Watson-Marlow Bredel 265 User manual

1
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:
The disc also contains quick-reference instructions for the replacement of the pump
hose. This replacement instruction is only for users that are familiar with the
replacement procedures in the user manual.
How to use the disc
1 Put the disc in the disc drive.
2 Close the disc drive.
The disc will start automatically.
3 Wait until the various language versions appear on screen.
4 Select the required language (click 1x with the left mouse button).
The PDF reader program will automatically start and the required user manual
appears on screen.
Shortcuts
In the left margin you will find the various chapters and paragraphs. These can be
accessed directly by clicking on the required chapter or paragraph.
In the text you will find hyperlinks to chapters or paragraphs. These hyperlinks are linked
with the required chapters or paragraphs. By clicking a shortcut the required chapter or
paragraph appears on screen.
System requirements
The program on the disc requires a PC with the following minimum system
requirements:
•Disc drive
The following software must be installed on the PC:
•PDF reader program
•an Internet browser
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3
Hose pump series
Bredel 265, Bredel 280 and Bredel 2100
Manual
Hose Pumps
TYPE EL - CLASS I
AUGUST 2012
Environmental
Management
ISO
14001
Quality
Management
ISO
9001

4
© 2013 Watson-Marlow Bredel B.V.
All rights reserved.
The information provided herein may not be reproduced and/or published in any form,
by print, photoprint, microfilm or any other means whatsoever (electronically or
mechanically) without the prior written authorisation of Watson-Marlow Bredel B.V.
The information provided can be changed without prior notification. Watson-Marlow
Bredel B.V. or one of its representatives cannot be held liable for possible damage
resulting from use of this manual. This is an extensive limitation of the liability which
applies to all damage, inclusive of (without limitation) compensating, direct , indirect or
consequential damage, loss of data, income or profit, loss or damage to possessions
and claims of third parties.
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.
Watson-Marlow Bredel B.V. rejects all responsibilities and guarantees. Furthermore,
Watson-Marlow Bredel B.V. does not take responsibility for and does not guarantee that
the information in this manual is accurate, complete or up to date.
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.

5
CONTENTS
1GENERAL
1.1 How to use this manual .......................................................................... 8
1.2 Original instructions ................................................................................ 8
1.3 Other supplied documentation ................................................................ 8
1.4 Service and support ................................................................................ 8
1.5 Environment and disposal of waste ........................................................ 9
2SAFETY
2.1 Symbols ................................................................................................ 10
2.2 Intended use ......................................................................................... 10
2.3 Responsibility ........................................................................................ 11
2.4 Qualification of the user ........................................................................ 11
2.5 Regulations and instructions ................................................................. 12
3 WARRANTY CONDITIONS
4 DESCRIPTION
4.1 Identification of the product ................................................................... 14
4.1.1 Identification of the product ....................................................... 14
4.1.2 Identification of the pump .......................................................... 14
4.1.3 Identification of the gearbox ...................................................... 14
4.1.4 Identification of the electric motor .............................................. 15
4.1.5 Identification of the pump hose ................................................. 15
4.2 Construction of the pump ...................................................................... 16
4.3 Operation of the pump .......................................................................... 16
4.4 Pump hose ............................................................................................ 18
4.4.1 General ...................................................................................... 18
4.4.2 Hose compression force adjustment (shimming) ...................... 20
4.4.3 Lubrication and cooling ............................................................. 20
4.5 Gearbox ................................................................................................ 20
4.5.1 General ...................................................................................... 20
4.5.2 Maintenance .............................................................................. 21
4.6 Electric motor ........................................................................................ 21
4.7 Available options ................................................................................... 22
5 INSTALLATION
5.1 Unpacking ............................................................................................. 23
5.2 Inspection ............................................................................................. 23

6
5.3 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
5.4 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 ............................................................... 29
5.5 Placing the pump .................................................................................. 30
6 COMMISSIONING
6.1 Preparations ......................................................................................... 32
6.2 Commissioning ..................................................................................... 33
7 OPERATION
7.1 Temperature ......................................................................................... 34
7.2 Power rating ......................................................................................... 34
7.3 Dry running ........................................................................................... 37
7.4 Hose failure .......................................................................................... 37
7.5 Fluid leakage ........................................................................................ 38
8 MAINTENANCE
8.1 General ................................................................................................. 40
8.2 Maintenance and periodic inspections ................................................. 41
8.3 Cleaning the pump hose ...................................................................... 43
8.4 Changing lubricant ............................................................................... 43
8.5 Changing oil in gearbox ........................................................................ 44
8.6 Replacing pump hose ........................................................................... 44
8.6.1 Removing pump hose ............................................................... 44
8.6.2 Cleaning the pump head ........................................................... 47
8.6.3 Fitting the pump hose ................................................................ 48
8.7 Exchanging replacement parts ............................................................. 51
8.7.1 General ..................................................................................... 51
8.7.2 Replacing pressing shoes ......................................................... 51
8.7.3 Replacing seal and wear ring .................................................... 53
8.7.4 Replacing bearings ................................................................... 57
8.8 Adjusting hose compression force (shimming) ..................................... 58
8.9 Fitting options ....................................................................................... 61
8.9.1 Fitting a high-level float switch .................................................. 61

7
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
9 STORAGE
9.1 Hose pump ........................................................................................... 68
9.2 Pump hose ............................................................................................ 68
9.3 Electric motor and gearbox ................................................................... 69
10 TROUBLESHOOTING
11 SPECIFICATIONS
11.1 Pumphead ............................................................................................ 75
11.1.1 Performance .............................................................................. 75
11.1.2 Materials .................................................................................... 76
11.1.3 Surface treatment ...................................................................... 77
11.1.4 Lubricant table pump ................................................................. 77
11.1.5 Weights ..................................................................................... 78
11.1.6 Torque figures ........................................................................... 79
11.1.7 Shims specifications .................................................................. 80
11.2 Lubricant for gearbox ............................................................................ 81
11.3 Parts list ................................................................................................ 81
11.3.1 Overview complete unit ............................................................. 81
11.3.2 Overview pump head ................................................................ 82
11.3.3 Cover assembly ......................................................................... 83
11.3.4 Rotor assembly ......................................................................... 84
11.3.5 Pump housing assembly ........................................................... 85
11.3.6 Flange assembly ....................................................................... 86
11.3.7 Lubricants per pumphead .......................................................... 87
11.3.8 Adaption assembly .................................................................... 88
11.3.9 Frame assembly ........................................................................ 90
11.3.10Shaft assembly ......................................................................... 92
11.3.11Revolution counter assembly .................................................... 93
SAFETY FORM
NOTES

GENERAL
8
1GENERAL
1.1 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.
1.2 Original instructions
The original instructions for this manual have been
written in English. Other language versions of this
manual are a translation of the original instructions.
1.3 Other supplied documentation
Documentation of components such as motors,
gearboxes and inverters is normally not included in this
manual. However, if additional documentation is
supplied, you must follow the instructions in this
additional documentation.
1.4 Service and support
For information with respect to specific adjustments,
installation, maintenance or repair jobs which fall
beyond the scope of this manual, contact your Bredel
representative. Make sure you have the following data
at hand:
•Serial number hose pump
•Article number pump hose
•Article number gearbox
•Article number electric motor
•Article number frequency controller
You will find these data on the identification plates or
stickers of the pumphead, the pump hose, the gearbox
and the electric motor. See § 4.1.1.

GENERAL
9
1.5 Environment and disposal of waste
Inquire within your local government about the
possibilities for reuse or environment-friendly
processing of packaging materials, (contaminated)
lubricant and oil.
CAUTION
Always observe the local rules and regula-
tions with respect to processing (non reus-
able) parts of the hose pump.

SAFETY
10
2SAFETY
2.1 Symbols
In this manual the following symbols are used:
2.2 Intended use
The hose pump is exclusively designed for pumping
suitable products. Every other or further use is not in
conformance with the intended use.
The "Intended use" as laid down in EN 292-1 is "… the
use for which the technical product is intended in
accordance with the specifications of the manufacturer,
inclusive of his indications in the sales brochure". In
case of doubt it is the use which appears to be its
intended use judging from the construction, execution
and function of the product. Observing the instructions
in the user’s documentation also belongs to intended
use.
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.
Remarks, suggestions and advice.

SAFETY
11
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.
2.3 Responsibility
The manufacturer does not accept any responsibility for
damage or harm caused by not (strictly) observing the
safety regulations and instructions in this manual and
the also supplied documentation, or by negligence
during installation, use, maintenance and repair of the
hose pumps mentioned on the front cover. Depending
on the specific working conditions or accessories used,
additional safety instructions can be required.
Immediately contact your Bredel representative, if you
noticed a potential danger while using your hose pump.
2.4 Qualification of the user
The installation, use and maintenance of the hose
pump should only be performed by well-trained and
qualified users. Temporary staff and persons in training
may use the hose pump only under the supervision and
responsibility of trained and qualified users.
WARNING
The user of the hose pump is always fully
responsible for observing the local valid
safety regulations and directives. Observe
these safety regulations and directives
when using the hose pump.

SAFETY
12
2.5 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.
•Always store the manual and the manuals of the
gearbox and the electric motor near the hose
pump.

WARRANTY CONDITIONS
13
3 WARRANTY CONDITIONS
The manufacturer offers a two-year warranty on all
parts of the hose pump. This means that all parts will be
repaired or replaced free of charge, with the exception
of consumables such as pump hoses, hose clamps, ball
bearings, wear rings, seals and rubber bushes, or parts
which have been used wrongly, misused, whether or
not they have been intentionally damaged. 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
warranty conditions can be returned to the
manufacturer. The parts must be accompanied by a
fully filled in and signed safety form, as present in the
back of this manual. The safety form must be applied to
the outside of the shipping carton. Parts which have
been contaminated or which have been corroded by
chemicals or other substances which can pose a health
risk must be cleaned before they are returned to the
manufacturer. Furthermore, it should be indicated on
the safety form which specific cleaning procedure has
been followed, and that the equipment has been
decontaminated. The safety form is required even if the
parts have not been used.
Warranties purporting to be on behalf of Bredel B.V.
made by any person, including representatives of
Bredel B.V., its subsidiaries, or its distributors, which do
not accord with the terms of this warranty shall not be
binding upon Bredel B.V. unless expressly approved in
writing by a Director or Manager of Bredel B.V.

DESCRIPTION
14
4 DESCRIPTION
4.1 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:
A: Pumphead
B: Gearbox
C: Electric motor
D: Pump hose
E: Frame
4.1.2 Identification of the pump
The identification plate on the pump head contains the
following data:
A: Pump model
B: Serial number
4.1.3 Identification of the gearbox
The identification plate on the gearbox contains the
following data:
A: Type number
B: Batch number
C: Motor power
D: Gear motor output speed
E: Gear reducer nominal power
F: Two months and year of manufacture
G: Mounting position
H: Gear motor service factor
J: Transmission ratio
K: Diameter Flange - motor shaft
Hose Pumps
A
D
B
C
E
BA
Rossi
1423382
a company of the Habasit Group
www.rossi-group.com Made in Italy
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min
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
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A F GB C D
J H

DESCRIPTION
15
4.1.4 Identification of the electric motor
The identification plate on the electric motor contains
the following data:
A: Serial number
B: Type number
C: Power
D: Voltage
E: Frequency
F: Pole no./Speed
G: Insulation class
H: Rise in temperature
I: Bredel article or order number
4.1.5 Identification of the pump hose
The identification sticker on the pump hose contains the
following data:
A: Pump type
B: Reorder number
C: Internal diameter
D: Type of material of inner liner
E: Remarks, if applicable
F: Maximum permissible working pressure
G: Production code
As. mot.
HP
No.
V
cosjIsol.
Hz.
min A
-1
R
FIG H
B A E
DC
A
B
C
D
E
F
G
High precision pump
element machined for

DESCRIPTION
16
4.2 Construction of the pump
A: Pump hose
B: Pump housing
C: Rotor
D: Pressing shoes
E: Cover
F: Inspection window
G: Frame
H: Gearbox
I: Electric motor
4.3 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). Both ends of the
hose are connected to the suction and discharge lines
E
D
A
FC
B
I
H
G
B

DESCRIPTION
17
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. As soon as the
pressing shoe has passed, the hose recovers to its
original shape due to the mechanical properties of the
material.
In phase 2 the product is drawn into the hose by the
(continuous) turning motion of the rotor.
In phase 3, the second pressing shoe will subsequently
compress the pump hose. Due to the continuous
rotating movement of the rotor not only new product is
sucked in, but also the already present product is
pressed out by the pressing shoe. When the first
pressing shoe runs from the pump hose, the second
pressing shoe has already closed the pump hose and
the product is prevented from flowing back. This
method of liquid displacement is also known as the
"positive displacement principle".
D E CBA

DESCRIPTION
18
4.4 Pump hose
4.4.1 General
The pump hose is made of special rubbers, reinforced
with nylon cords and is constructed as follows:
A: Outer extruded layer made of natural rubber
B: Four nylon reinforcement layers
C: Inner extruded liner
The pump hose liner material should be chemically
resistant with the product to be pumped. Dependent on
the specific requirements of your application a
corresponding pump hose must be selected. For each
pump model various hose types are available.
The material of the inner liner of the pump hose
determines the hose type. Each hose type is marked by
a unique color code.
Natural Rubber*
Always the first choice hose. A highly dynamic material,
which has excellent abrasion resistance and
mechanical strength, and is generally resistant to
diluted acids and alcohols.
Max. liquid temperature 80 °C (175 °F).
Min. temperature -20 °C (-5 °F).
Nitrile rubber*
A highly abrasion proof and wear resistant material that
is generally resistant to oils, fats, alkaline, and
detergents. Suitable for a wide range of food handling
and meets FDA and 3A standards.
Max. liquid temperature 80 °C (175 °F).
Min. temperature -10 °C (15 °F).
B C
A
Hose type Material Color code
NR Natural rubber Purple
NBR Nitrile rubber Yellow
EPDM EPDM Red
CSM CSM Blue

DESCRIPTION
19
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.
CSM*
Good chemical resistance for strong oxidizing products
like concentrated acids and oxygen generating
substances.
Max. liquid temperature 80 °C (175 °F).
Min. temperature -10 °C (15 °F)
Consult Bredel technical services for RPM limitations
when using CSM.
The Bredel pump hoses have been carefully machined,
therefore there are minimum tolerances in wall
thickness. This is very important to guarantee the
correct compression of the pump hose, because:
•When the compression is too high, it creates a
load on the pump and pump hose that is too
high, which may result in a reduction of the life
of the pump hose and bearings.
•When the compression is too low this will result
in high velocity backflow (slip). Backflow results
in a reduction of pump performance, hydraulic
efficiency, and negatively impact the life of the
pump hose.
* Consult your Bredel representative for
more detailed information about the chemi-
cal and temperature resistance of pump
hoses.

DESCRIPTION
20
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). The number of shims will vary for
each discharge pressure situation.
The paragraph 8.8 describes how to select and install
the shims.
4.4.3 Lubrication and cooling
The pump head, in which the rotor and pump hose can
be found, is filled with Bredel Genuine Hose Lubricant.
This lubricant lubricates the movement between the
hose and the pressing shoes and dissipates the
generated heat via the pump housing and the cover.
The lubricant is food grade. See § 11.1.4 for the
required quantity and NSF registration.
4.5 Gearbox
4.5.1 General
The hose pump types described in this manual use a
bevel-helical gearbox. The gearbox is mainly used for
high reduction ratios and low input speeds. This
modular construction enables a wide range of
reductions, torques and connection possibilities for the
electric motor.
A
B
C
Consult your Bredel representative for
lubrication recommendations when operat-
ing the hose pump below 2 rpm.