L100 & L150 User Manual
Contents
1. client requirements maintenance detail is not shown in this manual Please refer to the manufacturer s manual for maintenance detail on your specific drive 15 Cleaning the pump Hose The inside of the pump hose is easily cleaned by flushing with water or any other compatible cleaning fluid Ensure that the pump hose can not only resist the chemical compatibility of any cleaning fluids but also the temperature of cleaning liquid used Cleaning systems must not generate pressures in excess of the pump operating design pressure Hose Hemoval When pumping potentially hot hazardous or dangerous media it is critical AJ to ensure that personnel are adequately protected during hose removal and that the hose is washed through with a media harmless to man and the environment before the hose is dismantled There can be a significant pressure difference between the upper and the lower pump connections This can mean that while having vacuum in one A connecting pipe there can be a large overpressure in the other connecting pipe It is therefore essential that the pipework is depressurised safely prior to opening the pump cover and dismantling the hose Before dismantling any items shut off the suction and discharge valves Drain the hose lubricant by positioning a container at the base of the pump remove the top fill plug remove the drain plug at the bottom of the pump and drain the lubricant into the container A Always dispose of us2. wear down quickly occlusion Abrasive product mixed in Wash out pump body and the hose lubricant change lubricant Ensure pump body is fully cleaned when replacing a failed hose lubricant high Pumping Solutions Ltd Pump running too fast Reduce pump speed Possible restriction in the Dismantle the suction piping suction pipe identify the restriction and remove Lubricant leakage Leaking seal or gasket Identify the leaking seal or gasket Tighten retaining bolts Replace seal or gasket if needed For trouble free pump operation please refer also to the Routine Maintenance instructions as detailed earlier in this manual Specifications Pump operating conditions L100 L150 Max continuous flow rr l rev Maximum working pressure 10 Barg 7 5 Barg Ambient working 102C to 40 C temperature Product working temperature 10 C to 80 C Sound level at 1m 7 0 dB A whilst pumping water at maximum continuous flow Your pump may not have been configured to run at these stated maximums Please check your Technical Data Sheet Materials of Construction Compression Rollers POM a Hose connectors feas atesta Gekeseds Ne 28 Hose Lubricant Quantities uoo ase Volume of hose lubricant litres E Contact Environmental Pumping Solutions Limited or your authorised local dealer should you require a Material Safety Data Sheet MSDS for Envirolube hose lubricant Weights and D
3. Fax 44 0 1189 657 783
4. Fixing Screws 8 Flat Washer 8 22 mre E iai T Mu RN 2 15 Gearbox Mounting Flange 1 48 Roller Side Plate 4 16 Gearbox to Flange Fixing 15 49 pate 2 Roller Bush 14 Flat Washer 15 15 15 15 15 15 15 23 Adaptor Flange O Ring 1 61 Hose Connector 2 25 FrontCover 2 1 Hose Connector Fixing 8 Flat Washer 8 Spring Washer 8 Hose Clip 6 Front Cover Hinge Fixing O d ee E i rT Y E Y N 63 amp E a a aa 1s 23 EEFE eE SORE IRNI N gg glace LIA SERES DITE IF i Pa LLES E 3 dul et A 16117 XE cem E E M un a Ev i E mi i ii Neo pee un E PETERE To DLL 2 P nsn 24 25 User Guide Troubleshooting If the pump does not appear to be functioning correctly consult the following guide to see if you can identify and remedy the problem yourself If the problem still persists please contact Environmental Pumping Solutions Limited or your authorised local dealer for more detailed information Probable Cause s Suggested Remedy Defective motor Check motor is running Check fuses Check motor protection The pump does not start when turned on switch Make sure that all phases have required voltage Frequency inverter when Connect motor DOL used incorrectly set up Check inverter settings Shaft key broken or missing Make sure that a key is
5. fitted and that all surfaces of friction are clean and undamaged The hub screws re correctly tightened is correct The pump is taking in air Identify the source of air COEM intake and exchange seals or gaskets correctly Pump runs but there is no Hose blocked Reverse the pumps rotation flow of media and remove any obstacles If this is not possible with your system the pump needs to be disassembled and obstacles removed Pipeline on suction side of Clean pipeline valves filters the pump is clogged etc Pump has pumped against Hemove reason for excessive pressure and overpressure fit hose has detached from overpressure protection hose connector check pump for damage and reattach hose and refill lube Pump is running too slow It maybe possible to fit a speed inverter or make a gear ratio change not Flow is less than calculated always possible Call Environmental Pumping oolutions Ltd to discuss The pump is taking in air Locate the source of air intake and exchange seals or gaskets Flow is less than calculated Restriction in the suction Identify and remove the pipe restriction Viscosity is too high for the Turn down the pump speed size of pump and or utilise a larger pump 26 Probable Cause s Suggested Remedy Flow is less than calculated Rollers are not adjusted Adjust the roller occlusion correctly Backpressure is too high Change the pipeline on the pressure side of the pump Suction pipe is t
6. of Substances Hazardous to Health Regulations you the user are required to declare the substances which have been in contact with the product s you are returning to Environmental Pumping Solutions Limited or any of its subsidiaries or distributors Failure to do so will cause delays in servicing the item or in issuing a response Therefore please complete this form to ensure that we have the information before receipt of the item s being returned A FURTHER COPY MUST BE ATTACHED TO THE OUTSIDE OF THE PACKAGING CONTAINING THE ITEM S before returning You the user are responsible for cleaning and decontaminating the item s before returning them Please complete a separate Declaration Form for each item returned Company Address Postcode Fax Number Product Cleaning fluids to be used if residue product is found during servicing Serial Number Has the Product been used es w If yes please complete all the following sections If no please complete declaration only herby confirm that the only substance s that the item specified has handled or come into Details of Substances Pumped contact with are those named that the information given is correct and the carrier has been informed if the consignment is of a hazardous nature Chemical names Signed Name Position Date Any other additional information you may regard as useful Environmental Pumping Solutions Limited Tel 44 0 1635 576 028
7. shall not contain equipment which generates ozone e g mercury vapour lamps high voltage electrical equipment combustion gases organic vapours Store free from Superimposed tensions or compression For a hose this means that the supports must be wide enough and spaced in a way as to spread the load over a wide area We would recommend a minimum width of 100mm for any support spaced no more than 500mm apart It is preferable that hoses are supported over their entire length Do not store hoses coiled Do not allow contact with liquids e g petrol greases acids disinfectants cleaning fluids Avoid direct contact between hoses of different types particularly between hoses of different colours Hoses must be issued in strict rotation by manufacturing date or production code Hoses will be delivered wrapped individually in opaque polythene we would recommend that the packing is kept on the hoses prior to use to reduce the effects of light and to minimise contact with other materials Individual hoses are marked with a production code identifying the manufacturing period 30 EC Declaration of Conformity In accordance with EN ISO 17050 1 2004 We Environmental Pumping Solutions Limited 1210 Parkview Arlington Business Park Theale Berkshire RG7 of 4TY United Kingdom in accordance with the following Directive s 2004 108 EC The Electromagnetic Compatibility Directive 2006 42 EC The Machinery Directive hereby de
8. surface ensuring both insert flanges sit flat on the surface whilst assembly takes place It is important to ensure correct alignment of the hose inserts Misalignment will result in a twisted hose once the hose is fitted leading to premature hose failure Both inserts must be aligned Push the hose onto the hose insets along with the hose clamps do not tighten clamps e Aid assembly by lubricating inserts and hose bore with hose lubricant Never lubricate the hose or any components in contact with the pump hose with mineral oils or lubricants these are not compatible with the materials of hose construction Ensure the hose is pushed up to the insert flange on both connections and that the inserts are in correct alignment Tighten both hose clamps and re check the insert alignment e If the assembled hose element is not to be installed into the pump straight 1 away ensure the assembly is wrapped and stored in accordance with Environmental Pumping Solutions recommendations 19 Prior to fitting to the pump ensure the hose assembly is clean and free from grit and particles on the outer cover Place the hose connector gasket over the outer connections Insert the hose element assembly in to the pump passing the outer connections through the respective port in the pump body with the gaskets on the inside of the pump body Insert and tighten the insert retaining bolts The hose must now be properl
9. the user s documentation also belongs to intended use Warranty Conditions Unless stated otherwise in the Technical Selection Sheet provided at the time of pump selection the manufacturer offers a two year warranty on proper workmanship of all parts of the pump Exclusion is made for normal wear and tear of consumables such as pump hoses lubricant hose clamps compression rollers bearings and bushes wear ring and seals or parts which have been misused or damaged through negligence The warranty only applies if the pump has been used for the application specified in the technical selection sheet and according to the guidance in this manual Operation at pressures outside of the range specified in the Technical Selection Sheet shall invalidate this warranty This manufacturers warranty is null and void for any user who uses parts not of Environmental Pumping Solutions Limited original supply in their L series peristaltic pump including use of an alternative hose lubricant The warranty is strictly a return to base warranty which means that the pump is required to be returned to our UK factory by arrangement for any investigation replacement or repair work The cost of transport back to our factory is not covered by this warranty however with any valid warranty claim all time replacement parts and carriage back to the original delivery address are included Any parts to be returned to the manufacturer must be accompanied by a fully f
10. Area uud 10 LSENG IS enamora tut ai a qucd aaa alia Da tanc o latu data to od Ud E 11 i pl pie Mu e e UMD ARE ERE NC RPR E IE ORE O PRR 0 PRI ANR NR LU p 12 Mounting Me PEETIDsseiodi bona oaza iau eo pedo aai ata ni Be Da la ie atu olt A 12 Elecirical CORNEGU Gece cata gratia adio aaa ad ni a au N ea da TM 12 Use of Frequency Inverters e ete te penicilina a 13 ATEX ADDrOVEd WANS eM EE 13 COMMIS SIOMING isanne eee E AARE ERRER 14 Prestant UO CNECKS arieso ana daia Dusan e ia apa 14 Starr UD CNECKS nai ei aaa toane E aa d datat al e 14 Maintenance ep 15 Rou tine Maintenance ie ceai aa i i atat 0 aia 35 eee 15 Cleaning iNe UTI FOS esci dece ga atitea lat a ta ati al i alta a 16 Hose CMOV al ao src ine lasa tatal Sat TI TI TT 16 Replacing the Roller Bushes eese 17 Adjusting the Compression Rollers cc eee eee eee 18 FNO NePUNID FIOSER NR I em 18 PRNO MEFO COVER MERE TETTE 21 aite dar ete ple ama ce enable a tr ela lt eta arene i pita if Gearbox Drive REMOVAL ss iarasi stop ati at ca adi di ea a n a ra Gea DOXDiive Peplacernenit acvecuseia Asii vei dra RE ei pie ia iau deea Rotor Replacement ateu Beata ai aaa dea PODES Hose Connector ASSET DIV sec etniei n a at lat Pda OI patat de adopt Parts List amp Sectional Drawing eee eee anna EUS OR CUS c d Troubleshooting ccccceececceeeeeceeececceeeecsueeeeceueesseueesssueeeeseue
11. Installation Operation amp Maintenance Manual L100 amp L150 Peristaltic Pumps BEFORE INSTALLING YOUR PUMP HAVE YOU Tick Read this Manual in its entirety Ordered recommended spares spares not always in stock Checked we have shown the correct pump duty on the data sheet Checked pump supplied as per the technical data sheet Installed overpressure protection for the pump Protected the pump motor against over current Installed suitable pulsation dampeners where required Completed all Pre start up checks highlighted in this manual Tvironmental PUMPING SOLUTIONS LIMITED Contenis INTL OGUCII ON se crearea iata al dial aia aia lac aE iii aaa a Aaa 4 i e ec 4 Sale ARB RDI E IER ROI udi LATI IINE MEM AM UE 5 la zile di AR RR 5 Waranty COC MO Sic ass eat cae dai al m at Ratia iata but baile aaa uta ad 6 DESCHID OM sovata cies T 6 Operation ON ING PUNID esec oceg cate mei a de 0920 oo D 6 PUMP iO SO isaac oaie anii IURE 7 HOSS LUDIC CANON oeaan A 7 DIIVe SVSIOITIS asi seeccs aaa mcet sete atac tutes piene ia oed bi a barbat zcv sees ai ci nui tee bad 8 AVallable OPUONS m MEE c 8 litri eec c M aia 9 Tig LEII Olesea asa iati eee n aie e calea aa ad iti tt m ac boala ERE 9 Storage amet suedia Bo aaa ir Oe NER 9 LOCATING the UNI e si ea o Gaerne i a aia a ui im oer 9 CGonnecting ine PIDeWOEK iioii ta to ata aia et t oi Sp cai aa c aliate
12. ance The L series pumps are designed to have the minimum of service and maintenance A small number of simple preventive measures are however needed in order to ensure continuous and trouble free pump life Important it is very important that the pump is maintained according to the table below Never clean or repair the pump without it being fully isolated When cleaning maintaining or repairing the pump the power supply to the motor has to be disconnected by means of a key locked switch To be carried out Check hose lubricant level Before start up and Lubricant should be visible thereafter on a daily in the lower sight glass on operational basis the pump front cover Check the pumphead Before start up and for any lubricant leakage thereafter on a daily around the cover and the operational basis connections Check pump for high On a daily operational temperature or unusual basis noise for wear hose than 1mm wear across the roller lubricant hose lubricants Check gearbox oil level Before start up and thereafter on a daily operational basis Replacing the gearbox oil Refer to the gearbox manufacturers instructions In certain installations it may be desirable to try and change the pump hose before failure on a routine scheduled basis If this is the case we suggest changing the hose after 7596 of the time the first hose lasted Due to the variety of motor and gearboxes supplied according to both application and
13. ary maintenance activities Particularly ensure the front cover door can be opened and a hose taken out and replaced lf it cannot it maybe possible to modify the door to remove the hinge if fitted please enquire Ensure the installation environment is sufficiently ventilated allowing heat developed by the pump and drive to be discharged particularly that the motor cowl has sufficient air to circulate to support cooling No special tools are required to install the L series pumps other than ordinary hand tools and a hammer drilling machine for the installation of the foundation bolts Connecting the Pipework It is recommended that the connection to a pipe system is made as a flexible joint There are several flexible systems on the market which include both metallic and rubber systems By making a flexible joint the risk of introducing vibrations into the complete pipe system is reduced Vibrations may cause wear and in some cases fatigue fractures in the pipe system The pipework system must be independently supported and must not use the pump in anyway to support its weight The pipe system must never hang by the connections of the pump 10 Suction line bore must be larger than the bore size of the pump hose Discharge line bore must be the same or larger than the bore size of the pump hose Keep the suction and delivery lines as short and direct as possible Suction and discharge lines should preferably exit straight fr
14. ave the hoses removed and stored in accordance with Environmental Pumping Solutions recommendations The pumps should be repackaged and placed in a suitable clean dry storage area free from excess moisture and vibrations Protective blanking caps fitted before despatch from the factory should not be removed Any unpainted surfaces not factory treated with a rust inhibiting coating should have a protective coating applied Where applicable if pumps were supplied with electric motors fitted with anti condensation heaters these should be connected to a temporary supply and switched on throughout the storage period Locating the Pump have been reviewed and that any appropriate risk assessments have been Before mounting the pump make sure that all your site safety procedures completed Upon installation ensure that all markings on the pump will be clearly Li visible when installation is complete Ensure the pump is to be sited in an area where the ambient temperature during operation is not below 20 and above 45 Check that the foundation where the pump is to be mounted can carry the load of the pump Also have the appropriate SWL marked lifting gear crane ready for the given situation Ensure the foundation floor surface is flat and horizontal Minor irregularities in surface level can be accommodated by the use of shims placed under the support frame Ensure there is sufficient room around the pump to carry out the necess
15. clare that Equipment Peristaltic Pump Models L100 amp L150 is in conformity with the applicable requirements of the following documents Ref No Title Edition date BS EN ISO 12100 1 Safety of machinery Basic concepts general principles for design Basic 2003 terminology methodology BS EN ISO 12100 2 Safety of machinery Basic concepts general principles for design Technical 2003 principles BS EN 809 Pumps and pump units for liquids Common safety requirements 1998 BS EN 60204 1 Safety of machinery Electrical equipment of machines General requirements 2006 A1 2009 BS EN 61000 6 1 Electromagnetic compatibility EMC Generic standards Immunity for residential 2007 commercial and light industrial environments BS EN 61000 6 3 Electromagnetic compatibility EMC Generic standards Emission standard for 2007 residential commercial and light industrial environments hereby declare that the equipment named above has been designed to comply with the relevant sections of the above referenced specifications and is in accordance with the requirements of the Directive s IOC DY PINE M PR due ATD Pt Name Peter Wright Position Managing Director Done at Theale Berkshire UK On March 2010 The technical documentation for the machinery is available from the manufacturer at the above address Product Use Declaration Form Product Use Declaration Form In compliance with the Health amp Safety Regulations and the Control
16. d fluid through the hose and as soon as the compression roller has passed the hose recovers to its original shape due to the mechanical properties of the material Simultaneously fresh pumped fluid is drawn into the hose behind the compression roller by the continuous turning motion of the rotor The second compression roller will subsequently compress the pump hose Due to the continuous rotating movement of the rotor not only is new product sucked in but the already present product is pushed out by the moving compression roller When the first compression roller leaves the pump hose the second compression roller has already closed the pump hose and the product is prevented from flowing back This is known as the positive displacement principle pumping principle Pump hose The pump hose is made of specially compounded rubbers reinforced with nylon cords The outer cover of the pump hose is always made of natural rubber whilst the inner layer is supplied in a variety of materials to suit 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 Consult Environmental Pumping Solutions Limited or your authorised local 1 dealer for more detailed information about the range of hoses available and their chemical and temperature resistance Environmental Pumping Solutions pump hoses have been carefully machin
17. ed to ensure minimum tolerances in wall thickness It is very important to guarantee the correct compression of the pump hose because over compression can cause too high a load on the pump and pump hose leading to reduced pump hose life and gearbox failure Under compression will result in loss of capacity and backflow resulting in reduced pump hose life e Please refer to the maintenance section of this manual regarding adjustment of hose compression settings Hose Lubrication The pumphead is part filled with our specially compounded Envirolube lubricant The lubricant lubricates the compression rollers and movement between the hose and the pump housing and the cover To those familiar with other types of peristaltic pumps utilising compressions shoes our lubricant may appear thin but this is essential in order to reach the roller bearings with maximum efficiency of lubrication Our lubricant is the result of decades of development and is perfectly mixed for use specifically in the L series pumps ensuring the hose is fully lubricated at all times with no reaction on the hose material that would cause swelling and early hose failure Environmental Pumping Solutions Envirolube lubricant will not freeze during cold weather Drive systems The L series pumps described in this manual use a variety of drive types Motors and gearboxes are selected according to the particular application for which the pump is applied Available option
18. ed lubricant in safe and proper manner Refer to local Environmental restrictions as appropriate Unbolt the pump front cover and swing open on its hinges There are two options of hose removal with the L series pumps Either the complete hose and inserts can be removed as one element adele or the hose can be removed with the inserts left in the pump With both methods of hose removal we suggest that one of the compression rollers is removed To remove a roller ensure the roller is not in contact with the hose remove the roller spindle screw and screws holding the roller side plate in plate and lift the roller out Rotate the rotor so that the remaining roller lies between the inlet and outlet ports The hose can then be removed and a new one inserted easily without having to rotate the rotor To refit the compression roller rotate the rotor 180 so that the roller to be replaced lies between the inlet and outlet ports Removing the hose as an Element Assembly First disconnect suction and discharge piping Remove the insert retaining bolts from both hose inserts Lift the hose element assembly out of the pump withdrawing the inserts through the pump body Insert retaining bolts 16 Removing the hose only Note There is no need to disconnect the suction and discharge piping when removing the hose only via this method e Where difficulty pulling the hose off the connectors is encountered try cutting the hose along the
19. eessueeesseeeeseaeessanenenss SDSCIINCA VONIS sotiei RENE pl n at DAMIEN GIOI du i NEM Pump operating conditions ai ici asa aa aa sa a li ad o dn ac bt Materials of Construction eee ee eee e e a a aaa aaa Hose Lubricant Quantities c cccccccccececececscecececcccecececececscetacscavavaueuaunenensness Weights and DIMensiONS n suo initia inu omnia aul ia a a nn a Recommendations for Hose Storage eee eee eee ae EC Declaration of Conformity ne eee eee eee nenea eee Product Use Declaration Form eee eee eee eee aere Contact Information Manufacturer Authorised Distributor Environmental Pumping Solutions Limited 1210 Parkview Arlington Business Park Theale Berkshire RG7 4TY www environmentalpumping co uk Tel 0800 0180 007 Fax 0870 873 0282 International Tel 44 0 1635 576 028 International Fax 44 0 1189 657 783 Manual Revision 1 1 The information contained in this document is believed to be correct but neither Environmental Pumping Solutions nor its distributors or representatives accept any liability for any errors or omissions and reserves the right to alter any specifications without notice This manual is owned by Environmental Pumping Solutions Limited and may not be reproduced by any means in part without their written consent Reproduction by the user for the purposes of Installation Operation and Maintenance of their L Series peristaltic pump only excepted Copyri
20. ensure free running The motor should be rotated for enough turns to ensure the pump rotor has turned through 360 degrees If the gearbox ratio is 50 1 the motor fan must be rotated 50 revolutions If any difficulties are found these should be investigated and rectified otart up Checks Prepare the electric motor for operation in accordance with the manufacturer s instructions and ensure pump control panels are energised ready for operation When satisfied that all preliminary checks and procedures have been carried out start up the pump Whilst running carry out the following checks e Check the rotation of the rotor e Check for any leaks in the system e Check for excessive vibrations e Check the pumping capacity of the pump Generally monitor the behaviour of the pumpset during the run period ensuring that temperatures stabilise within the run period Check the integrity of the foundation holding bolts Following all start up checks if any items deviate from expected refer to the Troubleshooting section of this manual or contact Environmental Pumping Solutions Limited or your authorised local dealer 14 Maintenance Only use original Environmental Pumping Solutions parts when maintaining the pump Environmental Pumping Solutions Limited cannot A otherwise guarantee correct functioning of the pump Any consequential damage that occurs from the use of non original components cannot be warranted Routine Mainten
21. etween the inlet and outlet ports i Always recheck the roller gap after you have refitted the roller 20 Fitting the Front Cover The front cover gasket is a self adhesive strip that is pre applied to the pump and remains in place when the front cover is opened Should this gasket strip become damaged in any way it should be removed and a new strip applied owing the hinged front cover closed and hinge the swing bolts into the corresponding slots in the outer cover before tightening evenly e If the front cover has dropped on the hinges it may be helpful to use a lifting jack or similar under the cover to help align the swing bolts Be careful to avoid trapping hands and fingers when closing the hinged front cover Ensure the lubricant drain plug is installed with PTFE tape of similar demountable pipe thread sealant Fill the pump housing with lubricant through the fill plug hole Once filled you should be able to see the lubricant in the middle of the sight glass at the front of the pump Replace the fill plug and check the pump housing for leakage If previously disconnected reconnect all pipework and open all suction and discharge valves The pump is now ready for normal operation Upon restarting check for abnormal vibrations and other irregularities such as abnormal noise Rotor Removal Follow the procedures as detailed earlier for the removal of the pump hose Remove the rotor clamp screws B and slide the roto
22. ght 2009 2010 All rights reserved Introduction Thank you for choosing a quality pump from Environmental Pumping Solutions Ltd Critical information before start up pump it is necessary to read this manual thoroughly before putting it For safety reasons and in order for you to get the full usage of your new into service Ensure all commissioning checks on page 14 have been carried out Within 7 days of delivery and before mounting and installing the pump please make sure that the unit corresponds exactly to that ordered and has not been damaged during transport This manual is divided into 4 parts 1 Introduction to give the user an overview of the pump and this manual 2 Installation Guide for installing or uninstalling and commissioning the pump 3 Maintenance Guide for maintenance repair or troubleshooting 4 User Guide for daily use of the pump The L series pump range provides a high quality product that is designed to provide reliability low energy consumption and low maintenance costs Environmental Pumping Solutions Ltd supplies the complete range of peristaltic hose pumps including 10mm 15mm 20mm 32mm 40mm 50mm 65mm 80mm and 100mm In addition we proudly produce the largest hose pump in the World the L150 General These instructions are intended as a reference book by means of which qualified users are able to install commission and maintain Environmental Pumping Solutions L series peristaltic pump
23. illed in and signed declaration form declaring the conditions of use and materials pumped 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 in the declaration form what specific cleaning procedures have been followed and that the equipment has been decontaminated The declaration form is required for all items even if the parts have not been used A Declaration Form can be found at the end of this manual Warranties purporting to be on behalf of Environmental Pumping Solutions Limited made by any person including representatives of Environmental Pumping Solutions Limited its subsidiaries or its distributors which do not accord with the terms of this warranty shall not be binding upon Environmental Pumping Solutions Limited unless expressly approved in writing by a Director of Environmental Pumping Solutions Limited Description Operation of the pump The heart of the L series peristaltic pump is a specially constructed pump hose which lies within the pump housing Upon pump installation both ends of this hose are connected to the suction and discharge lines A rotor with two opposing compression rollers lies in the centre of the pumphead During pump operation the rotor rotates with the compression rollers compressing the pump hose This action pushes the pumpe
24. imensions The details below are approximate only Please refer to your Technical Data Sheet or Environmental Pumping Solutions for specific details of the supplied equipment mo L150 Net weight kgs 900 1800 Overall size cm 154x166x133 170x209x195 L100 L150 Gross packed weight kgs 1135 2264 Overall packed 170x190x150 190x230x215 case size cm 29 Recommendations for Hose Storage We recommend that pump hoses are stored in accordance with BS3574 Peristaltic Hoses can be considered as Group A products as detailed in this specification i e products with moderate susceptibility to deterioration The relevant points from this specification are Temperature Humidity Light Ozone Deformation Contact with Liquids Contact between Hoses Rotation of Stock To be below 25 c and articles stored away from direct sources of heat such as boilers radiators and direct sunlight For articles stored below 15 c their temperature should be raised to approx 30 c throughout their mass prior to use Humidity shall be such that condensation shall not occur The criterion for this is that either the storage temperature should be above the dew point or humidity levels should be low enough to ensure the dew point is below the storage temperature Protect from strong light sources in particular direct sunlight or intense artificial light having a high ultraviolet content Storage areas
25. ing strap may be positioned around the juncture of the gearbox and motor The length of this will need to be adjusted to establish a level lift if so desired Suitably rated lifting straps or slings only must be used Gearbox and motor lifting eyes must not be used for lifting the complete pump unit When lifting the pump ensure that all standard lifting practices are adhered to A and carried out by qualified personnel only X f lifting with a forklift truck ensure the forks are fully located through the complete pump frame Mounting the Pump The pump is fastened to the foundation via the holes in the frame or pump chassis using suitable anchor bolts If the pump is to be mounted on rubber pads it is very important that the connecting pipeline is fitted with a flexible joint Electrical Connection Electrical connection of the pump must only be done by suitably qualified personnel The motor is to be thermally protected against overload by a protective circuit switch and is to have the correctly sized fuse according to the local existing rules and regulations Important In order to insure that the pump remains free of static electricity the pump needs to be grounded This is done via the grounding of the motor The motor must be grounded with a wire of sufficient size 12 For electrical connection details please see the motor datasheet The pump should have its own dedicated electrical isolation switch meeting the requireme
26. nts of BS EN 60947 3 Switches disconnectors switch disconnectors and fuse combination units so that it is not possible to start the pump during maintenance There should also be an emergency stop button meeting the requirements of BS EN 60947 5 1 Electro mechanical control circuit devices and BS EN 60947 5 5 Electrical emergency stop devices with mechanical latching function It is recommended to have local electrical control to the pump for use during commissioning and maintenance operations These electrical items should be installed according to the manufacturer s instructions by an electrician qualified to install electrical equipment on machinery If the pump is incorporated into a more complex installation then the installer should ensure the completed installation complies with the Machinery Directive 2006 42 EC Use of Frequency Inverters The pump will not come with a motor that is suitable for use with a frequency inverter unless this has been stated on the pump technical data sheet Use of an inverter when no allowance has been made for one can be dangerous and may lead to motor failure Where the use of an inverter has been specified on the pump technical data sheet it is essential that the control panel does not allow an operator to run the pump outside of the turndown design parameters there specified Frequency inverters used with peristaltic hose pumps must be of the constant torque type and ideally sized a
27. om the pump so that the pump is not pumping directly into a restriction for example a 90 degree bend as this may cause the hose to come off Where bends are used ensure the radiuses are as large as possible It is recommended to use Y connections instead of T connections Prevent any possibilities of exceeding the maximum working pressure of the pump It is essential that you discuss this with your system designers in order to ensure safe system and pump operation If necessary fit an overpressure protection device To avoid misunderstanding protecting the motor against over current will A not protect the pump from overpressure Pump overpressure needs to be protected against independenily using a pipeline mounted overpressure protection device All L series pumps have a pressure overflow connection found on the front of the pump above the lubricant fill plug When the pump hose fails liquid will come out of this overflow connector If this is a potential safety or hygienic issue the connector will need to be piped back to a safe location in a way that will not impede normal atmospheric pressure reaching the pump body during normal operation Consider the maximum permissible working pressure of the pump and A pipework used Exceeding maximum working pressures may lead to serious damage Pulsations Some systems require pulsation dampers to avoid excessive and damaging pressure spikes and vibrations Situations that may lead to e
28. oo long for Consult Environmental the diameter creating too Pumping Solutions Ltd high suction pulsation losses Noise Pump cavitating Lower the speed or utilise a bigger pump or change the pipelines Pressure too high Clear pipelines and check pipe sizes Lower the pumping speed Rollers are not adjusted Adjust the roller occlusion correctly worn out needed not correctly fastened High pump speed with long Reduce pump speed suction and discharge lines Reduce the line lengths on or high product specific both suction and discharge Vibration of the pump and pipework gravity or a combination of where possible Consult these factors Environmental Pumping Solutions Ltd Too small diameter of Increase the pipework size suction and or discharge pipework Pressure too high Check discharge pressure is as per pump data sheet Check pump speed is as per pump data sheet Check pipelines are clear Check pump hose is not damaged New installation Check pipes sized correctly Pump draws too much Sedimentation of solid Empty the pump after use current substance when not using flush the pump with clean the pump water after use by the motor install larger pump Short Hose life Hose deteriorating Reassess the choice of High pulsations Consult Environmental Pumping Solutions Ltd for detailed advice lubricant on the outside occlusion 2 Probable Cause s Suggested Remedy on the inside occlusion Roller bearings bushings
29. ous damage to the pump equipment or in serious bodily harm CAUTION Procedures not carried out with the necessary care may result in serious damage to the pump equipment the surrounding area or the environment Remarks suggestions and advice During installation amp maintenance all personnel should ensure they wear suitable personal protection equipment PPE such as safety glasses gloves safety boots and safety helmets as appropriate Intended Use Environmental Pumping Solutions L series peristaltic pumps are designed exclusively for pumping suitable products as defined in the technical data sheet supplied with your final quotation Every other or further use is not in conformance with the intended use as laid down in EN 292 1 4 The manufacturer cannot be held responsible for damage or harm resulting from use other than the intended use If you wish to change the application of your pump please contact Environmental Pumping Solutions Limited or your authorised local dealer to establish if the change is appropriate for the supplied pump a 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
30. r and splined adapter off the shaft The rotor assembly is heavy and AN suitable lifting equipment will be peels required to support the load as it is mE A pulled off the gearbox shaft Gearbox Drive Removal Once the rotor has been removed the gearbox can be removed if required The fixing screws A are socket headed cap screws through the gearbox flange into the rear of the pump housing Before removing the gearbox fixing bolts ensure the gearbox is adequately supported via the correct lifting method and that the pump is properly fastened to the floor as removing the gearbox will cause a sudden change in the centre of gravity Remove the gearbox fixings and carefully pull the gearbox off the mating spigot 21 Gearbox Drive Replacement Prior to assembly clean and degrease all mating surfaces ensuring all faces are free from traces of paint and sealants Carefully lift the gearbox drive into place and locate the flange spigot on the rear of the pump housing Line up the fixing holes and insert the socket headed cap screws into the gearbox adapter on the rear of the pump housing Rotor Replacement Clean the bore of the rotor assembly applying a small amount of anti seize compound such as Copaslip to the gearbox splines Slide the rotor assembly onto the gearbox shaft ensuring it is square at all times and fit the retaining screws j Do not hammer the rotor assembly if the shaft is a tight fi
31. r in these instructions it may be found necessary to further adjust the rollers to decrease the distance A Should it be found necessary to further adjust the rollers to decrease the A distance A this should be done in increments of 0 5 mm If the rollers are adjusted too much over occlusion of the hose will occur Hose over occlusion is detrimental to hose life Fitting the Pump Hose Take care when fitting the pump hose there is a possibility of trapping hands if care is not taken Ensure the pump body housing is clean and free from foreign particles 18 If not already removed remove one of the compression rollers To remove a roller ensure the roller is not in contact with the hose remove the roller spindle screw and screws holding the roller side plate in plate and lift the roller out Rotate the rotor 180 so that the remaining roller lies between the inlet and outlet ports The hose can then be inserted easily without having to rotate the rotor To refit the compression roller rotate the rotor 180 so that the roller to be replaced lies between the inlet and outlet ports Hefitting the hose as an Element Assembly Prior to installing a new element hose assembly ensure that both hose inserts are aligned correctly The hose inserts can only be fitted to the pump in one a orientation checking the correct orientation and alignment now will avoid delays later Correct alignment can be achieved by assembly on a flat
32. s The following options are available for the L series range of pumps e High lubricant level float switch detects hose failure e Flanged pipework connections e Complete stainless steel pumps Installation Unpacking Upon unpacking of the pump check and inspect all items against the purchase order and packing list and for any damage caused during shipment All claims for shortages and or damage must be notified immediately to Environmental Pumping oolutions Limited Suitable lifting equipment must be used when handling components and assembling pumps ENVIRONMENT When disposing of unwanted packaging materials please consider the possibilities for reuse or environmentally friendly processing of packaging materials Always observe local regulations with respect to disposal of non reusable items Storage After receipt and inspection if pumps are not to be put into service immediately provision should be made for the pump to be rotated for a couple of turns on a weekly basis ensuring the rollers are not allowed to come to rest in the same position consecutively Alternatively one roller can be removed from the pump leaving the remaining roller not in contact with the hose between the inlet and outlet ports Failure to adhere to the above procedure may result in a permanent set of A the hose which can result in reduced performance and premature hose failure Pumps that are to be stored for extended periods of time should h
33. s These instructions do not absolve the user of responsibility for carrying out work in accordance with good engineering practices and adherence to local Health amp Safety regulations Documentation on the drive system used with the pump is not included within this manual Reference must be made to separate documentation for the drive system and its recommendations and instructions strictly observed For further information specifically about the L series range of peristaltic pumps which is not found within these instructions please contact Environmental Pumping oolutions Limited or your authorised local dealer Please ensure you have the following data at hand e Serial number of the pump e material of the pump hose e serial number of the drive gearbox and motor Identification plates are mounted on the pumphead drive gearbox and electric motor Model Year Ser No REFER TO OPERATION MANUAL BEFORE USE FOR DUTY RATING DETAILS SEE MANUAL Manufacturing information Givironmental Cc Arlington Business Park Theale RG7 4TY United Kingdom Tel 44 0 1635 576 028 www environmentalpumping co uk Suppliers Information Labels fixed to the pump body contain model type year of manufacture product serial number and manufacturer s details Safety In these instructions the following symbols are used WARNING Procedures which if not carried out with the necessary care may result in seri
34. side of the connector as shown Carefully loosen top and bottom hose clamps From the bottom hose connector pull the hose off and out as far as possible Continue pulling out the old hose until you have arrived at the top hose connection and finally pull the hose off this connection Check mechanical parts such as Rollers bushings and shafts for damage or wear Clean all components thoroughly flushing with clean water if necessary Pay particular attention to any residue of pumped material Deposits of any abrasive media left within the pump body will be detrimental to future component life Check before replacing the hose that it is the correct diameter and material and measure the exact thickness of the hose and note this down This is needed if adjustment of the rollers is needed Before fitting the new hose we recommend you check the compression roller occlusion setting to ensure optimum pumping efficiency throughout the pump life a When ordering spare parts please make reference to the serial number on the nameplate Replacing the Roller Bushes With the hose removed remove the compression rollers if not already done so by removing the roller spindle screw and lifting the roller out of the roller carrier Using a suitable mandrel press the old bushes out of the roller Lightly lubricate the outer surfaces of
35. t in the rotor pull the AN rotor onto the shaft with a long bolt Hose Connector Assembly The hose connector inserts may be fitted independently rather than as a hose element assembly After first ensuring all mating faces are clean fit the gaskets over the outer connection of each hose connector P ccr E TL ee Pe H Insert hose connector in to the pump passing the outer connection through the respective port in the pump body with the gaskets on the inside of the pump body Insert retaining bolts Insert and tighten the insert retaining bolts Parts List amp Sectional Drawing Please refer to the simplified parts list below in conjunction with the cross sectional drawings on the following pages For a more detailed drawing and information on spare parts and the ordering of spares please contact Environmental Pumping Solutions Limited or your authorised local dealer mre pp T 1 PumpHousing 1 1 36 washer 1 1 8 4 PumpFrameRight 1 38 Springwasher 4 5 j Pumprrmelet 1 39 Nu 4 6 CrossBarWelded 2 6 7 Frame Mounting Screws 4 8 FlatWasher 8 9 SpingwWasher 1 4 6 5m BESE LT 43 Rotor to Motor Fixings 12 44 FlatWasher 12 12 Spring Washer Nt o o 12 4 4 5m 1 1 12 12 12 12 11 Cross Bar
36. t least one size larger than the pump fitted motor kilowatts ATEX Approved Units Standard L series pumps must not be used in potentially explosive hazardous atmospheres European Directive 94 9 EC ATEX Directive If you require a pump to operate in a hazardous area classification please contact Environmental Pumping Solutions Limited or your authorised local dealer for more detailed information 13 Commissioning Prestart up Checks Before commissioning carry out the following checks e Check the pipework connections ensuring there is no undue strain on the pipework e Ensure that there are no obstructions such as closed valves in the pipework lt is advisable to flush the system TI through with water to clear any debris e Ensure the Transport Plug is removed alai from the pressure overflow connection on the front of the pump e Check the pump casing is filled to the correct level with Envirolube specially compounded Roller Hose Lubricant If necessary add lubricant Before adding lubricant check you have the correct hose lubricant fill only with our Roller grade lubricant e Check there is oil in the gearbox and filled to the correct level It is advisable prior to powering up the pump to check rotation by hand to ensure there are no obstructions This can be achieved as follows Isolate and lock off the electrical supply Remove the motor fan cowl and turn the electric motor fan by hand to
37. the new bushes and press into place ensuring the face of each bush is flush with the face of the roller each side Refitting the roller is a reversal of the removal process 17 Adjusting the Compression Rollers The distance A between the inner face of the pump body did and the compression roller should be set according to the following formula E Az 2xt t at pressures O to 5 bar When the application pressure is to exceed 5 bar subtract 0 25 x t1 x Pd m Variable Value A Distance from roller to pump housing see Figure 1 t Thickness of the hose wall see Figure 2 t1 Material dependent scale see below Pd Nominal working pressure on the pump FIGUER EUH een ane to pump housing Example Hose thickness t 14 mm Hose material NBR t1 1 0 mm Working pressure Pd 7 bar A 2x14 1 0 27 0 mm Subtraction from higher working pressure 0 25 x 1 0 x 7 1 75 mm Figure 2 Thickness of the hose A 27 0 mm 1 75 25 25 mm Hose material Scale t1 Hose material Scale t1 Natural rubber 1 5 mm Butyl 1 0 mm NBR Nitrile 1 0 mm Hypalon CSM 1 0 mm To adjust the compression roller gap shims should be inserted under the roller carrier Additional shims of 0 5mm and 1 0mm thickness are available from Environmental Pumping Solutions Limited or your authorised local dealer The above procedure is intended as a guide only After carrying out operational i tests as detailed late
38. xcessive pulsations and vibration are e incorrectly secured pipelines e high pump speeds with long suction and delivery lines or the product SG is high e pipeline bore is too small Where unacceptable pulsations are encountered it may be possible to install pulsation dampeners to alleviate the problems Dampeners need to be sized very carefully in order to protect the pump and system from excessive pressure peaks e Never use an existing dampener employed on another application or pump make and assume it will automatically work on an application with an L series pump Different pump displacements and system characteristics often mean a dampener will not work effectively e Many dampeners are not suitable for variable speed applications Where pump speeds and pressures vary dampeners need to be carefully selected and sized to accommodate all the duty conditions e Consult Environmental Pumping Solutions Limited or your authorised local Ra dealer for more detailed information about the need and use of pulsation dampeners 11 Lifting the Pump The complete pump may be lifted either with the use of a forklift truck by utilising the fork pockets in the pump frame or by use of the lifting eyes on the pump frame Due to the selection of drives available the centre of lift will vary dependant upon the size and weight of the drive fitted If desirable to lift the pump squarely an additional lift
39. y positioned in the pump housing as detailed below A Failure to correctly position the hose may lead to premature hose failure Insert retaining bolts Refitting the hose only inserts not removed Push the hose clamps and hose onto the top connector do not tighten clamps To aid assembly lubricate the hose connector and hose bore with a little Li hose lubricant Never lubricate the hose or any components A in contact with the pump hose with mineral oils or lubricants these are not compatible with the materials of hose construction Push the hose over the bottom connector put the hose clamps over the hose do not tighten clamps With the roller removed the hose can be pushed into the housing Positioning and Seating the hose Roller removed Ensure the hose clamps are loose If the hose was fitted as a complete element with inserts it will be necessary to loosen the clamps Push the hose firmly into the U arc of the pump body ensuring contact is made with the hose and pump body along the complete length of the compression path and then tighten both hose clamps If difficulty is found seating the hose against the 9 pump body try refitting the roller as below the a action of the rollers compressing the hose as the pump is rotated will help position the hose Refit the compression roller by first rotating the rotor 180 so that the roller to be replaced lies b
Download Pdf Manuals
Related Search