Peristaltic Hose Pump

Transcription

1 Peristaltic Hose Pmp Operating Manal Dra 55 Version Print-No v-07/2016

2 Version 2.2v-07/2016 Print-No. 01 Dra 55 The information in this docment is essential for the safe operation and servicing of Verderflex Dra 55 pmps. This docment mst be read and nderstood thoroghly prior to installation of nit, electrical connection and commissioning. Dra 55 Version 2.2v-07/ Page

3 Table of contents 1. Abot this docment 1.1 Target grops 1.2 Warnings and symbols 2. Safety 2.1 Intended se 2.2 General safety instrctions Prodct safety Obligation of the operating company Obligation of personnel 2.3 Specific hazards Hazardos pmped liqids Lbricants Sharp edges 3. Layot and fnction 3.1 Design details 3.2 Labelling Name Plate 3.3 Layot 3.4 Bearings and Lbrication 4. Transport, storage and disposal 4.1 Transport Unpacking and inspection on delivery Lifting 4.2 Treatment for storage 4.3 Interim storage before installation 4.4 Disposal 5. Installation and connection 5.1 Preparing for installation Checking the ambient conditions Preparing the installation site Preparing the fondation and srface 5.2 Installation at site 5.3 Planning the pipes Specifying spports and flange connections Specifying nominal diameters Specifying pipe lengths Optimizing cross-section of pipe work Providing safety and control devices (recommended) 5.4 Shimming 5.5 Electrical connection Installing motor and gearbox (where not spplied) Installing motor gearbox on bare-shaft pmp Connecting to power spply 5.6 Installing the Hose Inserting the hose Filling the pmp with lbricant Fitting the inspection window 5.7 Connecting the pipes Installing the piping 6. Operation 6.1 Pre-commissioning the pmp Checking the direction of rotation with dry pmp Starting the pmp Switching off 6.2 Operation Switching on Switching off (Refer to -> 6.1.3) 6.3 Shtting down the pmp 6.4 Start-p following a shtdown period 6.5 Operating the stand-by pmp 7. Maintenance 7.1 Inspections 7.2 Maintenance Cleaning the pmp Maintenance schedle 7.3 Repairs Preparations for dismonting Retrning the pmp to the manfactrer Rebild / Repair Re-alignment of Rotor after a stall 7.4 Hose change Dismonting the hose Re-installing the hose, port flanges, lbricant refill and fitting the inspection window 7.5 Ordering spare parts 8. Storing pmps and hoses Pre-Storage Actions Cleaning Protocol for hoses Storage Conditions 9. Trobleshooting 9.1 Pmp malfnctions 10. Appendix 10.1 Technical Specifications Pmp Specifications Ambient conditions Tightening torqes Preservatives Cleaning agents (After hose is removed) Lbricants Shimming Rotor setting distance 11. List of Figres and Tables 11.1 List of figres 11.2 List of tables 12. Declaration of conformity according to EC Machine Directive Dra 55 Version 2.2v-07/ Page

4 1. Abot this docment Verderflex Peristaltic pmp, Dra 55, has been developed according to the latest technology and sbject to continos qality control. These operating instrctions are intended to facilitate familiarization with the pmp and its designated se. The relevant information will act as a gideline for yo in operating the pmp; alternative corses of action are also described shold yo be nable, for any reason, to follow those procedres initially given. Yo are advised to follow these gidelines to achieve maximm efficiency. These operating instrctions Do not take into accont local reglations; the operator mst ensre that sch reglations are strictly observed by all, inclding the personnel called in for installation. 1.1 Target grops Target grops Table 1 Target grops and their dties Dty Operating company Keep this manal available at the operation site of the eqipment, also available for later reference. Ensre that personnel read and follow the instrctions in this manal and the other applicable docments, especially all safety instrctions and warnings. Observe any additional rles and reglations referring to the system. Qalified personnel, fitter Read, observe and follow this manal and the other applicable docments, especially all safety instrctions and warnings. 1.2 Warnings and symbols Warning Risk Level Conseqences of disregard DANGER WARNING CAUTION NOTE Immediate acte risk Potential acte risk Potential hazardos sitation Potential hazardos sitation Death, serios bodily harm Death, serios bodily harm Minor bodily harm Material damage Table 2 Warnings and conseqences of disregarding them Symbol Meaning Safety warning sign in accordance with DIN W9 Take note of all information highlighted by the safety warning sign and follow the instrctions to avoid injry or death. Instrction 1., 2., Mltiple-step instrctions Precondition g Cross-reference Information, recommendation Table 3 Symbols and their meaning Dra 55 Version 2.2v-07/ Page

5 2. Safety The manfactrer does not accept any liability for damage reslting from disregard of this docmentation. 2.1 Intended se Only se the pmp to handle compatible flids as recommended by the manfactrer (g 10.1 Technical specifications). Adhere to the operating limits. Conslt the manfactrer regarding any other se of the pmp. Pmps delivered withot a motor mst be fitted with a motor in accordance with the provisions of EC Machine Directive 2006/42/EC. Prevention of obvios misse (examples) Note the operating limits of the pmp with regard to temperatre, pressre, flow rate and motor speed (g 10.1 Technical specifications). Do not operate the pmp while the inlet/otlet valve is closed. Only install the pmp as recommended in this manal. For example, the following are not allowed: Installing the pmp withot proper spport. Installation in the immediate vicinity of extreme hot or cold sorces. 2.2 General safety instrctions Observe the following reglations before carrying ot any work. Only se the pmping system as intended, flly aware of safety and risk factors involved, and in adherence to the instrctions in this manal. Keep this manal and all other applicable docments complete, legible and accessible to personnel at all times. Refrain from any procedre or action that wold pose a risk to personnel or third parties. In the event of any safety-relevant falts, sht down the pmp immediately and have the malfnction corrected by qalified personnel. The installation of the pmp, associated pipe work and electrical fittings mst comply with the reqirements of installation given in this manal and any local national or regional health and safety reglations Obligation of the operating company Safety-conscios operation Ensre that the following safety aspects are observed and monitored: Adherence to intended se Stattory or other safety and accident-prevention reglations Safety reglations governing the handling of hazardos sbstances if applicable Applicable standards and gidelines in the contry where the pmp is operated Make personal protective eqipment available pertinent to operation of the pmp; as reqired Prodct safety These operating instrctions contain fndamental information which mst be complied with dring installation, operation and maintenance. Therefore this operating manal mst be read and nderstood both by the installing personnel and the responsible trained personnel / operators prior to installation and commissioning, and it mst always be kept easily accessible within the operating premises of the machine. Not only mst the general safety instrctions laid down in this chapter on Safety be complied with, bt also the safety instrctions otlined nder specific headings. Operate the pmp only if the pmping nit and all associated systems are in good fnctional condition. Dra 55 Version 2.2v-07/ Page

6 Qalified personnel Ensre that all personnel tasked with work on the pmp have read and nderstood this manal and all other applicable docments, inclding the safety, maintenance and repair information, prior to se or installation of the pmp. Organize responsibilties, areas of competence and the spervision of personnel. Have all work carried ot by specialist technicians only. Ensre that trainee personnel are nder the spervision of specialist technicians, at all times, when working on the pmping system. Safety eqipment Provide the following safety eqipment and verify its fnctionality: For hot, cold and moving parts: safety garding shold be provided by the operating company. For potential bild p of electrostatic charge: ensre appropriate gronding if and when reqired. Warranty The warranty is voided if the cstomer fails to follow any and all instrctions, warnings and cations in this docment. Verder has made every effort to illstrate and describe the prodct(s) in this docment. Sch illstrations and descriptions are, however, for the sole prpose of identification and Do not express or imply a warranty that the prodcts are merchantable or fit for a particlar prpose, or that the prodcts will necessarily conform to the illstration or descriptions. Do not se them as a fixing point for winches or spports Do not de-ice sing gas brners or similar tools Do not remove the safety garding for hot, cold or moving parts dring operation. Reinstall the safety eqipment on the pmp as reqired by reglations after any repair / maintenance work on the pmp. 2.3 Specific hazards Hazardos pmped liqids Follow the stattory safety reglations when handling hazardos pmped liqids (e.g. hot, flammable, poisonos or potentially harmfl). Use appropriate personal protective eqipment when carrying ot any work on the pmp Lbricants Ensre that the lbricant and pmped liqid are compatible with each other. This is a precationary measre in case of accidental hose brst whereby the pmped liqid comes in contact with the lbricant. (Refer datasheet for lbricant to ensre compatibility) Sharp edges Pmp parts, sch as the shims, can be sharp Use protective gloves when carrying ot any work on the pmp Obtain the manfactrer s approval prior to carrying ot any modifications, repairs or alterations dring the warranty period. Only se genine parts or parts that have been approved by the manfactrer. For frther details regarding warranty, please refer terms and conditions Obligation of personnel It is imperative that the instrctions contained in this manal are complied with by the operating personnel at all times. Pmp and associated components: Do not lean or step on them or se as climbing aid Do not se them to spport boards, ramps or beams Dra 55 Version 2.2v-07/ Page

7 3. Layot and fnction Peristaltic hose pmp, Verderflex Dra, is simple by design in its constrction and operation. The medim to be pmped does not come into contact with any moving parts and is totally contained within a robst, heavy-dty hose, which consists of an inner layer, two six reinforcement layers and an oter 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 natral elasticity of the polymer reinforced rbber forces the hose to open and regain its rond profile, creating sction pressre, which recharges the pmp. 3.1 Design details Verderflex Dra is a twin lobe, single rotor, peristaltic pmp with qick-fit tapered port flange design which clamps and seals in one easy movement to speed hose replacement. 3.2 Labelling Name Plate Figre 1 Name plate 1. Pmp type 2. Serial nmber 3. Year of manfactre Note: When reqesting spares, the model and serial nmber shold always be qoted. Dra 55 Version 2.2v-07/ Page

8 3.3 Layot Figre 2 Layot 1 Inspection window 6 Shims 11 Pmp casing 2 Inspection window gasket 7 Rotor shoe 12 Clamp ring 3 Front cover 8 Rotor 13 Port flange 4 Front cover o-ring 9 Hose 14 ¼ trn flange 5 Slip bsh 10 Bearing hosing 15 Monting frame 3.4 Bearings and Lbrication Pmp: To be filled at installation with appropriate lbricant if not spplied pre filled. (g Lbricants) Bearings are sealed nits and need no additional lbricant. Dra 55 Version 2.2v-07/ Page

9 4. Transport, storage and disposal 4.1 Transport Always transport the nit in an pright position and ensre that the nit is secrely attached to the pallet Unpacking and inspection on delivery 1. Unpack the pmp/pmp nit pon delivery and inspect it for transport damage. 2. Report any transport damage to the manfactrer/ distribtor immediately. 3. Retain the pallet if any frther transport is reqired. 4. Dispose all packaging material according to local reglations Lifting DANGER Death or crshing of limbs can be cased 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 illstration. 3. Do not stand nder sspended loads. 4.2 Treatment for storage Unpainted steel srfaces shold be coated with rst inhibitor and the nit shold be stored in a dry, dst free environment not exceeding 60 C NOTE Material damage de to inappropriate treatment for storage! Treat all internal and external bare metal pmp parts for storage. Renew treatment if necessary. 4.3 Interim storage before installation NOTE Material damage de to inappropriate storage! Treat the pmp with preservatives compatible with pmped media (precation in case of spillage). 1. Close all openings with blanks, plgs or plastic covers. 2. Make sre the storage room meets the following conditions: Dry, hmidity not to exceed 80% Ot of direct snlight Frost-free; temperatre range 0 to 40 C Vibration-free; minimize Dst-free; minimize *Storage information for pmps withdrawn from se is listed in section 8, Storing pmps and hoses. Figre 3 Fastening lifting gear to pmp nit Dra 55 Version 2.2v-07/ Page

10 4.4 Disposal With prolonged se, pmp parts can get contaminated by poisonos or radioactive pmped liqids to sch an extent that cleaning may be insfficient. Risk of poisoning and environmental damage by the pmped liqid or oil! Use sitable personal protective eqipment when carrying ot any work on the pmp. Prior to disposal of the pmp: Drain and dispose the lbricant in accordance with local reglations. Collect and dispose of any leaking pmped liqid or oil in accordance with local reglations. Netralize resides of pmped liqid in the pmp. WARNING Dispose of the pmp nit and associated parts in accordance with stattory reglations. 5. Installation and connection NOTE Material damage de to nathorized modification on pmp nit! Do not make any strctral modifications to the pmp nit or pmp casing Do not carry ot any welding work on the pmp nit or pmp casing 5.1 Preparing for installation Checking the ambient conditions 1. Make sre that the operating conditions are complied with (g Pmp specifications) 2. Make sre the reqired ambient conditions are flfilled (g Ambient conditions) Preparing the installation site Ensre the installation site meets the following conditions: Pmp is freely accessible from all sides Sfficient 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 Preparing the fondation and srface Make sre the fondation and srface meet the following conditions: Level Clean (no oil, dst or other imprities) Capable of bearing the weight of the pmp nit and all operating forces Ensre the pmp is stable and cannot tip over Concrete fondation: Standard concrete strong enogh to spport the pmp nit nder load. 5.2 Installation at site 1. Lift the pmp nit (g Lifting) 2. Pt the pmp nit down at the installation site. 3. Bolt the pmp down; se all 4 holes. NOTE Material damage cased by ingress! Do not remove any protective flange covers ntil immediately before connecting the pipes to the pmp Dra 55 Version 2.2v-07/ Page

11 5.3 Planning the pipes Specifying spports and flange connections 1. When planning pipe rns take every possible operating condition into accont: Cold/warm medim Empty/fll Unpressrized/pressrized Positional change of the flanges 2. Ensre that the pipe spports are designed to accommodate any movement from environmental or pressre imposed forces. Do s 1. Short pipe rn to sction side Don ts Long pipe rn to sction side 2. Redced Joints/Bends Mltiple Joints/Bends Specifying nominal diameters Keep the flow resistance in the pipes as low as possible. Pipe work immediately connected to both inlet and otlet port of the pmp shold be straight rns for at least 1 meter. Ensre that nominal pipe diameter is at least 1.5 times nominal pmp-hose diameter to redce plsation Specifying pipe lengths 1. Keep pipe work as short and direct as possible. 2. To allow easy access when changing hoses, inclde a short, removable section adjacent to the port flanges Optimizing cross-section of pipe work 1. Avoid bending radii of less than 10r (r - the radii of nominal piping) 2. Avoid abrpt changes of cross-section along the piping Providing safety and control devices (recommended) Making provisions for isolating and shtting off pipes 3. Connecting pipe with diameter 1.5 times pmp hose diameter Pipe ID 1.5 times hose ID 4. Plsation damper connected close to the pmp Plsation Damper Connecting pipe with smaller than pmp hose diameter Pipe ID < pmp hose ID Plsation damper connected away from pmp 10% loss in damper efficiency for every meter For maintenance and repair work. Provide sht-off valves in the sction and discharge lines. Bellows Allowing safe removal of prodct Inclde drainage taps in sction and discharge lines at the lowest point. Table 4 Do s and Don ts Dra 55 Version 2.2v-07/ Page

12 5.4 Shimming The pmp mst be shimmed for the reqired discharge pressre (g Shimming). Normally, shims are factory set and wold not reqire any ser adjstment. Bt if and when reqired shims can be adjsted with the following procedre Installing motor and gearbox (where not spplied) Death or crshing of limbs cased by falling loads! DANGER Use lifting gear appropriate for the total weight to be transported. Do not stand nder sspended loads Figre 4 Shimming 1. Rotate the pmp 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 nmber of shims for the reqired pressre (g Shimming). 5. Tighten the shoe bolt (g Tightening torqes). 6. Repeat with the other rotor shoe. 7. Ensre the lbricant level is correct. 8. Replace the window and gasket ensring it is fitted the correct way with the bolts (g Fitting the inspection window). 5.5 Electrical connection DANGER Risk to health de to electric shock! All electrical work mst be carried ot by qalified electricians. Figre 5 Installing motor gearbox Installing motor gearbox on bare-shaft pmp 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 hosing. 4. Align key to the key way. 5. Fit the eight M10 bolts. 6. Use a torqe wrench to apply tightening torqe (g Tightening torqes) Connecting to power spply 1. Connect motor to the rated power spply. Ensre the correct gland is sed and that the earth connection is made and secred. 2. Rn the pmp slowly to ensre correct rotation. Dra 55 Version 2.2v-07/ Page

13 5.6 Installing the Hose Inserting the hose Flly lbricate the oter wall of the hose with Verderlbe / Verdersil to aid installation. 1. Add 1/2 a liter of lbricant to the pmp hosing Figre 8 Port flange assembly & insert Figre 6 Inserting Hose Insert one end of the hose into the moth of the sction port (the hose shold be fed into the pmp in the direction of normal operation). Once the hose reaches the rotor, the drive can be inched forward slowly to feed in the remainder of the hose into the pmp hosing. Figre 9 Bolting down the flange Figre 7 Inserting clamp ring Leave 45-50mm hose protrding ot of the sction port to fit the clamp ring. Slide on the clamp ring with tapered side facing away from the pmp; allow the hose to slightly protrde past the clamp ring. Dra Fit the inner and oter O rings to the port flanges. If sing a solid port flange ensre the o ring is in place in the face groove and psh the flange into the hose. For port flanges with an insert, load the insert into the port flange, then apply a small amont of lbricant to the flange to aid fitting. Using either the clamp tool provided or two G clamps hold the insert in place within the port flange. Fit the flange to the sction port by holding on to the flange-insert nit, pshing it in together. Tighten the bolts in a seqence, repeating the seqence ntil each flange is evenly fitted. All 4 bolts shold be fitted to each flange to avoid compromising the performance of the pmp Version 2.2v-07/2016 Rn the pmp forward and stop when the hose protrdes from the other end by abot 30mm. Repeat the seqence for installing the flange (refer points 1-6). Fit the ¼ trn flange connector to both ports. 13 Page

14 5.6.2 Filling the pmp with lbricant The safety data sheets for both Verderlbe and Verdersil are available from the manfactrer for compatibility check. Provide a sitable container to collect spilt lbricant. Ensre compatibility of lbricant with the pmped liqid. Fill the pmp to the level where flid starts to come throgh the lowest bolt hole of the inspection window (g Lbricants). Figre 10 Filling pmp with lbricant Fitting the inspection window 5.7 Connecting the pipes NOTE Contamination of pmped media de to imprities in the pmp! Care shold be taken to avoid ingress of contaminants into the pmped media. 1. Clean all piping parts and fittings prior to assembly. 2. Ensre that the flange seal do not protrde inwards occlding the flow path. 3. Remove flange covers on both the sction and discharge side prior to installation Installing the piping 1. Check all fasteners are tightened (g Tightening torqes) 2. Ensre that the 1/4 trn flange is correctly indexed. 3. Remove the transport and sealing covers from the pmp. 4. Before connecting any piping to the pmp: Ensre that the hose is properly secred by rnning the pmp dry for revoltions in both the directions. 5. Rn the pipes in a continos pward or downward slope to avoid air pockets 6. Connect the piping Figre 11 Monting the inspection window 1. Fit M6 cap head bolts with washers into the window. The window is threaded to make bolts captive and conter-bored on the back face. 2. Mont the gasket on to the bolts. 3. Mont the window nit, with the bolts and gasket, ove the front cover, aligned as shown in fig Nip the bolts down in seqence. Ensre that the bolts are not over-tightened. Yo can see the gasket pressing against the window as the bolts clamping force takes effect. Dra 55 Version 2.2v-07/ Page

15 6. Operation 6.1 Pre-commissioning the pmp Checking the direction of rotation with dry pmp 1. Ensre the pmp has lbricant 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) Starting the pmp Pmp set p and connected properly Motor set p and connected properly All connections stress-free and sealed Pmp hosing lbricant level correct (g Lbricants). All safety eqipment installed and tested for fnctionality DANGER Risk of injry and poisoning de to pmped liqid spraying ot! Use personal protective eqipment when carrying ot any work on the pmp. WARNING Risk of injry and poisoning de to hazardos pmped liqids! Safely collect any leaking pmped liqid and dispose of it in accordance with environmental rles and reqirements. DANGER Eqipment damage de to excess pressre! Do not operate the pmp with the discharge-side fitting closed. Operate the pmp only inside the tolerances specified by the manfactrer (g 10.1 Technical specifications) 5. Verify that neither the pmp nit nor the pipe connections are leaking. 6. Perform a second flsh by rnning the pmp, revoltions with pmped liqid, to remove reside and water inside the pmp Switching off NOTE Risk of dead heading and hose brst de to closed sction or discharge! Keep the sction and discharge side fittings opened till the rotor has come to a complete stop. WARNING Risk of injry de to hot pmp parts! Use personal protective eqipment when carrying ot any work on the pmp. NOTE Eqipment damage de to sediments! If the pmped liqid crystallizes, polymerizes or solidifies: Flsh pmp Make sre that the flshing liqid is compatible with the pmped liqid. 1. If necessary: Flsh and empty the pmp. 2. Switch off power to the motor. 3. Close the discharge side fitting. 4. Check all tie bolts and tighten them if necessary (only after ptting the pmp into service for the first time). 1. Close all drainage taps. 2. Open the sction-side and the discharge-side fittings. 3. Switch on the motor and make sre it is rnning smoothly. 4. Rn the pmp, flshing with water first (cold commissioning) to check for leaks. Dra 55 Version 2.2v-07/ Page

16 6.2 Operation Switching on Pmp pre-commissioned (g6.1) Pmp prepared and filled DANGER Risk of injry de to rnning pmp! Do not toch the moving parts of a rnning pmp. Do not carry ot any repair/ maintenance work on the rnning pmp. Allow the pmp to cool down completely before starting any work on the nit. DANGER Risk of injry and poisoning de to pmped liqid spraying ot! Use personal protective eqipment when carrying ot any work on the pmp. NOTE Risk of plsation when throttling down the sction flow rate! Flly open the sction-side fitting and DO NOT se it to adjst the flow as this cold damage the hose. 1. Open the sction-side and the discharge-side fittings. 2. Switch on the motor and make sre it is rnning smoothly Switching off (Refer to g 6.1.3) WARNING Risk of injry de to hot pmp parts! Use personal protective eqipment when carrying ot any work on the pmp. NOTE Damage to hose de to sediments! If the pmped liqid crystallizes, polymerizes or solidifies Flsh the hose Make sre that the flshing liqid is compatible with the pmped liqid. 6.3 Shtting down the pmp Pmp is Measre sht down Take measres according to the pmped liqid (g Table 6 Measres depending on the behavior of the pmped liqid)....dismonted Isolate the motor from its power spply and secre it against nathorized switch-on....pt into storage Table 5 Take the following measres whenever the pmp is sht down: Behavior of the pmped liqid crystallized or polymerized, Solids sedimenting Solidifying non-corrosive Solidifying corrosive Liqid, non-corrosive Liqid, corrosive Follow the storage instrctions (g 8 Storage). Measres to be taken if the pmp is sht down Dration of shtdown (depending on process) Short Flsh the pmp. Heat p or empty the pmp Heat p or empty the pmp - - Empty the pmp Long Flsh the pmp, remove the hose. Empty the pmp Empty the pmp. Treat the pmp with preservative. Empty the pmp. Treat the pmp with preservative. Table 6 Measres depending on the behavior of the pmped liqid Dra 55 Version 2.2v-07/ Page

17 6.4 Start-p following a shtdown period 1. After a prolonged shtdown period, re-commission the pmp as follows: Replace the seals. Install or change hose (g 7.4 Hose change). 2. Carry ot all steps as for the initial start-p (g 6.1 Pre-commissioning the pmp). 6.5 Operating the stand-by pmp Stand-by pmp is filled with lbricant (g5.6.2 Filling the pmp with lbricant) Operate the stand-by pmp at least once a week to avoid formation of permanent dents/setting on the hose. 7. Maintenance Only trained service technicians shold be employed for fitting and repair work. Present a pmped medim certificate (DIN safety data sheet or safety certificate) when reqesting service. DANGER Risk of injry de to rnning pmp or hot parts! Do not carry ot any repair/maintenance work on a pmp in operation. Allow the pmp to cool down completely before starting any repair work. DANGER Risk of injry de to pressre bildp! Do not carry ot any repairs/maintainence work on a pmp in operation Do not block the breather tbe which is designed for pressre relief In the nlikely event of a hose brst which leads to blockage of the breather tbe - safely relieve the presre inside the casin before dissembling the pmp 7.1 Inspections The inspection intervals depend on the pmp operating cycle. 1. Check at appropriate intervals: Normal operating conditions nchanged 2. For troble-free operation, always check the following: Lbricant level No leaks No nsal rnning noises or vibrations Hose in position 7.2 Maintenance These pmps are generally maintenance free and any work shold normally be limited to inspections and pmp lbricant changes as reqired; these may be more freqent in dst and/or hot condition. DANGER Risk of electroction! Have all electrical work carried ot only by qalified electricians Cleaning the pmp NOTE High water pressre or spray water can damage motors! Do not clean motors with water or steam jet. 1. Clean large-scale grime from the pmp. 2. Rinse the hose careflly to remove chemicals (follow the cleaning protocol as listed in g Cleaning protocol for hoses). WARNING Risk of injry and poisoning de to hazardos pmped liqids! Use protective eqipment when carrying ot any work on the pmp. Dra 55 Version 2.2v-07/ Page

18 7.2.2 Maintenance schedle Task Freqency Action Check pmp and gearbox for leaks and damage Before pmp start p Daily visal inspection Schedled intervals dring operation Repair leaks and damage before operating the pmp Replace components as necessary. Clean p any spillage. Check pmp hosing lbrication level Check geared motor nit lbrication level Check pmp for nsal temperatres or noise in operation Before pmp start p Daily visal inspection Schedled intervals dring operation Before pmp start p Daily visal inspection Schedled intervals dring operation Daily visal inspection Schedled intervals dring operation Make sre that lbricant level is visible in the inspection window between the lower sill and the first pair of bolts. Do not operate the pmp if the level is too low or too high. Refill lbricant as reqired (g5.6.2 Filling the pmp with lbricant) g Motor instrction manal. Check pmp, gearbox and bearing hosing for damage. Replace worn components. Replace pmp hosing lbricant At every hose change or every six months After inspection when reqired Refill lbricant (g5.6.2 Filling the pmp with lbricant) Replace hose Check pmp hosing, rotor, rotor shoes and inserts internally Replace bearing hosing Replace bearing hosing seal After inspection when reqired When flow has dropped by 25% of nominal vale When the hose is brst/damaged Annally On replacing the hose After 30,000 rnning hors When damage is sspected When damage is sspected When leak is detected Replace hose (g 7.4 Hose change) Replace flange sealing kit Worn and damaged srfaces give rise to prematre hose failre Replace worn components. Check bearing play and fnction. Check bearing play and fnction. Replace worn components. Table 7 Maintenance schedle Dra 55 Version 2.2v-07/ Page

19 7.3 Repairs DANGER Risk of death de to electric shock! Have all electrical work carried ot by qalified electrician only WARNING Risk of injry de to heavy components! Pay attention to the component weight. Lift and transport heavy components sing sitable lifting gear. Set down components safely and secre them against overtrning or rolling away Preparations for dismonting Safely release any pressre bild p in the pmp hosing. (There may be significant bilt p of pressre in the discharge line or possible sction side vacm). Pmp completely emptied, flshed and decontaminated Electrical connections disconnected and motor locked ot against being switched on again Pmp cooled down Axiliary systems sht down, depressrized and emptied Before dismonting the pmp, mark the precise orientation and position of all components before dismonting them. WARNING Retrning the pmp to the manfactrer Pmp npressrized Completely emptied and decontaminated. Pmp cooled down Hose dismonted (g7.4.1 Dismonting the hose) Obtain prior athorization before repair or retrn of the pmp. Enclose a completed docment of compliance when retrning pmps or components to the manfactrer Repairs...at the cstomer s premises...at the manfactrer s premises...at the manfactrer s premises for warranty repairs Table 8 Measres for retrn Measre for retrn Retrn the defective component to the manfactrer. Decontaminate if necessary. Flsh the pmp and decontaminate it if it was sed for hazardos pmped liqids. Only in the event of hazardos pmped liqid, flsh and decontaminate the pmp Risk of injry while dismonting the pmp! Use protective eqipment when carrying ot any work on the pmp. Observe manfactrer s instrctions (e.g. for Motor, copling, gearbox). Dra 55 Version 2.2v-07/ Page

20 7.3.3 Rebild / Repair Reinstall the components, in accordance with the marks applied. Material damage de to nsitable components! Always replace lost or damaged bolts with bolts of the same strength and material. 1. Observe the following dring the installation: Replace worn parts with genine spare parts. Maintain the prescribed tightening torqes (g Tightening torqes) 2. Clean all parts (g Cleaning agents). Do not remove any markings which have been applied. 3. Reassemble the pmp (g refer sectional drawing). 4. Install the pmp in the system (g 5 Installation and connection) Re-alignment of Rotor after a stall The rotor is attached to the drive shaft with a friction copling, the intent of which is to permit the rotor to slip in the event of the pmp scking a large solid object throgh the inlet. The general effect of sch an event is that the friction copling absorbs the initial inertia permitting the motor to overrn before stalling. This protects the motor, drive shaft and rotor from failre. NOTE On the Dra 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 pmp has been stalled at any time then the positions of these marks shold be checked and if not matched the rotor shold be removed and the condition of the friction joint assessed and replaced as reqired. In the event of a rotor stall, indced by external forces; sch as large solids in the hose, the taper joint fixing the rotor to the shaft may need re-setting. To do this: 1. Drain the pmp of lbricant, remove the front cover 2. Slacken each of the clamp bolts 3. Re-torqe. The torqing shold be done in stages checking each bolt in trn ntil no frther movement occrs. 7.4 Hose change Risk of injry! Always isolate the power spply before working on the pmp. The hose change involves removal and re-installing the port flanges Dismonting the hose Draining lbricant Motor isolated. System secred against being switched back on again. Slip hazard de to spilt lbricant! Care mst be taken when lbricant is drained into a container. Dispose of sed lbricant in accordance with local laws and good environmental practices. 1. Remove the drain plg at the rear of the pmp. 2. Drain the lbricant into a sitable container. 3. Remove the lower flange and allow any excess lbricant to drain ot. Removing the hose WARNING WARNING CAUTION Risk of injry if the hose is expelled too qickly Slowly remove the hose by rnning the motor at a redced speed 1. Remove both the flanges. 2. Use the motor to drive ot the old hose. If no power is available, remove the fan cover and trn the fan shaft by hand or sing sitable leverage. 3. Clean the pmp hosing. 4. Inspect the flanges for damage and signs of wear Re-installing the hose, port flanges, lbricant refill and fitting the inspection window - Follow step by step, the instrctions listed in section g 5.6 (Installing the hose) Dra 55 Version 2.2v-07/ Page

21 7.5 Ordering spare parts For troble-free replacement in the event of falts, we recommend keeping spare parts available on site. The following information is mandatory when ordering spare parts (g Name plate): Pmp model Year of manfactre Part nmber / Description of part reqired Serial nmber Qantity 8. Storing pmps and hoses Verderflex pmps are designed for continos se, however, there may be instances when pmps are withdrawn from se and stored for extended periods. We recommend certain pre-storage actions and precations be taken whilst pmps and their components are not in se. Similarly, hoses and lbricants may be held in stock to service working pmps and their recommended storage conditions are advised Pre-Storage Actions The hose shold be removed from the pmp and lbricant drained ot from the pmp casing. The pmp casing shold be washed ot allowed to dry and any external bild p of prodct removed Cleaning Protocol for hoses VERDERFLEX hoses shold be cleaned with the following protocol NBRF Hoses: VERDERFLEX NBRF food grade hoses shold be cleaned with the following protocol: 1 First flsh 0.5% Nitric Acid (HNO3) soltion at p to 60 C 2 Second flsh 4% Castic soda (NaOH) soltion and eventally steamed open ends for 15 mintes at p to 110 C 3. Final flsh: flsh with clean water to remove all traces of cleaning soltions Under no circmstances shold VERDERFLEX NBRF food grade hoses be cleaned with Sodim hypochlorite (NaOCl) based cleaning soltions, neither shold the above concentrations, exposre, drations or temperatres be exceeded. EHEDG Approval VERDERFLEX NBRF food grade hoses can be sed with sitably specified VERDERFLEX pmps to form an EHEDG accredited hygienic pmping system. To comply with this certification both the approved particle velocity mst be maintained dring the cleaning cycle and the appropriate hygienic port flanges fitted. Shold a pmp to this specification be reqired, it shold be agreed with yor local VERDERFLEX distribtor before the pmp is spplied. Food Grade Approval All VERDERFLEX NBRF food grade hoses inner liners are certified as compliant to FDA CFR 21 Parts 170 to 189 Item Hose Description All VERDERFLEX NBRF food Grade hoses consist of a smooth black inner food grade liner bonded to a non-food grade oter. The inner liner is a taste-free and odorless. Hose Installation All VERDERFLEX NBRF food Grade hoses mst be installed in accordance with the procedres defined in the VERDERFLEX Operating and Maintenance manal. Dra 55 Version 2.2v-07/ Page

22 Identification VERDERFLEX NBRF food Grade hoses can be identified by: a) Both an external Yellow Coding / Identification tape and an additional white longitdinal stripe b) On spply as a spare part, they will have their endssealed with Alminim foil Pmp Installation 9. Trobleshooting 9.1 Pmp malfnctions If malfnctions occr which are not specified in the following table or cannot be traced back to the specified cases, please conslt the manfactrer. Possible malfnctions are identified and respective case and remedy are listed in the table. VERDERFLEX pmps sing VERDERFLEX NBRF Food Grade hoses mst be installed in accordance with recommendations made by the pmp s spplier. In particlar, special care mst be given to the sction and discharge line conditions and that the hose is shimmed in accordance with VERDERFLEX s recommendations. Shold there be any dobt abot any installation details, these mst be discssed with the pmps spplier. Particle Release All hoses will release small qantities of rbber into the prodct stream, especially immediately after the hose installation and jst prior to hose failre. Whilst the rbber released will be food grade particles, these may case end-ser concerns abot contamination and so we recommend sitable particle captring devices sch as filters are fitted into the pmp s discharge line Storage Conditions Pmps shold be stored in a dry environment, ot of direct snlight. Depending on these conditions, it may be advisable to place a moistre-absorbing prodct, sch as Silica gel, inside the pmp s casing or to coat the pmp s inner srfaces with moistrerepelling oil, sch as WD40, whilst the pmp is stored. Gearboxes may reqire intermittent attention as indicated by the gearbox manfactrer s recommendations. Hoses shold be stored as spplied in their wrapper and shold be stored away from direct snlight, flat withot any bends or kinks and at room temperatre, with end caps fitted. Lbricants shold be stored nder normal warehose conditions with their caps secrely fastened. Dra 55 Version 2.2v-07/ Page

23 Abnormally high pmp temperatre Low flow/pressre Pmp and pipe-work vibrating Hose plled in to pmp hosing X X X - - X - X - - X - - Possible Case Incorrect lbricant Low lbricant level Prodct ambient temperatre too high Over shimming of the pmp Blocked sction / bad sction characteristics / no prodct High pmp speed Sction/discharge valve closed Hose failre Remedy Conslt the manfactrer to obtain correct lbricant. Add reqired amont. Conslt the manfactrer regarding maximm temperatre. Check for and remove excess shims. Check pipe-work and valves for blockages. Check that the sction pipe-work is as short and as large in diameter as feasible. Correct the piping layot. Conslt the manfactrer. Redce speed to a minimm. Conslt the manfactrer. Open sction/discharge valve. Replace hose(g 7.4 Hose change) - - X X Poor pmp selection, incorrect shoe shimming Sction line too long Pmp speed too high Sction line bore too small High prodct viscosity Sction/discharge lines not secred properly Long sction/discharge lines / Damper malfnction High prodct specific gravity / viscosity Under-sized sction/discharge diameter Insfficient lbricant in the casing Inlet pressre too high Blocked hose / incorrectly fitted Conslt the manfactrer to check pmp selection. Conslt the manfactrer. Conslt the manfactrer. Conslt the manfactrer. Conslt the manfactrer. Check and secre sction/discharge lines. Shorten long sction/discharge lines wherever possible. Conslt the manfactrer. Conslt the manfactrer. Increase sction/discharge pipe-work diameter. Fit damper. Check lbrication chart and add the reqired amont of lbrication. Redce the inlet pressre. Check the hose and remove any blockages. Large particles in the prodct Mont sieve or filter in sction line to avoid very large particles from entering the hose. Do not allow filters to limit sction below accepted levels. Table 9 Pmp trobleshooting list Dra 55 Version 2.2v-07/ Page

24 10. Appendix 10.1 Technical Specifications Pmp Specifications Size Max. delivery pressre Temperatre of pmped liqid Max. continos operation pmp speeds Dimensions Table 10 Pmp Specifications Vale 16 bar < 100 C 60 rpm at 0 bar 45 rpm at 5 bar 38 rpm at 10 bar 35 rpm at 16 bar g Setp drawing Ambient conditions Operation nder any other ambient condition wold reqire approval from the manfactrer Operating conditions Ambient temperatre 5 C to +45 C Relative hmidity long term 85 % Setp height above sea level 1000 Storage conditions Ambient temperatre +10 C to +50 C Relative hmidity long term 85 % Tightening torqes Tightening torqes shold be applied at the below mentioned torqe vales: Preservatives Use e.g. RUST-BAN 335 or similar preservatives on bare metal Cleaning agents (After hose is removed) Cleaning agents Wax solvents, diesel paraffin, alkaline cleaners, Warm water Cleaning agents Wax solvents, diesel paraffin, alkaline cleaners, Warm Water Table 12 Cleaning agents Lbricants Recommended lbricants for longer hose life are VERDERLUBE or VERDERSIL. Pmp type Dra 55 Table 13 Amont of Lbricant cover *The pmp is filled to the lowest screw hole on the window Shimming Nmber of shims reqired remains naffected by change in rpm of the pmp. Each shim is 0.5 mm thick. Hose material Table 14 Nmber of shims reqired Amont of Lbricant 15*Litres (4.0 US Gallons) 0 bar 6 bar 7.5 ba 10 bar 16 bar EPDM NR NBR N/A Position Inspection Window Port flange Rotor shoe Bearing hosing to casing Gearbox to bearing hosing Motor to gearbox Frames to casing Front cover Keyless bsh Seal Plate Torqe vales 3.4 Nm 90 Nm 50 Nm 90 Nm 65 Nm 55 Nm 35 Nm 27 Nm 35 Nm 3.4 Nm Rotor setting distance The rotor is factory aligned, bt for maintenance or assembly from flat pack the rotor setting distance shold be known. Pmp type Dra 55 Table 15 Rotor setting distance Rotor setting distance (mm) 4mm from the front of casing to the front of rotor shoe Table 11 Pmp fastener tightening torqes Dra 55 Version 2.2v-07/ Page

25 11 List of Figres and Tables 11.1 List of figres Figre 1 Name plate Figre 2 Layot 3.3 Figre 3 Fastening lifting gear to pmp nit Figre 4 Shimming 5.4 Figre 5 Installing motor gearbox Figre 6 Inserting Hose Figre 7 Inserting clamp ring Figre 8 Port flange assembly & insert Figre 9 Bolting down the flange Figre 10 Filling pmp with lbricant Figre 11 Monting the inspection window List of tables Table 1 Target grops and their dties 1.1 Table 2 Warnings and conseqences of disregarding them 1.2 Table 3 Symbols and their meaning 1.2 Table 4 Do s and Don ts 5.3 Table 5 Measres to be taken if the pmp is sht down 6.3 Table 6 Measres depending on behavior of the pmped liqid 6.3 Table 7 Maintenance schedle Table 8 Measres for retrn Table 9 Pmp trobleshooting list 9.1 Table 10 Pmps specifications Table 11 Pmp fastener tightening torqes Table 12 Cleaning agents Table 13 Amont of Lbricant Cover Table 14 Nmber of shims reqired Table 15 Rotor setting distance Table 16 Declaration of conformity according to EC Machine Directive 12 Dra 55 Version 2.2v-07/ Page

26 12 Declaration of conformity according to EC Machine Directive EC declaration of conformity according to machine directive, appendix II A We, VERDER Ltd., Unit 3 California Drive, Castleford hereby declare that the following machine adheres to the relevant EC directives detailed below Designation Dra 55 EC directives: Machine Directive (2006/42/EC) Low-voltage directive (2014/35/EU) EMC directive (2014/30/EU) Applicable harmonized norms: EN ISO 12100: 2010 Responsible for the docmentation VERDER Ltd. Unit 3 California Drive Castleford WF10 5QH UK Date: 01/07/2016 Company stamp / signatre: Company stamp / signatre: David Sampson Head of Development/Constrction David Hoyland Head of Qality Table 16 Declaration of conformity according to EC Machine Directive Dra 55 Version 2.2v-07/ Page