Peristaltic Industrial Hose Pump

Transcription

1 Peristaltic Indstrial Hose Pmp Original Operating Manal Print-No. 01 5, 7, 10, 15, 25, 35

2 Print-No. 01 5, 7, 10, 15, 25, 35 The information in this docment is essential for the safe operation of Verderflex pmps. This docment mst be read and nderstood thoroghly prior to installation of nit, electrical connection and commissioning. 2 Page

3 Table of Contents 1. Abot this Docment 1.1 Target Grops 1.2 Warnings and Symbols Used in the Manal 2. Safety 2.1 Intended Use 2.2 General Safety Instrctions Prodct Safety Obligation of the Operating Company Obligation of Personnel 2.3 Specific Hazards Hazardos Pmped Liqids Sharp Edges 3. Transport, Storage and Disposal 3.1 Transport Unpacking and Inspection on Delivery Lifting 3.2 Storage Conditions 3.3 Interim Storage After Using the Pmp 3.4 Interim Storage Before Using the Pmp 3.5 Disposal 4. Layot and Fnction 4.1 Design Details 4.2 Labelling Name Plate 4.3 Layot 4.4 Bearings and Lbrication 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 Electrical Connection Connecting to Power Spply 5.5 Installing the Hose 5.6 Fitting the Port Flange Standard Port Flange Assembly Split Flange Assembly 5.7 Filling the Pmp with Lbricant 5.8 Connecting the Pipes Installing the Piping 7. Inspection, Maintenance and Repair 7.1 Inspection 7.2 Maintenance Cleaning the Pmp Cleaning Protocol for Hoses Maintenance Schedle 7.3 Repair Preparations for Dismonting Retrning the Pmp to the Manfactrer Rebild/Repair 7.4 Hose Change Dismonting the Hose Draining Lbricant Removing the Hose Re-installing the Hose, Port Flanges, Lbricant Refill and Fitting the Inspection Window 7.5 Ordering Spare Parts 8. Trobleshooting 8.1 Pmp malfnctions 9. Appendix 9.1 Technical Specifications Pmp Specifications Ambient conditions Tightening Torqes Preservatives Cleaning Agents (After hose is removed) Lbricants Rotor Options 10. List of Figres and Tables 10.1 List of Figres 10.2 List of Tables 11. Declaration of Conformity According to EC Machine Directive 6. Operation 6.1 Pre-commissioning the Pmp Checking the Direction of Rotation with Dry Pmp Starting the Pmp Switching OFF the Pmp 6.2 Commissioning the Pmp Switching ON the Pmp Switching OFF the Pmp (Refer to g 6.1.3) 6.3 Shtting Down the Pmp 6.4 Start-p Following a Shtdown Period 6.5 Operating the Stand-by Pmp 3 Page

4 1. Abot this Docment The Verderflex range of peristaltic pmps have been developed according to the latest technology and sbject to continos qality control. These operating instrctions are intended to facilitate familiarisation with the pmp and its designed se. This manal will act as a gide for operating the pmp. Yo are advised to follow these gidelines to operate the pmp correctly. These operating instrctions do not take local reglations into accont; the operator mst ensre that sch reglations are strictly observed by all, inclding the personnel responsible for installation. 1.1 Target Grops Target Grops Operating Company Dty Keep this manal available at the operating site of the pmp. Ensre that personnel read and follow the instrctions in this manal and any 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. Table 1 Target Grops 1.2 Warnings and Symbols Used in the Manal Warning Risk Level Conseqences of disregard DANGER Immediate risk Death, serios bodily harm WARNING Potential acte risk Death, serios bodily harm CAUTION Potential hazardos sitation Potential damage to the pmp Note Table 2 Warnings Used in the Manal For information Possible incorrect se/maintenance of pmp 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 p g Precondition Cross-reference Information Table 3 Symbols Used in the Manal 4 Page

5 2. Safety The manfactrer does not accept any liability for damage reslting from disregard of this docmentation. 2.1 Intended Use Only se the pmp to handle compatible flids as recommended by the manfactrer (g 9.1 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 9.1 Technical Specifications). Do not operate the pmp with any inlet/otlet valves 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 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 it and all associated systems are in good fnctional condition. Only se the pmp as intended, flly aware of safety and risk factors involved and 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 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. 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 responsibilities, 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 with the pmp. 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 void if the cstomer fails to follow any Instrction, Warning or Cation in this docment. Verder has made every effort to illstrate and describe the prodct 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. 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, refer to terms and conditions. 5 Page

6 2.2.3 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 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 Sharp Edges Pmp parts, sch as the shims and impellers, can be sharp Use protective gloves when carrying ot any work on the pmp 6 Page

7 3. Transport, Storage and Disposal 3.1 Transport Always transport the pmp in a stable position and ensre that the pmp is secrely attached to the pallet Unpacking and Inspection on Delivery 1. Report any transport damage to the manfactrer/distribtor immediately. 2. Retain the pallet if any frther transport is reqired 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. Make sre the pmp and accessories are lifted and moved by qalified lifting personnel eqipped with sitable lifting gear. 3. Fasten the lifting gear to the lifting eye as shown in the following illstration. 4. Do not stand nder sspended loads. 3.2 Storage Conditions 1. Make sre the storage location meets the following conditions: Dry, hmidity not to exceed 85%, non-condensing Ot of direct snlight Frost-free; temperatre range -5 to +45 C Vibration-free Dst-free 2. Depending on these conditions, it may be advisable to place a moistre-absorbing prodct, sch as Silica gel, inside the pmp s hosing or to coat the pmp s inner srfaces with moistre-repelling oil, sch as WD40, whilst the pmp is stored. 3. 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. 4. Lbricants shold be stored nder normal warehose conditions with their caps secrely fastened. 5. Gearboxes may reqire intermittent attention as indicated by the gearbox manfactrer s recommendations. 3.3 Interim Storage After Using the Pmp The hose shold be removed from the pmp. The pmp hosing lbricant shold be drained. The pmp hosing shold be washed ot, allowed to dry and any external bild p of prodct removed. 3.4 Interim Storage Before Using the Pmp CAUTION Pmp damage cased by interim storage Allow the pmp to reach ambient temperatre before se. Please observe the storage recommendations and se by dates which apply to hose yo may wish to bring into service after storage. Figre 1 Fastening Lifting Gear to Pmp 7 Page

8 3.5 Disposal With prolonged se, pmp parts can be contaminated by hazardos pmped liqids to sch an extent that cleaning may be insfficient. 4.2 Labelling Name Plate WARNING 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. Dispose of the pmp and associated parts in accordance with local reglations Figre 2 Name Plate 1. Pmp Type 2. Serial Nmber 3. Year of Manfactre When reqesting spares, the model and serial nmber shold always be qoted. 4. Layot and Fnction The medim to be pmped does not come into contact with any moving parts and is totally contained within the hose. 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. 4.1 Design Details Verderflex 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. 8 Page

9 4.3 Layot Figre 3 Layot (Generic View) 1 Inspection Window 6 V-Ring Seal 11 Cir-Clip 16 Port Flange 2 Inspection Window Gasket 7 Drive Shaft 12 O-Ring 17 Filler Tbe 3) 3 Front Cover 8 Oil Seal Hosing 13 Gasket 1) 18 Frames 4 Hose 9 Seal Shaft 14 Pmp Hosing 19 Gearbox with 5 Rotor 10 Bearing 15 Clamp Ring 2) Adaptor Flange 20 Motor 1) For D35 se O-ring instead of gasket. 2) Applies only for D5, D7, D10 and D35. (g 5.6 Fitting the Port Flange) 3) For D25 and D35 se polypropylene filler tbe instead of copper filler tbe. 4.4 Bearings and Lbrication Pmp: To be filled at installation with appropriate lbricant if not spplied pre filled. (g9.1.6 Lbricants) Bearings are sealed nits and need no additional lbricant. 9 Page

10 5. Installation and Connection CAUTION Material damage de to nathorized modification on pmp Unathorized modification will invalidate the warranty. 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 and all operating forces Ensre the pmp is stable and cannot tip over Concrete fondation: Standard concrete strong enogh to spport the pmp nder load. 5.2 Installation at Site 1. Lift the pmp. (g Lifting) 2. Pt the pmp down at the installation site. 3. Bolt the pmp down; se all 4 holes. 10 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 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 metre. Do s 1. Short pipe rn to sction side Don ts Long pipe rn to sction side 2. Redced Joints/Bends Mltiple Joints/Bends 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 For maintenance and repair work. Provide sht-off valves in the sction and discharge lines. Allowing safe removal of prodct Inclde drainage taps in sction and discharge lines at the lowest point. 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 Bellows Table 4 Do s and Don ts 11 Page

12 5.4 Electrical Connection DANGER 5.5 Installing the Hose Connect the motor to the power spply and rn the pmp slowly to ensre correct connection. Risk to health de to electric shock All electrical work mst be carried ot by qalified electricians. DANGER Death or crshing of limbs cased by falling loads Use lifting gear appropriate for the total weight to be transported. Do not stand nder sspended loads 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. Figre 5 Installing the Hose 1. Lbricate the hose generosly with Verderlbe/Verdersil. 2. Insert the hose into the lower port. 3. Rn the pmp forward ntil the hose is fed throgh the pmp casing and is protrding from the port flange monting face by abot 15mm. Figre 4 Electrical Connection 14 Page

13 5.6 Fitting the Port Flange Standard Port Flange Assembly 5, 7, 10 and Split Flange Assembly Figre 6 Fitting the Port Flange Standard Port Flange Assembly Note 5, 7,10 and 35 port flange assembly have an additional clamp ring to enable easier flange insertion and hose change. Make sre the clamp ring will slide on inside and in level with the pmp hosing and the smallest diameter facing the pmp. Hose in position and protrding abot 15 mm on the inlet side (the side throgh which the hose had been inserted). 1. Apply some lbricant compatible with the pmped media to the port flange. 2. Psh the port flange-insert into the hose. 3. Install the 4 bolts. 4. Tighten the bolts in a seqence ntil the flange is evenly fitted, bt not completely tightened, leaving abot 10 mm slack. 5. Rotate the rotor slowly in a direction to feed the hose onto the taper. 6. Tighten all 4 bolts flly to clamp the hose and ensre the hose can be seen throgh the apertre in the side of casing formed between the flange and the casing. 7. Rn the pmp forward and stop when the hose protrdes from the other end by abot 15 mm and follow the previos steps to complete assembly Split Flange Assembly Note 5, 7,10 and 35 split flange assembly have an additional clamp ring to enable easier flange insertion and hose change. Make sre the clamp ring will slide on with tapered side facing in towards the pmp. Hose in position and protrding abot 15 mm on the inlet side (the side throgh which the hose had been inserted). 1. Place both halves of the steel flange assembly arond the appropriate hose insert. 2. Screw the halves together with the screws provided and tighten with a screwdriver, se a smear of grease on the screw threads to help avoid seizre. 3. The flanges are then assembled into the hoses on the pmp as per the standard solid port flange assembly. ( Standard Port Flange Assembly) 4. It is recommended the flange bolts be installed with a small amont of grease smeared on the thread. 15 Page

14 5.7 Filling the Pmp with Lbricant The safety data sheets for both Verderlbe and Verdersil are available from the manfactrer for compatibility check. 1. Provide a sitable container to collect spilt lbricant. 2. Ensre compatibility of lbricant with the pmped liqid. Fill the pmp casing with lbricant to the lowest bolt hole of the inspection window ( Lbricants). 5.8 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. ( Tightening Torqes) 2. Remove the transport and sealing covers from the pmp. 3. 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. 4. Rn the pipes in a continos pward or downward slope to avoid air pockets. 5. Connect the piping. 16 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 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 9.1 Technical Specifications) Switching OFF the Pmp 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). p p p p p 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. 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. 5. Verify that neither the pmp 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. 17 Page

16 6.2 Commissioning the Pmp Switching ON the Pmp 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. p Pmp pre-commissioned. (g 6.1 Pre-commissioning the Pmp) p Pmp prepared and filled. 1. Open the sction-side and the discharge-side fittings. 2. Switch on the motor and make sre it is rnning smoothly Switching OFF the Pmp (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 Take the following measres whenever the pmp is sht down: 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 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 3.2 Storage Conditions) Measres to be Taken if the Pmp is Sht Down Dration of Shtdown (Depending on Process) Short Long Flsh the pmp Heat p or empty the pmp Heat p or empty the pmp - - Empty the pmp 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 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 5.5 Installing the Hose). 2. Carry ot all steps as for the initial start-p (g 6.1 Precommissioning the Pmp). 6.5 Operating the Stand-by Pmp p Stand-by pmp is filled with lbricant (g 5.7 Filling Pmp with Lbricant). Operate the stand-by pmp at least once a week to avoid formation of permanent dents/setting on the hose. 18 Page

17 7. Inspection, Maintenance and Repair 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. 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. Risk of injry de to pressre bildp! Do not carry ot any repairs/maintenance 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 pressre inside the casing before dissembling the pmp. Risk of injry and poisoning de to hazardos pmped liqids! Use protective eqipment when carrying ot any work on the pmp. 7.1 Inspection 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 DANGER DANGER WARNING 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. Risk of electroction! Have all electrical work carried ot only by qalified electricians Cleaning the Pmp 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) 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. 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 DANGER NOTE 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. 19 Page

18 Hose Installation All VERDERFLEX NBRF food Grade hoses mst be installed in accordance with the procedres defined in the VERDERFLEX Operating and Maintenance manal. Identification VERDERFLEX NBRF food Grade hoses can be identified by: Both an external Yellow Coding / Identification tape and an additional white longitdinal stripe. Pmp Installation 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. 20 Page

19 7.2.3 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 gearbox 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 (g5.7 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 or after 300 hors rnning of pmps After inspection when reqired Refill lbricant (g 7.4.2) Replace hose After inspection when reqired When flow has dropped by 25% of nominal vale When the hose is brst/damaged Replace hose (g 7.4 Hose Change) Replace flange sealing kit Table 7 Maintenance Schedle 21 Page

20 7.3 Repair 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 WARNING 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). p 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). p Pmp completely emptied, flshed and decontaminated. p Electrical connections disconnected and motor locked ot against being switched on again. p Pmp cooled down. p Axiliary systems sht down, depressrized and emptied. p Before dismonting the pmp, mark the precise orientation and position of all components before dismonting them. Repairs...at the cstomer s premises...at the manfactrer s premises...at the manfactrer s premises for warranty repairs Table Rebild/Repair 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 Measres for Retrning the Pmp to the Manfactrer Reinstall the components, in accordance with the marks applied. NOTE 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. 4. Install the pmp in the system (g 5 Installation and Connection) Retrning the Pmp to the Manfactrer p Pmp npressrized. p Completely emptied and decontaminated. p Pmp cooled down. p 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. 22 Page

21 7.4 Hose Change WARNING 7.5 Ordering Spare Parts For troble-free replacement in the event of falts, we recommend keeping spare parts available on site. 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 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 Draining Lbricant p Motor isolated. p System secred against being switched back on again. WARNING 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 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 Installation and Connection) 23 Page

22 8. Trobleshooting 8.1 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. 24 Page

23 Abnormally high pmp temperatre Low flow/pressre Pmp and pipe-work vibrating Hose plled in to pmp hosing X Possible Case Incorrect lbricant Low lbricant level Prodct ambient temperatre too high Remedy Conslt the manfactrer to obtain correct lbricant. Add reqired amont. Conslt the manfactrer regarding maximm temperatre. X X - - X - X - - X - - Blocked sction / bad sction characteristics / no prodct High pmp speed Sction/discharge valve closed Hose failre 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 rotor 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 25 Page

24 9. Appendix 9.1 Technical Specifications Pmp Specifications Size Vale Max. delivery pressre Dra bar Dra bar Dra bar Temperatre of pmped liqid < 100 C (sbject to hose material) Cleaning Agents (After hose is removed) 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 Amont of Lbricant Max. continos operation pmp speeds Dimensions Table 10 Pmp Specifications *(refer pmp datasheet) *(refer pmp datasheet) Dra 5 Dra 7 Dra Ltrs (0.06 US Gallons) 0.25 Ltrs (0.06 US Gallons) 0.25 Ltrs (0.06 US Gallons) 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 (non-condensing) long term 85 % Setp height above sea level 1000 m Storage conditions Ambient temperatre +10 C to +50 C Relative hmidity (non-condensing) long term 85 % Tightening Torqes Tightening torqes shold be applied at the following torqe vales: Position Torqe Vales (Nm) D5,7,10 D15 D25 D35 Inspection Window Port Flange Rotor Seal Plate Frames to Casing Front Cover Gear Box Dra 15 Dra 25 Dra 35 Table 13 Amont of Lbricant Cover The pmp is filled to the lowest screw hole on the window Rotor Options Verderflex Dra range has standard and high pressre rotor options: Pmp Type 0.50 Ltrs (0.13 US Gallons) 2.0 Ltrs (0.53 US Gallons) 2.5 Ltrs (0.66 US Gallons) NOTE Standard Rotor Option (bars) High Pressre Dra 5 5 bar 8 bar Dra 7 5 bar 8 bar Dra 10 6 bar 12 bar Dra 15 6 bar 12 bar Dra 25 6 bar. 12 bar Dra 35 6 bar 16 bar Table 11 Pmp Fastener Tightening Torqes Table 14 Rotor Options Preservatives Use RUST-BAN 335 or similar preservatives on bare metal. 26 Page

25 10 List of Figres and Tables 10.1 List of Figres Figre 1 Fastening Lifting Gear to Pmp Figre 2 Name plate Figre 3 Layot (Generic View) 4.3 Figre 4 Electrical Connection 5.4 Figre 5 Installing the Hose 5.5 Figre 6 Fitting the Port Flange List of Tables Table 1 Target Grops 1.1 Table 2 Warnings Used in the Manal 1.2 Table 3 Symbols Used in the Manal 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 Retrning the Pmp to the Manfactrer Table 9 Pmp Trobleshooting List 8.1 Table 10 Pmps Specifications Table 11 Pmp Fastener Tightening Torqes Table 12 Cleaning Agents Table 13 Amont of Lbricant Cover Table 14 Rotor Options Table 15 Declaration of Conformity According to EC Machine Directive Page

26 11 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 EC directives: Machine Directive (2006/42/EC) Applicable harmonized norms: EN ISO 12100: 2010 BS EN 809 Manfactrer VERDER Ltd. Unit 3 California Drive Castleford WF10 5QH UK Date: 01/ 10/ 2016 Company stamp / signatre: Company stamp / signatre: Andrew McLennan Head of Development/Constrction David Hoyland Head of Qality Table 15 Declaration of conformity according to EC Machine Directive 28 Page