for advice. Lifting and moving the pump Lifting should be performed according to standard Health and Safety guidelines and should be performed by qualified personnel only.

  • Page 24: Placing The Pump

    (A). Placing the pump Do not use holes (B) when the pump is placed on the leveling elements. This can cause the pump to tilt. Do not use the holes in the pump supports to lift the hose pump. m-bredel-cip20-en-01...
  • Page 25 Follow the next steps to make sure the anchor bolts are used properly. Use the specifications below. A. Pump support B. Foundation Drill the holes. Clean the bore holes. Use a hammer to drive the anchor bolt into the bore. Tighten the bolt to the applicable torque setting (MD). m-bredel-cip20-en-01...
  • Page 26 Item Unit Bredel CIP20 Flange thickness (d Flange hole diameter 12 x 16 Bredel part no. 28-F550016 Bolt thread Bolt length (l) Minimum foundation height (d) Drill diameter Minimum drill depth (h) Mounting depth (hs) Torque setting (MD) Using levelling elements Use four suitable levelling elements to place the pump on a horizontal surface.

  • Page 27: Commissioning

    Have the electrical installation work carried out by qualified personnel. Check that the lubricant level is above the minimum level line in the inspection window. If necessary refill with Bredel Genuine Hose Lubricant via the breather plug. See also Refer to "Frequency controller" on page 23 Refer to "Changing lubricant"...

  • Page 28: Commissioning

    Check the capacity of the hose pump. If the capacity differs from your specification, follow the instructions in Troubleshooting or contact your Bredel representative for advice. If a frequency controller is present, check the capacity range. In case of any deviations consult the supplier’s documentation.

  • Page 29: Operation

    45 °C. If the duty for an application is specified in the area of intermittent operation, let the pump stand still to cool down for at least one hour after two hours of operation. m-bredel-cip20-en-01...
  • Page 30 Start at the product temperature (D) Meet the line of the required discharge pressure (E). Read the maximum allowed pump speed (F). Note: Pump stroke volume is based on new hoses and flooded suction. Actual stroke volume may vary. m-bredel-cip20-en-01...

  • Page 31: Dry Running

    Capacity per revolution: 0.152 l/rev Dry running Dry running is a running condition of the pump when no fluid is flowing through the hose. Bredel hose pumps allow dry running for limited periods. Dry running imposes an additional thermal load on the hose.
  • Page 32 Process fluid can enter and contaminate the pump housing and lubricant. Thoroughly clean the interior before installling a new hose. In general, this will not cause a hazardous situation because the Bredel Genuine Hose Lubricant is harmless (approved by the United States Food and Drug Administration). However, there is an exception in case of pumping a strong oxidiser or a strong acid.

  • Page 33: Fluid Leakage

    To avoid consequential damage, the pump must be stopped and lubricant levels of the pumphead and gearbox must be checked. The damaged seal should be replaced. WARNING Risk of injury from falling! Process fluid mixed with pump lubricant that is leaking from the pump can make floors slippery. m-bredel-cip20-en-01...

  • Page 34: Maintenance

    Check that all components are present. Inspect components for damage in transit. If anything is missing or damaged, contact your distributor immediately. Note: Do not install damaged parts. If in doubt, contact your Bredel representative for advice. Maintenance and periodic inspections The following maintenance schedule shows the maintenance and periodic inspection that need to be carried out on the hose pump to guarantee optimal safety, operation and life of the pump.
  • Page 35 Remark Check that the lubricant level is above the minimum level line in the inspection window. If Before start-up of the necessary refill with Bredel Check the lubricant pump and at scheduled Genuine Hose Lubricant via the level. intervals during breather plug.

  • Page 36: Cleaning The Hose

    Refer to the documentation of the cleaning products and the hose for more information. A proper result of a cleaning process in this way is not guaranteed by Bredel, while it strongly depends on the type of pumped fluid and the cleaning fluid applied.

  • Page 37: Changing Lubricant

    Position the drain plug and tighten it to the specified torque. The pump housing can be filled with lubricant via the breather (A). For this purpose remove the breather cap (B) and position a funnel (C) in the breather.Pour the lubricant into the pump housing through the funnel. m-bredel-cip20-en-01...

  • Page 38: Changing The Hose

    Remove the drain plug (B). Collect the lubricant from the pump housing in the tray. Position the drain plug and tighten it to the specified torque. Disconnect the suction and discharge lines. m-bredel-cip20-en-01...
  • Page 39 Pull the bracket and the hose clamp from the hose. Then pull off the rubber bush (C). Do steps 7 and 8 both for the inlet and the outlet ports. Connect the pump to the electrical supply. Switch on the electrical supply. m-bredel-cip20-en-01...
  • Page 40 Do not try to guide the hose by hand. • Keep loose clothing and long hair away from pump ports and any moving parts. See also Refer to "Torque figures" on page 67 Cleaning the pumphead Isolate the pump from the electrical supply. m-bredel-cip20-en-01...
  • Page 41 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 hose. Do not use high pressure cleaner. m-bredel-cip20-en-01...
  • Page 42 See also Refer to "Torque figures" on page 67 Fitting the hose Clean the (new) hose on the outside and fully lubricate the outside with Bredel Genuine Hose Lubricant. Make sure CIP rotor is in PUMP mode Fit the hose (A) via the inlet port.
  • Page 43 First fit the inlet port. Slide the rubber bush (D) over the hose. Push the bracket (A) and the hose clamp (B) together over the hose. Align the holes in the bracket with the holes at the front of the port. Position the retaining bolts (C) and tighten them to the specified torque. m-bredel-cip20-en-01...
  • Page 44 Tighten the bolt (A) of the hose clamp (B). Now fit the other port. For this port proceed in the same way as described above for the inlet port. Fill the pump housing with Bredel Genuine Hose Lubricant. Connect the suction and discharge lines. See also Refer to "Torque figures"...

  • Page 45: Exchanging Replacement Parts

    Isolate the pump from the electrical supply. Remove the cover (B) by loosening the retaining bolts (A). Check the gasket (C) for damage and replace it if necessary. Remove the 3 bolts and gently pull out the actuation disc m-bredel-cip20-en-01...
  • Page 46 Remove centre locking bolt of the drive shaft Place two M8x100 bolts into rotor. Tighten bolts to gently push out the rotor assembly and drive shaft. Remove/Refit bearings and seal m-bredel-cip20-en-01...
  • Page 47 Gently press the new seal ring (B) into the cavity. The seal ring must be fitted in the correct orientation (C), with the open side towards the pump cover. If needed for ease of mounting, slightly oil the cavity area (A). Slightly grease the seal lip of the dynamic seal (B). m-bredel-cip20-en-01...
  • Page 48 (B) star section is aligned with coupling bush (C) star section. WARNING If coupling bush star section is not aligned properly with drive shaft it will be pushed out from the rotor base during assembly. If this happens, reposition drive shaft and gently push it back into main rotor. m-bredel-cip20-en-01...
  • Page 49 Refer to "Refit rotor" on the previous page Refer to "Remove/Refit bearings and seal" on page 46 Install actuator disc by mounting the 3 bolts. Ensure arrow on the disc (A) corresponds to pump rotation direction. Make sure actuation bushings are in the slots of actuator disc. m-bredel-cip20-en-01...
  • Page 50 See also Refer to "Changing the hose" on page 38 Isolate the pump from the electrical supply. Remove the cover. Remove the actuation disc and rotor assembly. See also Refer to "Replacing rotor, seal and bearings of pump casing" on page 45 m-bredel-cip20-en-01...
  • Page 51 Mount the rotor assembly. See also Refer to "Replacing rotor, seal and bearings of pump casing" on page 45 Replacing shoes and roller bushings Remove the pump hose. See also Refer to "Changing the hose" on page 38 m-bredel-cip20-en-01...
  • Page 52 Refer to "Replacing rotor, seal and bearings of pump casing" on page 45 Bredel 20 retrofit of CIP rotor The Bredel 20 pump can be turned into a CIP 20 by replacing existing rotor, bearings, seal and front cover. Referring to Bredel 20 manual, remove Bredel 20 rotor, bearings and seal.

  • Page 53: Fitting Options

    Remove breather and breather seal from Bredel 20 cover. Mount breather with breather seal to new CIP20 cover. Check cover seal for damage. Replace if needed. Install cover seal together with new cover. After the upgrade the following parts are redundant: •...
  • Page 54 Check if the float switch is mounted with the NC sign at the top. Fitting a revolution counter For feedback of the pump revolutions signal to an "intelligent" system, the pump can be equipped with an inductive sensor (A). This sensor is mounted between the two ports. m-bredel-cip20-en-01...
  • Page 55 The speed sensor can be connected via the 2 meter long PVC cable (3 x 0.34 mm Specifications Voltage 10-65 V DC Current Max. 200 mA *For use in non-explosive atmospheres. Sensor adjustment 0.75-1.25 mm The sensor (A) must be adjusted at an offset of 0.75 - 1.25 mm to the extended pressing shoe (B). m-bredel-cip20-en-01...

  • Page 56: Storage

    Replace the pump lubricant in case of failure of the pump hose and in any case after one year. • Use the lubricant before the best-before date marked on the container. • The lubricant must be stored in closed bottles or cans to avoid absorption of moisture. m-bredel-cip20-en-01...

  • Page 57: Troubleshooting

    If the hose pump does not function (correctly), consult the following check list to see if you can remedy the error yourself. If you cannot, contact your Bredel representative for advice. Problem Possible cause Correction Check if the power supply switch is on.
  • Page 58 Problem Possible cause Correction In case of doubt, consult your Bredel Non-standard hose lubricant used. representative. Add Bredel Genuine Hose Lubricant. Low lubricant level. For the required amount of lubricant Check the performance graph. Refer to Product temperature too high.
  • Page 59 The filling degree of the pump hose is too low, because the speed is too high in relation to the viscosity of the product to In case of doubt, consult your Bredel be pumped and the inlet pressure. The representative.
  • Page 60 High discharge pressures. opened and the pressure relief valve Short hose life. functions properly (if present in the discharge line). In case of doubt, consult your Bredel High product temperature. representative. Restructure the discharge and inlet High pulsations. conditions.
  • Page 61 Inspect rubber bush and replace if necessary. Lubricate the bush with Bredel Genuine Hose Lubricant before Rubber bush damaged or not properly installation. Tighten the clamp positioned in the bracket. according instructions. Refer to Refer to "Tightening the hose clamps" on page 44...

  • Page 62: Specifications

    Specifications 11.1 Pumphead Performance Description Bredel CIP20 Hose inner diameter [mm] Max. capacity, continuous [m 0.60 Max. capacity, intermittent [m /h] * 0.82 Capacity per revolution [l/ rev] 0.152 Max. permissible inlet pressure [kPa] Refer to "Maximum working pressure" on Max.
  • Page 63 Maximum working pressure Description Maximum working pressure [kPa] Rotor pressure range* Medium High NR Metering 1000 NR Transfer — 1000 Hose type F-NBR 1000 EPDM 1000 1000 *By actuation disc (L, M or H). m-bredel-cip20-en-01...
  • Page 64 Materials Pos. Description Material Pump housing Cast-iron Cover Cast-iron CIP rotor See exploded view of rotor below Pump support Galvanised steel (AISI 316 optional) Brackets AISI 316 Fasteners AISI 316 Seals, gaskets Seals, gaskets EPDM Coupling Steel m-bredel-cip20-en-01...
  • Page 65 Shoe pivot pin Steel Base rotor Cast-iron Bearing Steel Seal ring Surface treatment After surface preparation, one layer of two- component acrylate is used for surface protection. Standard colour is RAL9010. Contact your Bredel representative for advice on surface treatment. m-bredel-cip20-en-01...
  • Page 66 Lubricant table pump Item Bredel CIP20 Lubricant Bredel Genuine Hose Lubricant Required quantity [litres] Bredel Genuine Hose Lubricant is registered at NSF: NSF Registration No 123204; Category Code H1. Also refer to: www.nsf.org/certified-products-systems, and search for 'Bredel'. Components Glycerol 50-100% w/w Glycol 2.5-10% w/w...
  • Page 67 Weights Weight [kg] Description Bredel CIP20 Pumphead complete* 25.2 Pump support Hose Lubricant Pump cover (complete) Coupling 28-GA52... Gearbox 28-GA53... Electric motor *Weight of a completely mounted pumphead (including hose, lubricant and supports). Torque figures m-bredel-cip20-en-01...

  • Page 68: Gearbox

    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. In case of doubt, contact your Bredel representative for advice.

  • Page 69: Electric Motor

    230/400 V - 3 phases - 50 Hz 11.4 Bredel Variable Frequency Drive (VFD) (optional) The Bredel Variable Frequency Drive (VFD) has been preprogrammed and only needs to be connected to the mains. RFI filter Integrated RFI filter B (industrial applications).

  • Page 70: Parts List

    Refer to "Replacing rotor, seal and bearings of pump casing" on page 45 Refer to "Replacing the seal and bearing of the base rotor" on page 50 Refer to "Replacing shoes and roller bushings" on page 51 Refer to "Bredel 20 retrofit of CIP rotor" on page 52 m-bredel-cip20-en-01...
  • Page 71 Cover assembly Bredel CIP20 Pos. Qty. Description Part number Cover, Bredel CIP20 28-1008815 Bolt, hex. head 28-F504058 Washer 28-F523012 Drain plug 28-F911502 Gasket 28-S120131 Inspection window 28-1008828 Gasket 28-1008829 Round head screw 28-F552535 Breather 28-1000051 Gasket 28-29056334-1 m-bredel-cip20-en-01...
  • Page 72 Pos. Qty. Description Part number Round head screw 28-F552535 Sticker, Bredel CIP20 28-1008830 m-bredel-cip20-en-01...
  • Page 73 Pumphead assembly m-bredel-cip20-en-01...
  • Page 74 Bredel CIP20 Pos. Qty. Description Part number Hose NR Metering 28-1000057 Hose NR Transfer 28-1007880 Hose NBR 28-020040 Hose NBR Food 28-020061 Hose F-NBR 28-020065 Hose EPDM 28-020075 Hose CSM 28-020070 Pump housing 28-215101 Gasket 28-215123 CIP Rotor 28-1008968 Seal ring...
  • Page 75 Rotor assembly m-bredel-cip20-en-01...
  • Page 76 Actuation disc (Medium) 28-1008817 Actuation disc (High) 28-1008818 Drive shaft 28-1008819 Circlip 28-F543005 Circlip 28-F543007 Roller bush 28-1008822 Pump shoe 28-1008831 Actuation pin 28-1008821 Pivot pin 28-1008820 Base rotor 28-1008778 Bearing 28-1008833 Seal Ring 28-1007612 Circlip 28-F546002 Dowty seal 28-1008888 m-bredel-cip20-en-01...
  • Page 77 Support assembly Bredel CIP20 Pos. Qty. Description Part number Pump support 28-215106 Hexagon flange nut with serration 28-1008148 Screw, countersunk head 28-F507040 m-bredel-cip20-en-01...
  • Page 78 Barbed nipple assembly (PTFE/PVDF) Bredel CIP20 Pos. Qty. Description Part number Rubber bush 28-215119 Hose clamp 28-C112508 Barbed nipple PTFE 28-215688020 Barbed nipple PVDF 28-215690020 Bracket 28-215197 Bolt, Hex. head 28-F504054 Washer 28-F532009 m-bredel-cip20-en-01...
  • Page 79 Barbed or threaded nipple assembly (stainless steel) m-bredel-cip20-en-01...
  • Page 80 Barbed nipple SS 28-215686020 Threaded nipple DIN 11851 SS 28-215702020 Threaded nipple (NPT) PP 28-215696020 Threaded nipple (NPT) PVC 28-215697020 Threaded nipple (NPT) SS 28-215698020 The barbed nipple SS for the Bredel 20 has an outer diameter of 25 mm. m-bredel-cip20-en-01...
  • Page 81 Flange assembly (1) Bredel CIP20 Pos. Qty. Description Part number Rubber bush 28-215119 Hose clamp 28-C112508 Bracket 28-215197 Bolt, Hex. head 28-F504054 Washer 28-F532009 Threaded nipple (BSP) SS 28-215693020 28-F519004 Threaded flange EN SS 28-29105325 Threaded flange ANSI SS 28-29098325...
  • Page 82 Flange assembly (2) Bredel CIP20 Pos. Qty. Description Part number Rubber bush 28-215119 Hose clamp 28-C112508 Flange bracket 28-215197A Bolt, Hex. head 28-F504054 Washer 28-F532009 Flange EN 28-215199 Flange ANSI 28-215199A Insert SS 28-220186 Insert PP 28-220189 m-bredel-cip20-en-01...
  • Page 83 Revolution counter assembly Bredel CIP20 Pos. Qty. Description Part number Pump housing 28-215101A Revolution counter 28-29060367 Gasket ring 28-F724009 m-bredel-cip20-en-01...
  • Page 84 Lubricant Pos. Qty. Description Part number 0.5 l can Bredel Genuine 28-901143 Hose Lubricant m-bredel-cip20-en-01...
  • Page 85 Bredel hose pump series Type designa�on: Bredel 10, Bredel 15, Bredel 20 , Bredel CIP20 This declara�on of conformity is issued under the sole responsibility of the manufacturer. The object of the declara�on described above is in conformity with the relevant harmonisa�on legisla�on:...

  • Page 86: 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.

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