Verderflex Dura 55 User manual

Peristaltic Hose Pump
Operating Manual Dura 55
Version 2.3v-03/2018
Print-No. 01

Dura 55 Version 2.3v-03/2018
Version 2.3v-03/2018
Print-No. 01
2 | Page
Dura 55
The information in this document is essential for the safe operation and servicing of Verderex®
Dura 55 pumps. This document must be read and understood thoroughly prior to installation
of unit, electrical connection and commissioning.

Dura 55 Version 2.3v-03/2018
1. About this document
1.1 Target groups
1.2 Warnings and symbols
2. Safety
2.1 Intended use
2.2 General safety instructions
2.2.1 Product safety
2.2.2 Obligation of the operating company
2.2.3 Obligation of personnel
2.3 Specic hazards
2.3.1 Hazardous pumped liquids
2.3.2 Lubricants
2.3.3 Sharp edges
3. Layout and function
3.1 Design details
3.2 Labelling
3.2.1 Name Plate
3.3 Layout
3.4 Bearings and Lubrication
4. Transport, storage and disposal
4.1 Transport
4.1.1 Unpacking and inspection on delivery
4.1.2 Lifting
4.2 Treatment for storage
4.3 Interim storage before installation
4.4 Disposal
5. Installation and connection
5.1 Preparing for installation
5.1.1 Checking the ambient conditions
5.1.2 Preparing the installation site
5.1.3 Preparing the foundation and surface
5.2 Installation at site
5.3 Planning the pipes
5.3.1 Specifying supports and ange connections
5.3.2 Specifying nominal diameters
5.3.3 Specifying pipe lengths
5.3.4 Optimizing cross-section of pipe work
5.3.5 Providing safety and control devices
(recommended)
5.4 Shimming
5.5 Electrical connection
5.5.1 Installing motor and gearbox (where not supplied)
5.5.2 Installing motor gearbox on bare-shaft pump
5.5.3 Connecting to power supply
5.6 Installing the Hose
5.6.1 Inserting the hose
5.6.2 Filling the pump with lubricant
5.6.3 Fitting the inspection window
5.7 Connecting the pipes
5.7.1 Installing the piping
6. Operation
6.1 Pre-commissioning the pump
6.1.1 Checking the direction of rotation
with dry pump
6.1.2 Starting the pump
6.1.3 Switching off
6.2 Operation
6.2.1 Switching on
6.2.2 Switching off (Refer to -> 6.1.3)
6.3 Shutting down the pump
6.4 Start-up following a shutdown period
6.5 Operating the stand-by pump
7. Maintenance
7.1 Inspections
7.2 Maintenance
7.2.1 Cleaning the pump
7.2.2 Maintenance schedule
7.3 Repairs
7.3.1 Preparations for dismounting
7.3.2 Returning the pump to the manufacturer
7.3.3 Rebuild / Repair
7.3.4 Re-alignment of Rotor after a stall
7.4 Hose change
7.4.1 Dismounting the hose
7.4.2 Re-installing the hose, port anges, lubricant
rell and tting the inspection window
7.5 Ordering spare parts
8. Storing pumps and hoses
8.1.1 Pre-Storage Actions
8.1.2 Cleaning Protocol for hoses
8.1.3 Storage Conditions
9. Troubleshooting
9.1 Pump malfunctions
10. Appendix
10.1 Technical Specications
10.1.1 Pump Specications
10.1.2 Ambient conditions
10.1.3 Tightening torques
10.1.4 Preservatives
10.1.5 Cleaning agents (After hose is removed)
10.1.6 Lubricants
10.1.7 Shimming
10.1.8 Rotor setting distance
11. List of Figures and Tables
11.1 List of gures
11.2 List of tables
12. Declaration of conformity according
to EC Machine Directive
Table of contents
3 | Page

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Verderex Peristaltic pump, Dura 55, has been developed according to the latest technology and
subject to continuous quality control. These operating instructions are intended to facilitate familiarization with the
pump and its designated use. The relevant information will act as a guideline for you in operating the pump;
alternative courses of action are also described should you be unable, for any reason, to follow those
procedures initially given. You are advised to follow these guidelines to achieve maximum efciency.
These operating instructions Do not take into account local regulations; the operator must ensure that such
regulations are strictly observed by all, including the personnel called in for installation.
1. About this document
1.1 Target groups
Table 1 Target groups and their duties
Table 3 Symbols and their meaning
1.2 Warnings and symbols
Table 2 Warnings and consequences of disregarding them
DANGER
WARNING
CAUTION
NOTE
Target groups Duty
Operating company u Keep this manual available at the operation site of the equipment,
also available for later reference.
u Ensure that personnel read and follow the instructions in this
manual and the other applicable documents, especially all safety
instructions and warnings.
uObserve any additional rules and regulations referring to the system.
Qualied personnel, tter u Read, observe and follow this manual and the other applicable
documents, especially all safety instructions and warnings.
Warning Risk Level Consequences of disregard
Immediate acute risk Death, serious bodily harm
Potential acute risk Death, serious bodily harm
Potential hazardous situation Minor bodily harm
Potential hazardous situation Material damage
Symbol Meaning
Safety warning sign in accordance with DIN 4844 - W9
uTake note of all information highlighted by the safety
warning sign and follow the instructions to avoid injury
or death.
uInstruction
1., 2., Multiple-step instructions
Precondition
gCross-reference
Information, recommendation

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2. Safety
The manufacturer does not accept any liability
for damage resulting from disregard of this
documentation.
2.1 Intended use
• Only use the pump to handle compatible uids
as recommended by the manufacturer
(g 10.1 Technical specications).
• Adhere to the operating limits.
• Consult the manufacturer regarding any other use
of the pump.
• Pumps delivered without a motor must be tted
with a motor in accordance with the provisions of
EC Machine Directive 2006/42/EC.
Prevention of obvious misuse (examples)
•Note the operating limits of the pump with regard to
temperature, pressure, ow rate and motor speed
(g 10.1 Technical specications).
• Do not operate the pump while the inlet/outlet valve
is closed.
• Only install the pump as recommended in this manual.
For example, the following are not allowed:
– Installing the pump without proper support.
– Installation in the immediate vicinity of extreme hot
or cold sources.
2.2 General safety instructions
Observe the following regulations before carrying
out any work.
2.2.1 Product safety
These operating instructions contain fundamental
information which must be complied with during
installation, operation and maintenance. Therefore
this operating manual must be read and
understood both by the installing personnel and
the responsible trained personnel / operators prior
to installation and commissioning, and it must
always be kept easily accessible within the
operating premises of the machine.
Not only must the general safety instructions laid
down in this chapter on “Safety” be complied with,
but also the safety instructions outlined under
specic headings.
• Operate the pump only if the pumping unit and all
associated systems are in good functional
condition.
• Only use the pumping system as intended, fully
aware of safety and risk factors involved,
and in adherence to the instructions in this manual.
• Keep this manual and all other applicable documents
complete, legible and accessible to personnel at all
times.
• Refrain from any procedure or action that would
pose a risk to personnel or third parties.
• In the event of any safety-relevant faults, shut down
the pump immediately and have the malfunction
corrected by qualied personnel.
• The installation of the pump, associated pipe work and
electrical ttings must comply with the requirements
of installation given in this manual and any local
national or regional health and safety regulations.
2.2.2 Obligation of the operating company
Safety-conscious operation
• Ensure that the following safety aspects are
observed and monitored:
– Adherence to intended use
– Statutory or other safety and accident-prevention
regulations
– Safety regulations governing the handling of
hazardous substances if applicable
– Applicable standards and guidelines in the country
where the pump is operated
• Make personal protective equipment available
pertinent to operation of the pump; as required.

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– Do not use them as a xing point for winches
or supports
– Do not de-ice using gas burners or similar tools
– Do not remove the safety guarding for hot, cold or
moving parts during operation.
• Reinstall the safety equipment on the pump as
required by regulations after any repair / maintenance
work on the pump.
2.3Specichazards
2.3.1 Hazardouspumpedliquids
Follow the statutory safety regulations when handling
hazardous pumped liquids (e.g. hot, ammable,
poisonous or potentially harmful).
Use appropriate personal protective equipment when
carrying out any work on the pump.
2.3.2 Lubricants
Ensure that the lubricant and pumped liquid are
compatible with each other. This is a precautionary
measure in case of accidental hose burst whereby
the pumped liquid comes in contact with the
lubricant.
(Refer datasheet for lubricant to ensure
compatibility)
2.3.3 Sharp edges
• Pump parts, such as the shims, can be sharp
– Use protective gloves when carrying out any
work on the pump
Qualiedpersonnel
• Ensure that all personnel tasked with work on the pump
have read and understood this manual and all other
applicable documents, including the safety,
maintenance and repair information, prior to use or
installation of the pump.
• Organize responsibilties, areas of competence and
the supervision of personnel.
• Have all work carried out by specialist technicians
only.
• Ensure that trainee personnel are under the
supervision of specialist technicians, at all times, when
working on the pumping system.
Safety equipment
• Provide the following safety equipment and verify its
functionality:
– For hot, cold and moving parts: safety guarding
should be provided by the operating company.
– For potential build up of electrostatic charge:
ensure appropriate grounding if and when
required.
Warranty
The warranty is voided if the customer fails to follow
any and all instructions, warnings and cautions in this
document. Verder has made every effort to illustrate
and describe the product(s) in this document. Such
illustrations and descriptions are, however, for the sole
purpose of identication and Do not express or imply a
warranty that the products are merchantable or t for a
particular purpose, or that the products will necessarily
conform to the illustration or descriptions.
Obtain the manufacturer’s approval prior to carrying
out any modications, repairs or alterations during the
warranty period. Only use genuine parts or parts that
have been approved by the manufacturer.
For further details regarding warranty, please refer
terms and conditions.
2.2.3 Obligation of personnel
It is imperative that the instructions contained in this
manual are complied with by the operating personnel
at all times.
• Pump and associated components:
– Do not lean or step on them or use as climbing
aid
– Do not use them to support boards, ramps
or beams

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3. Layout and function
Peristaltic hose pump, Verderex Dura, is simple by
design in its construction and operation. The medium
to be pumped does not come into contact with any
moving parts and is totally contained within a robust,
heavy-duty hose, which consists of an inner layer, two
– six reinforcement layers and an outer layer. A rotor
passes along the length of the hose, compressing it.
This motion forces the contents of the hose directly in
front of the rotor to move forward along the length of
the hose in a ‘positive displacement’, peristaltic
movement. In the wake of the rotor’s compressing
action, the natural elasticity of the polymer reinforced
rubber forces the hose to open and regain its round
prole, creating suction pressure, which recharges the
pump.
3.1 Design details
Verderex Dura is a twin lobe, single rotor,
peristaltic pump with quick-t tapered port ange
design which clamps and seals in one easy movement
to speed hose replacement.
3.2 Labelling
3.2.1 Name Plate
1. 2. 3.
Figure 1 Name plate
1. Pump type
2. Serial number
3. Year of manufacture
Note: When requesting spares, the model and serial
number should always be quoted.

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Figure 2 Layout
3.4 Bearings and Lubrication
u Pump: To be lled at installation with appropriate
lubricant if not supplied pre lled.
(g10.1.6 Lubricants)
uBearings are sealed units and need no additional
lubricant.
1 Inspection window 6 Shims 11 Pump casing
2 Inspection window gasket 7 Rotor shoe 12 Clamp ring
3 Front cover 8 Rotor 13 Port ange
4 Front cover o-ring 9 Hose 14 ¼ turn ange
5 Slip bush 10 Bearing housing 15 Mounting frame
3.3 Layout
5
1
2
3
4
6 7 10 11
8
13 14 15
912

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4. Transport, storage and
disposal
4.1 Transport
Always transport the unit in an upright position and
ensure that the unit is securely attached to the
pallet.
4.1.1 Unpacking and inspection on delivery
1. Unpack the pump/pump unit upon delivery and
inspect it for transport damage.
2. Report any transport damage to the manufacturer/
distributor immediately.
3. Retain the pallet if any further transport is required.
4. Dispose all packaging material according to local
regulations.
4.1.2 Lifting
Death or crushing of limbs can be caused by falling
loads!
1. Use lifting gear appropriate for the total weight to be
transported.
2. Fasten the lifting gear to the lifting eye as shown in the
following illustration.
3. Do not stand under suspended loads.
DANGER
Figure 3 Fastening lifting gear to pump unit
4.2 Treatment for storage
Unpainted steel surfaces should be coated with rust
inhibitor and the unit should be stored in a dry, dust
free environment not exceeding 60°C
Material damage due to inappropriate treatment for
storage!
u Treat all internal and external bare metal pump parts
for storage.
u Renew treatment if necessary.
4.3 Interim storage before installation
Material damage due to inappropriate storage!
Treat the pump with preservatives compatible with
pumped media (precaution in case of spillage).
1. Close all openings with blanks, plugs or plastic
covers.
2. Make sure the storage room meets the following
conditions:
– Dry, humidity not to exceed 80%
– Out of direct sunlight
– Frost-free; temperature range 0 to 40°C
– Vibration-free; minimize
– Dust-free; minimize
*Storage information for pumps withdrawn from use is listed in
section 8, Storing pumps and hoses.
NOTE
NOTE

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4.4 Disposal
With prolonged use, pump parts can get contaminated
by poisonous or radioactive pumped liquids to such an
extent that cleaning may be insufcient.
Risk of poisoning and environmental damage by the
pumped liquid or oil!
u Use suitable personal protective equipment when
carrying out any work on the pump.
u Prior to disposal of the pump:
– Drain and dispose the lubricant in accordance with
local regulations.
– Collect and dispose of any leaking pumped liquid or
oil in accordance with local regulations.
– Neutralize residues of pumped liquid in
the pump.
uDispose of the pump unit and associated parts in
accordance with statutory regulations.
5. Installation and connection
Material damage due to unauthorized modication
on pump unit!
uDo not make any structural modications to the pump
unit or pump casing
uDo not carry out any welding work on the pump unit or
pump casing
Material damage caused by ingress!
– Do not remove any protective ange covers until
immediately before connecting the pipes to the
pump
5.1 Preparing for installation
5.1.1 Checking the ambient conditions
1. Make sure that the operating conditions are complied
with (g 10.1.1 Pump specications)
2. Make sure the required ambient conditions are fullled
(g10.1.2 Ambient conditions)
5.1.2 Preparing the installation site
u Ensure the installation site meets the following
conditions:
– Pump is freely accessible from all sides
– Sufcient space is available for the installation/
removal of the pipes and for maintenance and
repair work, especially for the removal and
installation of the hose.
5.1.3 Preparing the foundation and surface
uMake sure the foundation and surface meet the
following conditions:
– Level
– Clean (no oil, dust or other impurities)
– Capable of bearing the weight of the pump unit and
all operating forces
– Ensure the pump is stable and cannot tip over
– Concrete foundation: Standard concrete strong
enough to support the pump unit under load.
5.2 Installation at site
1. Lift the pump unit (g4.1.2 Lifting)
2. Put the pump unit down at the installation site.
3. Bolt the pump down; use all 4 holes.
NOTE
NOTE
WARNING

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5.3 Planning the pipes
5.3.1 Specifyingsupportsandange
connections
1. When planning pipe runs take every possible
operating condition into account:
– Cold/warm medium
– Empty/full
– Unpressurized/pressurized
– Positional change of the anges
2. Ensure that the pipe supports are designed to
accommodate any movement from environmental
or pressure imposed forces.
5.3.2 Specifying nominal diameters
Keep the ow resistance in the pipes as low as possible.
Pipe work immediately connected to both inlet and
outlet port of the pump should be straight runs for at
least 1 meter.
Ensure that nominal pipe diameter is at least 1.5 times
nominal pump-hose diameter to reduce pulsation.
5.3.3 Specifying pipe lengths
1. Keep pipe work as short and direct as possible.
2. To allow easy access when changing hoses, include
a short, removable section adjacent to the port
anges.
5.3.4 Optimizingcross-sectionofpipework
1. Avoid bending radii of less than 10r (r - the radii of
nominal piping)
2. Avoid abrupt changes of cross-section along the
piping.
5.3.5 Providing safety and control devices
(recommended)
Making provisions for isolating and shutting off pipes
For maintenance and repair work.
uProvide shut-off valves in the suction and discharge
lines.
Allowingsaferemovalofproduct
uInclude drainage taps in suction and discharge lines
at the lowest point.
1. Short pipe run to
suction side
Long pipe run to suction
side
2. Reduced Joints/Bends Multiple Joints/Bends
4. Pulsation damper
connected close
to the pump
Pulsation Damper
Bellows
Pulsation damper
connected away from
pump
10% loss in damper efciency
for every meter
3. Connecting pipe with
diameter 1.5 times pump
hose diameter
Pipe ID 1.5 times hose ID
Connecting pipe with
smaller than pump hose
diameter
Pipe ID < pump hose ID
Table 4 Do’s and Don’ts
Do’s Don’ts

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5.4 Shimming
The pump must be shimmed for the required
discharge pressure (g10.1.7 Shimming).
Normally, shims are factory set and would not require
any user adjustment. But if and when required shims
can be adjusted with the following procedure.
1. Rotate the pump so that a rotor shoe is visible in the
window and then remove the window and gasket.
Leave the bolts on the window for reassembly.
2. Loosen the shoe bolt.
3. Remove any existing shims.
4. Replace with correct number of shims for the required
pressure (g10.1.7 Shimming).
5. Tighten the shoe bolt (g 10.1.3 Tightening torques).
6. Repeat with the other rotor shoe.
7. Ensure the lubricant level is correct.
8. Replace the window and gasket ensuring it is tted
the correct way with the bolts (g5.6.3 Fitting the
inspection window).
5.5 Electrical connection
Risk to health due to electric shock!
All electrical work must be carried out by qualied
electricians.
5.5.2 Installing motor gearbox on bare-shaft
pump
1. Lift motor and gearbox on a sling.
2. Apply anti seize grease to the gearbox shaft and motor
shaft.
3. Attach the gearbox to the bearing housing.
4. Align key to the key way.
5. Fit the eight M10 bolts.
6. Use a torque wrench to apply tightening torque
(g10.1.3 Tightening torques).
5.5.3 Connectingtopowersupply
1. Connect motor to the rated power supply. Ensure the
correct gland is used and that the earth connection
is made and secured.
2. Run the pump slowly to ensure correct rotation.
5.5.1 Installingmotorandgearbox(wherenot
supplied)
Death or crushing of limbs caused by falling loads!
uUse lifting gear appropriate for the total weight to
be transported.
uDo not stand under suspended loads
Figure 5 Installing motor gearbox
Figure 4 Shimming
DANGER
DANGER

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5.6 Installing the Hose
5.6.1 Inserting the hose
Fully lubricate the outer wall of the hose with
Verderlube / Verdersil to aid installation.
1. Add 1/2 a liter of lubricant to the pump housing
2. Insert one end of the hose into the mouth of the
suction port (the hose should be fed into the pump in
the direction of normal operation).
3. Once the hose reaches the rotor, the drive can be
inched forward slowly to feed in the remainder of the
hose into the pump housing.
4. Leave 45-50mm hose protruding out of the suction
port to t the clamp ring.
5. Slide on the clamp ring with tapered side facing away
from the pump; allow the hose to slightly protrude past
the clamp ring.
6. Fit the inner and outer ‘O’ rings to the port anges.
7. If using a solid port ange ensure the o ring is in place
in the face groove and push the ange into the hose.
8. For port anges with an insert, load the insert into the
port ange, then apply a small amount of lubricant to
the ange to aid tting. Using either the clamp tool
provided or two G clamps hold the insert in place
within the port ange. Fit the ange to the suction port
by holding on to the ange-insert unit, pushing it in
together.
9. Tighten the bolts in a 1-3-4-2 sequence, repeating the
sequence until each ange is evenly tted. All 4 bolts
should be tted to each ange to avoid compromising
the performance of the pump.
10. Run the pump forward and stop when the hose
protrudes from the other end by about 30mm.
11. Repeat the sequence for installing the ange
(refer points 1-6).
12. Fit the ¼ turn ange connector to both ports.
Figure 6 Inserting Hose
Figure 7 Inserting clamp ring
Figure 8 Port ange assembly & insert
Figure 9 Bolting down the ange

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5.6.2 Fillingthepumpwithlubricant
The safety data sheets for both Verderlube and
Verdersil are available from the manufacturer for
compatibility check.
• Provide a suitable container to collect spilt lubricant.
• Ensure compatibility of lubricant with the pumped
liquid.
• Fill the pump to the level where uid starts to come
through the lowest bolt hole of the inspection window
(g10.1.6 Lubricants).
1. Fit M6 cap head bolts with washers into the window.
The window is threaded to make bolts captive and
counter-bored on the back face.
2. Mount the gasket on to the bolts.
3. Mount the window unit, with the bolts and gasket, ove
the front cover, aligned as shown in g. 10
4. Nip the bolts down in sequence. Ensure that the bolts
are not over-tightened.
You can see the gasket pressing against the window
as the bolts clamping force takes effect.
5.6.3 Fittingtheinspectionwindow
5.7 Connecting the pipes
Contamination of pumped media due to impurities in
the pump!
uCare should be taken to avoid ingress of contaminants
into the pumped media.
1. Clean all piping parts and ttings prior to assembly.
2. Ensure that the ange seal do not protrude inwards
occluding the ow path.
3. Remove ange covers on both the suction and
discharge side prior to installation.
5.7.1 Installing the piping
1. Check all fasteners are tightened (g10.1.3 Tightening
torques)
2. Ensure that the 1/4 turn ange is correctly indexed.
3. Remove the transport and sealing covers from the
pump.
4. Before connecting any piping to the pump: Ensure
that the hose is properly secured by running the pump
dry for 10–20 revolutions in both the directions.
5. Run the pipes in a continuous upward or downward
slope to avoid air pockets
6. Connect the piping
Figure 10 Filling pump with lubricant
Figure 11 Mounting the inspection window
NOTE

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6.1 Pre-commissioning the pump
6.1.1 Checkingthedirectionofrotationwith
dry pump
1. Ensure the pump has lubricant in it
2. Switch the motor on and check the direction of
rotation; switch immediately off again.
3. If the direction of rotation is different: swap two of
the phases (*check with electrician)
6.1.2 Starting the pump
Pump set up and connected properly
Motor set up and connected properly
All connections stress-free and sealed
Pump housing lubricant level correct (g10.1.6
Lubricants).
 All safety equipment installed and tested for
functionality
Risk of injury and poisoning due to pumped liquid
spraying out!
u Use personal protective equipment when carrying out
any work on the pump.
Risk of injury and poisoning due to hazardous
pumped liquids!
u Safely collect any leaking pumped liquid and dispose
of it in accordance with environmental rules and
requirements.
Equipment damage due to excess pressure!
uDo not operate the pump with the discharge-side
tting closed.
u Operate the pump only inside the tolerances specied
by the manufacturer (g 10.1 Technical specications)
1. Close all drainage taps.
2. Open the suction-side and the discharge-side
ttings.
3. Switch on the motor and make sure it is running
smoothly.
4. Run the pump, ushing with water rst (cold
commissioning) to check for leaks.
DANGER
DANGER
6. Operation
5. Verify that neither the pump unit nor the pipe
connections are leaking.
6. Perform a second ush by running the pump, 10–20
revolutions with pumped liquid, to remove residue
and water inside the pump.
6.1.3 Switchingoff
Risk of dead heading and hose burst due to closed
suction or discharge!
u Keep the suction and discharge side ttings opened
till the rotor has come to a complete stop.
Risk of injury due to hot pump parts!
u Use personal protective equipment when carrying
out any work on the pump.
Equipment damage due to sediments!
u If the pumped liquid crystallizes, polymerizes or
solidies:
– Flush pump
– Make sure that the ushing liquid is compatible
with the pumped liquid.
1. If necessary: Flush and empty the pump.
2. Switch off power to the motor.
3. Close the discharge side tting.
4. Check all tie bolts and tighten them if necessary (only
after putting the pump into service for the rst time).
WARNING
NOTE
NOTE
WARNING

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Pump is Measure
shut down uTake measures according to the
pumped liquid (gTable 6
Measures depending on the
behaviour of the pumped liquid).
...dismounted u Isolate the motor from its power
supply and secure it against
unauthorized switch-on.
...put into
storage
u Follow the storage instructions
(g8 Storage).
16 | Page
6.2 Operation
6.2.1 Switchingon
Pump pre-commissioned (g6.1)
Pump prepared and lled
Risk of injury due to running pump!
uDo not touch the moving parts of a running pump.
uDo not carry out any repair/ maintenance work on the
running pump.
u Allow the pump to cool down completely before
starting any work on the unit.
Risk of injury and poisoning due to pumped liquid
spraying out!
u Use personal protective equipment when carrying
out any work on the pump.
Risk of pulsation when throttling down the suction
owrate!
u Fully open the suction-side tting and DO NOT use
it to adjust the ow as this could damage the hose.
1. Open the suction-side and the discharge-side
ttings.
2. Switch on the motor and make sure it is running
smoothly.
6.2.2 Switchingoff(Referto g6.1.3)
Risk of injury due to hot pump parts!
u Use personal protective equipment when carrying out
any work on the pump.
Damage to hose due to sediments!
u If the pumped liquid crystallizes, polymerizes or
solidies
– Flush the hose
– Make sure that the ushing liquid is compatible
with the pumped liquid.
DANGER
6.3Shuttingdownthepump
uTake the following measures whenever the pump is
shut down:
NOTE
Table 5 Measures to be taken if the pump is shut down
NOTE
DANGER
WARNING
Behaviour of
the pumped
liquid
Durationofshutdown(depending
on process)
Short Long
crystallized or
polymerized,
Solids
sedimenting
uFlush the
pump.
uFlush the
pump,
remove the
hose.
Solidifying
non-corrosive
uHeat up or
empty the
pump
uEmpty the
pump
Solidifying
corrosive
uHeat up or
empty the
pump
uEmpty the
pump.
uTreat the
pump with
preservative.
Liquid,
non-corrosive
- -
Liquid,
corrosive
uEmpty the
pump
uEmpty the
pump.
uTreat the
pump with
preservative.
Table 6 Measures depending on the behaviour of the
pumped liquid

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6.4Start-upfollowingashutdown
period
1. After a prolonged shutdown period, re-commission
the pump as follows:
– Replace the seals.
– Install or change hose (g7.4 Hose change).
2. Carry out all steps as for the initial start-up
(g6.1 Pre-commissioning the pump).
6.5 Operating the stand-by pump
Stand-by pump is lled with lubricant (g5.6.2 Filling
the pump with lubricant)
u Operate the stand-by pump at least once a week to
avoid formation of permanent dents/setting on the hose.
7. Maintenance
Only trained service technicians should be employed
for tting and repair work. Present a pumped medium
certicate (DIN safety data sheet or safety certicate)
when requesting service.
Risk of injury due to running pump or hot parts!
uDo not carry out any repair/maintenance work on
a pump in operation.
u Allow the pump to cool down completely before
starting any repair work.
Risk of injury due to pressure buildup!
u Do not carry out any repairs/maintainence work on a
pump in operation
u Do not block the breather tube which is designed for
pressure relief
u In the unlikely event of a hose burst which leads to
blockage of the breather tube - safely relieve the presure
inside the casin before dissembling the pump
Risk of injury and poisoning due to hazardous
pumped liquids!
u Use protective equipment when carrying out any
work on the pump.
DANGER
DANGER
7.1 Inspections
The inspection intervals depend on the pump
operating cycle.
1. Check at appropriate intervals:
– Normal operating conditions unchanged
2. For trouble-free operation, always check the
following:
– Lubricant level
– No leaks
– No unusual running noises or vibrations
– Hose in position
7.2 Maintenance
These pumps are generally maintenance free and any
work should normally be limited to inspections and
pump lubricant changes as required; these may be
more frequent in dust and/or hot condition.
Risk of electrocution!
u Have all electrical work carried out only by qualied
electricians.
7.2.1 Cleaning the pump
High water pressure or spray water can damage
motors!
uDo not clean motors with water or steam jet.
1. Clean large-scale grime from the pump.
2. Rinse the hose carefully to remove chemicals
(follow the cleaning protocol as listed in g8.1.2
Cleaning protocol for hoses).
NOTE
WARNING
DANGER

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7.2.2 Maintenance schedule
Table 7 Maintenance schedule
Task Frequency Action
Check pump and gearbox for leaks and
damage
– Before pump start up
– Daily visual inspection
– Scheduled intervals during
operation
uRepair leaks and damage before
operating the pump
u Replace components as necessary.
uClean up any spillage.
Check pump housing lubrication level – Before pump start up
– Daily visual inspection
– Scheduled intervals during
operation
uMake sure that lubricant level is
visibleintheinspectionwindow
betweenthelowersillandtherst
pair of bolts.
uDo not operate the pump if the level
is too low or too high. Rell lubricant
as required (g5.6.2 Filling the
pump with lubricant)
Check geared motor unit lubrication
level
– Before pump start up
– Daily visual inspection
– Scheduled intervals during
operation
ugMotor instruction manual.
Check pump for unusual temperatures
or noise in operation
– Daily visual inspection
– Scheduled intervals during
operation
u Check pump, gearbox and bearing
housing for damage.
u Replace worn components.
Replace pump housing lubricant – At every hose change or every six
months
– Afterinspectionwhenrequired
u Rell lubricant (g5.6.2 Filling the
pump with lubricant)
Replace hose – After inspection when required
– When ow has dropped by 25% of
nominal value
– When the hose is burst/damaged
u Replace hose (g7.4 Hose change)
uReplace ange sealing kit
Check pump housing, rotor, rotor shoes
and inserts internally
– Annually
– On replacing the hose
Worn and damaged surfaces give rise to
premature hose failure
u Replace worn components.
uCheck bearing play and function.
Replace bearing housing – After 30,000 running hours
– When damage is suspected
uCheck bearing play and function.
Replace bearing housing seal – When damage is suspected
– When leak is detected
u Replace worn components.

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7.3 Repairs
Risk of death due to electric shock!
u Have all electrical work carried out by qualied
electrician only
Risk of injury due to heavy components!
u Pay attention to the component weight. Lift and
transport heavy components using suitable lifting
gear.
u Set down components safely and secure them against
overturning or rolling away.
7.3.1 Preparations for dismounting
Safely release any pressure build up in the pump
housing. (There may be signicant built up of pressure
in the discharge line or possible suction side
vacuum).
Pump completely emptied, ushed and
decontaminated
Electrical connections disconnected and motor locked
out against being switched on again
Pump cooled down
Auxiliary systems shut down, depressurized and
emptied
Before dismounting the pump, mark the precise
orientation and position of all components before
dismounting them.
Riskofinjurywhiledismountingthepump!
u Use protective equipment when carrying out any work
on the pump.
Observe manufacturer’s instructions (e.g. for Motor,
coupling, gearbox).
DANGER
7.3.2 Returning the pump to the manufacturer
Pump unpressurized
Completely emptied and decontaminated.
Pump cooled down
Hose dismounted (g7.4.1 Dismounting the hose)
Obtainpriorauthorizationbeforerepairorreturnof
the pump.
u Enclose a completed document of compliance when
returning pumps or components to the manufacturer
WARNING
Table 8 Measures for return
WARNING
Repairs Measure for return
...at the customer’s premises – Return the defective
component to the
manufacturer.
– Decontaminate if
necessary.
...at the manufacturer’s
premises
– Flush the pump and
decontaminate it if it
was used for hazardous
pumped liquids.
...at the manufacturer’s
premises for warranty
repairs
– Only in the event of
hazardous pumped
liquid, ush and
decontaminate the pump

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7.3.3 Rebuild / Repair
Reinstall the components, in accordance with the
marks applied.
Material damage due to unsuitable components!
u Always replace lost or damaged bolts with bolts of the
same strength and material.
1. Observe the following during the installation:
– Replace worn parts with genuine spare parts.
– Maintain the prescribed tightening torques
(g 10.1.3 Tightening torques)
2. Clean all parts (g10.1.5 Cleaning agents). Do not
remove any markings which have been applied.
3. Reassemble the pump (g refer sectional drawing).
4. Install the pump in the system (g5 Installation and
connection)
7.3.4 Re-alignment of Rotor after a stall
The rotor is attached to the drive shaft with a friction
coupling, the intent of which is to permit the rotor to
slip in the event of the pump sucking a large solid object
through the inlet. The general effect of such an event is
that the friction coupling absorbs the initial inertia
permitting the motor to overrun before stalling. This
protects the motor, drive shaft and rotor from failure.
On the Dura 55, an index marking has been provided
which will be matched to a mark on the end of the drive
shaft to show relative positions at assembly. If the
pump has been stalled at any time then the positions
of these marks should be checked and if not matched
the rotor should be removed and the condition of the
friction joint assessed and replaced as required.
u In the event of a rotor stall, induced by external forces;
such as large solids in the hose, the taper joint xing
the rotor to the shaft may need re-setting. To do this:
1. Drain the pump of lubricant, remove the front
cover
2. Slacken each of the clamp bolts
3. Re-torque. The torquing should be done in stages
checking each bolt in turn until no further
movement occurs.
7.4 Hose change
Risk of injury!
u Always isolate the power supply before working on
the pump.
The hose change involves removal and re-installing
the port anges.
7.4.1 Dismounting the hose
uDraining lubricant
Motor isolated.
System secured against being switched back on
again.
Sliphazardduetospiltlubricant!
u Care must be taken when lubricant is drained into
a container.
u Dispose of used lubricant in accordance with local
laws and good environmental practices.
1. Remove the drain plug at the rear of the pump.
2. Drain the lubricant into a suitable container.
3. Remove the lower ange and allow any excess
lubricant to drain out.
uRemoving the hose
Risk of injury if the hose is expelled too quickly
u Slowly remove the hose by running the motor at
a reduced speed
1. Remove both the anges.
2. Use the motor to drive out the old hose. If no power
is available, remove the fan cover and turn the fan
shaft by hand or using suitable leverage.
3. Clean the pump housing.
4. Inspect the anges for damage and signs of wear.
7.4.2 Re-installing the hose, port anges,
  lubricant rell and tting the inspection
  window
- Follow step by step, the instructions listed in section
g5.6 (Installing the hose)
WARNING
NOTE
WARNING
CAUTION