Boyser DS-M Series User manual

Operating instructions
DS-M Series
Peristaltic Pump
INS.7.2-09 DSM I

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Table of contents
1. Introduction......................................................................................3
2. Safety and Responsibility ..................................................................5
3. Functional description.......................................................................9
4. Transport and Storage ....................................................................11
5. Assembly and Installation ...............................................................12
6. Commissioning................................................................................14
7. Maintenance, repair, malfunctions, disposal and spare parts .........15
8. Spare parts .....................................................................................18
9. Declaration of Conformity...............................................................20
10. Guarantee ......................................................................................21

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1. Introduction
This manual forms an integral part of the pump and must accompany it until its
demolition. The series DS peristaltic pump is a machine destined to work in
industrial areas and as such the instruction manual must form part of the
legislative dispositions and the applicable technical standards and does not
substitute any installation standard or eventual additional standard.
1.1 Explanation of the safety information
1.2 Users’ qualifications
Pumps are machines that due to their functioning under pressure and moving
parts can present dangers.
- Improper use
- Removing the protections and/or disconnecting the protection device
The instructions of this manual, whose inobservance is
determined as a failure to meet safety standards, are
identified by this symbol
The instructions of this manual, whose inobservance
compromises electrical safety
The instructions of this manual, whose inobservance
compromises the correct working of the pump, are
identified with this symbol.

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- The lack of inspections and maintenance
They can cause serious damage or injury.
The person in charge of safety should therefore guarantee that the pump is
transported, installed, put in service, used, maintained and repaired by qualified
personnel who should therefore possess:
- Specific training and sufficient experience.
- Knowledge of the technical standards and applicable laws.
- Knowledge of the general national and local safety standards and also
of installation.
Any work carried out on the electrical part of the pump should be authorized by
the person responsible for safety. Given that the pump is destined to form part
of an installation, it is the responsibility of whoever supervises the installation to
guarantee absolute safety, adopting the necessary measures of additional
protection.

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2. Safety and Responsibility
2.1 General safety information
Live parts
Possible consequence: Fatal or very serious injuries.
-Measure: The device must be disconnected from the power
supply before it is opened
-Isolate damaged faulty or manipulated devices from the mains in
order to de-energise.
Emergency stop switch
Possible consequence: Fatal or very serious injuries.
An emergency stop switch is to be connected for the entire plant. This
should enable the entire plant to be shut down in the event of an
emergency in such a way that the overall plant can be brought into a
safe condition.
Unauthorized access
Possible consequence: Fatal or very serious injuries.
-Measure: Ensure that there can be no unauthorized access to the
unit.
Hazardous media/contamination of persons and equipment
Possible consequence: Fatal or very serious injuries material damage.
-Ensure that the pump hoses are resistant against the media being
conveyed
-Always observe the safety data sheets for the media to be
conveyed. The system operator must ensure that these safety
data sheets are available and that they are kept up-to-date.
-The safety data sheets for the media being conveyed are always
decisive for initiating countermeasures in the event of leakage to
the media being conveyed.

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-Observe the general restrictions in relation to viscosity limits,
chemical resistance and density.
-Always switch the pump off before exchanging the pump hose
Correct and proper use
Possible consequence: Fatal or very serious injuries.
-The unit is not intended to convey or regulate gases or solid
media
-Do not exceed the rated pressure, speed or temperature for the
pump
-The unit may only be used in accordance with the technical data
and specifications provided in these operating instructions and in
the operating instructions for the individual components
-The system is not designed for use in areas of risk from explosion
-Only switch the pump on if it has been properly fastened to the
floor
-Only switch the pump on if it the front cover has been attached.
-Do not carry out any maintenance operations or dismantle the
pump without first making sure that the pipes are not under
pressure and are empty or isolated.
-In the case of the hose becoming stuck during extraction or fitting
it is necessary to reverse the direction of the pump, relubricate,
and then repeat the operation.
-As the peristaltic pump is volumetric and its functioning is positive
displacement, it is necessary to prevent a possible overload of
pressure, due to for example, the accidental closure of a valve.
For this reason it is advisable to fit a safety device such as: a
safety valve, pressure limiter, etc.
Operational lifetime of the pump hoses
Possible consequence: Fatal or very serious injuries.
The operational lifetime of the pump hoses cannot be precisely
specified. For this reason, the possibility of fracture and consequential
leakage of liquids must be accounted for. If the hose rupture alarm
(optional) is fitted, then the pump can be stopped and / or an electrical
valve can be actuated.

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CIP cleaning
In the event of CIP cleaning, it is necessary to obtain information from
the manufacturer about correct installation of the pump (a special
installation is required) as well as regarding the compatibility of the
cleaning agents with the pump hoses and the hydraulic connections.
Cleaning should be undertaken at the recommended maximum
temperature.
Direction of rotation/flow direction
Possible consequence: Material damage right through to destruction of
the unit.
-The pump's direction of rotation in relation to the desired flow
direction must be checked prior to every start.
Disconnect the pump from the mains
Possible consequence: Personal injury.
You may only carry out work on the pump after it has previously been
switched off and disconnected from the mains.
In addition, as the hose has an indeterminate life and due to the
possibility of its breakage or deterioration, the user is responsible for the
prevention of a possible (although most unlikely) incorporation of
particles form the hose into the product being pumped. This can be
achieved e.g. by means of filtration, a hose rupture alarm or other means
suitable for the respective process

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Environmental influences
Possible consequence: Material damage right through to destruction of
the unit.
-The device is not suitable for outdoor operation
-Take suitable measures to protect the device from environmental
influences such as:
–UV rays
–Moisture
–Frost, etc.

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3. Functional description
The DS Series is a displacement pump. The feed chemical is conveyed by the
rotor squeezing the hose in the direction of flow. No valves are needed for this.
This ensures gentle handling of the metered media.
The DS Series has been designed for safe and uncomplicated operation, as
well as straightforward maintenance.
The DS Series can be used for many different media. However, this pump type
is often the optimal solution for abrasive, shear-sensitive and viscose media.
Typical areas of use include processes where only a low discharge pressure is
required (max. 2 bar).
3.1 Construction
Main modules:
-Drive Unit
-Tubing
-Base frame
The pump housing is closed off with a screwed front cover in order to avoid the
risk of injury.
The motor serves to drive the rotor. Three rollers at the ends of the rotor serve
to press the pump hose against the pump housing.
The rotary movement of the rotors alternately press and relax the rollers in
relation to the pump tube. This serves to suck the media and convey it into the
metering line.

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Fig. 1: Diagram of functional principle
1 Housing 3 Rollers
2 Rotor 4 Tube

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4. Transport and Storage
4.1 Transport
-The pump is protected by a cardboard packaging.
-The packaging materials are recyclable.
4.2 Storage
-The pump should be in a resting position. (The hose should not be
compressed).
-Avoid areas open to harsh weather or excessive humidity.
-For storage periods of longer than 60 days, protect the coupling surfaces
(clamps, reducers, motors) with adequate anti-oxidant products.
-Spare hoses should be stored in a dry place away from direct light.

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5. Assembly and Installation
5.1 Ambient conditions
Assembly is to be carried out in the following order. If the pump has to be
installed outdoors, then it is to be equipped with protection against sunlight and
weather influences. When positioning the pump, ensure that sufficient room for
access is provided for all types of maintenance work.
Limit values for hose temperature and pressure
Material Hose
Min. Temp.
(ºC) Feed
chemical
Max. Temp
(ºC) Feed
chemical
Min. Temp (ºC)
Environment
Max.
Pressure
(Bar)
Norprene A60F
- 10
120*
- 40
2
Norprene A60G
- 10
120*
- 40
2
SOLVA
- 10
70*
- 40
2
SILICONE
- 10
135*
- 40
2
TYGON
- 10
70*
- 40
2
* At max. Tª, the life of hose is drastically reduced. Please contact with Boyser or
authorized distributor for high Tª application.
5.2 Correct installation of the pump
5.2.1 Suction side
The pump is to be positioned as near as possible to the liquid container, so that
the suction side is kept as short and straight as possible. The suction line must
be absolutely airtight and made of a suitable material, so that it is not squeezed
together under vacuum. The diameter must correspond to the rated diameter of
the pump tube. A larger diameter is recommended in the event of viscose
liquids. The pump is self-priming and does not require an admission valve. The
pump is reversible and the suction connection can therefore comprise of one of
two options. Normally the option is selected which is best suited to the physical
conditions of the installation. It is recommended to use a flexible transition

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between two fixed pipes and the hydraulic connection of the pump, in order to
avoid the transmission of vibrations.
5.2.2 Discharge side
The discharge line is to be kept as straight and short as possible, in order to
avoid performance reduction. The diameter must correspond to the rated
diameter of the pump tube. A larger diameter is recommended in the event of
viscose liquids. It is recommended to use a flexible transition between two fixed
pipes and the hydraulic connection of the pump, in order to avoid the
transmission of vibrations.

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6. Commissioning
6.1 Testing prior to commissioning the pump
The following tests are to be carried out:
-Ensure that the pump has not been damaged during transportation or
storage. Immediately report any damage to the supplier.
-Check that the mains voltage is suitable for the motor.
-Ensure that the tube is suitable for the fluid to be conveyed and that it is
not damaged.
-Make sure that the temperature of the liquid does not exceed the
recommended temperature range.
-Only switch the pump on if it the front cover has been properly attached.
-Check that the rollers are correctly fitted and fastened.
-Check that the drive pump and the inner of the rollers are correctly
greased. The specially formulated grease can be obtained from
BOMBAS BOYSER, S.L. or from the authorized distributor.
-Check that the thermal overload protection (not included in the delivery
scope) corresponds to the value specified on the motor type plate.
-Check whether the direction of rotation is correctly adjusted.
-Check that the optional electrical components are connected and are
working properly.
-Install a manometer in the pressure line if the back-pressure value is
unknown.
-Check the operating instructions in order to ensure that the flow values,
pressures and power consumption of the motor do not exceed the rated
values.
-Install a pressure relief valve in the pressure line in order to protect the
pump in the event that a valve is unintentionally closed off or the line is
blocked in another way.

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7. Maintenance, repair, malfunctions, disposal and spare parts
7.1 Lubrication:
-Check that the rollers and the hose are sufficiently lubricated
oCheck every 300 operating hours
-Gear reducer:
oThe lubrication is permanent. Is not necessary any servicing
7.2 Exchanging the pump hoses
7.2.1 Exchanging the pump tubes –dismantling
1. Close off all valves, in order to prevent leakage of the feed chemical
2. Dismantle the pump pipes from both discharge and suction sides
3. Remove the front cover
4. Remove the pump body from the support
5. Remove the tube
7.2.2 Exchanging the pump tubes- installation
1. Clean the interior surfaces of the pump housing
2. Lubricate the internal surfaces of the pump housing at the contact
surfaces to the pump hose with original silicon grease
3. Check the rollers. Ensure that the roller surfaces are not damaged
4. Lay the pump tube into the pump support
5. Mount the pump body on the support
6. Attach the front cover to the pump body, pulling a little bit the tube to
ensure that the tube is installed in its correct position
7. Adjust the position of the front cover press pommel until the tube
become correctly pressed
8. Mount the pipes from both discharge and suction sides
9. Open all of the valves

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7.3 Troubleshooting
Problem
Possible cause
Solution
Increased pump
temperature
Pump tube has no lubricant
Lubricate pump tube
Increased product temperature
Reduce product temperature
Insufficient or poor suction conditions
Check suction line for blockages
Pump speed too high
Reduce pump speed
Reduced flow or
pressure
Valves on discharge and or suction side
completely or partially closed
uuuuuuuuuuuuuuuuuuuuuuu
partially closed
Open valves
Pump hose insufficiently compressed
Check roller fastening
Pump tube rupture (the product leaks
out into the housing)
Exchange pump tube
Partial blockage of the suction line
Clean pipe
Insufficient product quantity in storage
container
Fill storage container or exchange pump
Insufficient diameter on the suction side
Increase the diameter on the suctions
side, as far as possible
Suction line too long
Shorten the suction line, as far as possible
High viscosity of medium
Reduce viscosity, as far as possible
Reduced flow or
pressure
Air introduction in the suction
connections
Check connections and accessories for air
tightness
Reduced flow or
pressure
High pulsation on suction
Tighten connections and accessories
Mount antipulsation equipment
Reconsider application (speed, etc)
Vibrations on
pumps and
pipelines
The pipes are not correctly fastened
Fasten pipes correctly (e.g. wall brackets)
Pump speed too high
Reduce pump speed
Insufficient nominal width of the pipes
Increase nominal width
Pump base plate loose
Fasten base plate
Pulsation dampers insufficient or
missing
Install pulsation dampers on suction and /
or discharge side.
Short
operational
lifetime of the
Chemical exposure
Check the compatibility of the hose with
the liquid being conveyed, the cleaning
fluid and the lubricant

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hoses
High pump speed
Reduce pump speed
High conveying temperature
Reduce product temperature
High operating pressure
Reduce operating pressure
Pump cavitation
Check the suction conditions
Abnormal elevation of temperature
Check rollers shaft mounting
Unsuitable lubricant
Use lubricant BOYSER
Insufficient quantity of grease
Top up lubricant
Pump hose
pulled into the
pump housing
High inlet pressure
Reduce inlet pressure
Pump hose filled with deposits
Clean or replace the pump hose
Holder (press flange) insufficiently
tightened
Re-tighten holder (press flange)
Insufficient grease
Top lubricant
The pump does
not start up
Insufficient motor performance
Check motor and replace if necessary
Insufficient output from frequency
converter
The frequency converter must match the
motor
Blockage in the pump
Check voltage. Start occurs at minimum
10 Hz
Blockage in the pump
Check if the suction or discharge side is
blocked. Rectify blockage

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8. Spare parts
8.1 Spare parts exploded DSM

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Pos.
Description
Quantity
Reference
1
Pump support
1
115.00.01
2
Pump body
1
115.00.02
3
Rotor with shaft S.S.
1
115.00.04
4
7
Roller ( 2,4mm tube wall thickness )
3
115.00.05
Roller ( 1,6mm tube wall thickness )
3
115.00.07
5
Roller shaft
3
115.00.09
6
Shaft
Shaft seeger ring
1
115.00.10
7
Pump screw S.S.
2
115.00.12
8
Pump press pommel
2
115.00.13
9
Base plate
1
115.00.14
12
Base plate S.S.
1
115.00.15
10
Front cover plastic part
1
115.00.16
11
Tube pressing part S.S.
1
115.00.18
12
Front cover S.S. part
1
115.00.20
13
Tube pressing pommel S.S.
1
115.00.22
14
Tube pressing pommel plastic part
1
115.00.23
15
Spring
1
115.00.24
16
Press pommel seeger ring
1
115.00.25
17
Insert S.S:
1
115.00.27
18
Driver
1
19
Tube
1

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9. Declaration of Conformity
- Original-
EC Declaration of Conformity
We hereby declare, BOMBAS BOYSER S.L
C/ Narcís Monturiol, 24 –Pol. Ind. Can Magre
08187 –Sta. Eulàlia de Ronçana (Barcelona)
Spain
That the following designated product complies with the pertinent fundamental safety and health requirements
of the EC Directive in terms of its design and construction and in terms of the version marketed by us.
This declaration loses its validity in the event of a modification to the product not agreed with us.
Description of the product: Peristaltic pump BOYSER DS
Product type: DSM
Serial no.: Refer to nameplate on the device
Pertinent EC Directives: CE Declaration of Conformity (Ann. II. A, 2006/42/CE): The pump
is conform to the safety requirements according to the 2006/42/CE
norms and amendments
Manufacture Declaration (Ann. II. B, 2006/42/CE): The pump cannot
be operated before the machine in which is assembled the pump, will
be declared in conformity with the safety requirements according to the
2006/42/CE norms and amendments.
Signature:
Details of the signatory: Technical Manager