Operating instructions
Contents
1. bovyser Operating instructions AMP Series Peristaltic Pump AMP Instruction Manual AT Table of contents L ANE OGUCHON i asse ee AE EE Ge OAR EE ae oe ER EE OE De 3 2 Safety and Responsibility ccecccceccccsccccsceccececcecsccccececcececcccsceccececes 5 3 Functional QeSHIDUON asie ei eed es De ee Ee EE RO GE EE EE Ee 9 4 Transport and Storage EE 11 5 Assembly and Installation sesse sesse ses ese see Ee ee GE Ee ee EN ee ee ese 12 6 COMMISSIONING sesse Ed SIE De GE II GE GE EG GE OE EG EG Ge 18 7 Maintenance repair malfunctions disposal and spare parts 19 ES Ge OE AA PAA AAP AA 22 9 Declaration of CONMPOIMItY cscccccccecccccceccececcccsceccececccceccccsceccececes 31 10 Guard OC sd EER DE ES N NG EE GE EE BE 32 AMP Instruction Manual el ee E 1 Introduction This manual forms an integral part of the pump and must accompany it until its demolition The series AMP peristaltic pump is a machine destined to work in industrial areas and as such the instruction manual must form part of the legislative dispositions and the applicable technical standards and does not substitute any installation standard or eventual additional standard 1 1 Explanation of the safety information The instructions of this manual whose inobservance is determined as a failure to meet safety standards are identified by this symbol The instructions of this manual whose inobservance compromises electri2. 8 2 Spare parts exploded AMP 16 C and AMP 19 C Model SI ei K PP ooN E Y e AMORO FR Ge ys e H 1 6 M e SA MI 4 If TS f 4 AMP Instruction Manual ml od 8 2 1 AMP 16 C Model Pos Description Guantity Reference 101 0201 Long tu Ma e Metalic cover Jo 10 Press flange standard Press flange thermoplastic hose iT Base plate lameness a pe EE Om a 21 AMP Instruction Manual el gf er re ee 8 2 2 AMP 19 C Model Pos Description Quantity Reference 101 02 01 Long stud aa Short stud 8 Netallie cover JO 11 Ng Base plate SS 14 Hose NORPRENE 105 00 26 NG Hose TYGON as Dier li simo TOTOass 28 AMP Instruction Manual AA mmm 8 3 Spare parts exploded AMP 22 Model FA AGS 5 REY Swit PP S 29 AMP Instruction Manual Pos Description Bes 1 Pump casing 113 00 01 2 130002 Roller thermoplastic hose 113 00 06 e Vroler suppor Ja mamm eeng 02007 o Front cover matalic par 7 moo 10 Front cover plastic part TJ 180009 113 00 11 Connection PP NPT 2 113 00 14 Connection SMS 113 00 17 Connection TRECLAMP mor 12 Press flange rubber hose Press flange thermoplastic 113 00 20 13 Base plate enee mepiess 114 Rotorwasher 1 80028 115 Press porimei 114020025 1116 Press pommel blind 181 1020025 3 i7 113 00 24 Hose NBR 1 113 00 25 mosens J CT 18 Dr
3. protect the device from environmental influences such as UV rays Moisture Frost etc AMP Instruction Manual 3 Functional description The AMP Series is a displacement pump The feed chemical is conveyed by the rotor squeezing the hose in the direction of flow No valves are needed for this This ensures gentle handling of the metered media The AMP Series has been designed for safe and uncomplicated operation as well as straightforward maintenance The AMP Series can be used for many different media However this pump type is often the optimal solution for abrasive shear sensitive and viscose media Typical areas of use include processes where only a low discharge pressure is required max 8 bar 3 1 Construction Main modules Drive Unit Housing Base frame The pump housing is closed off with a screwed front cover in order to avoid the risk of injury The motor serves to drive the rotor Two rollers at the ends of the rotor serve to press the pump hose against the pump housing The rotary movement of the rotors alternately press and relax the rollers in relation to the pump hose This serves to suck the media and convey it into the metering line AMP Instruction Manua Fig 1 Diagram of functional principle 1 Housing 2 Rotor 3 Rollers 4 Hose 10 AMP Instruction Manual d Transport and Storage 41 Transport The pump is protected by a cardboard packaging The pack
4. 00 17 102 00 18 102 00 19 102 00 20 102 00 21 102 00 22 102 00 11 102 00 23 102 00 12 102 00 24 102 00 25 102 00 26 102 00 27 102 00 32 102 00 28 102 00 29 102 00 30 102 00 31 102 00 33 102 01 06 102 01 13 102 01 07 23 AMP Instruction Manual Description Shim 3 rollers 18 Rotor washer 8 1 2 AMP 13 B Model Description Casing Rotor Rotor 3 rollers 3 Roller shaft 4 Roller ball bearing 5 Roller 35 Long stud Short stud 7 Press flange standard Press flange thermoplastic hose 11 Base plate Base plate S S 2 Press pommel 3 Press pommel blind 14 Hose NR Hose NR A Hose NBR Hose NBR A Hose EPDM Hose NORPRENE 10 mma Quantity Reference 102 01 14 1 102 01 10 Reference 102 01 01 102 01 03 102 01 11 102 01 04 102 01 02 102 01 09 102 00 07 102 00 14 102 01 08 102 01 05 103 00 10 103 00 15 103 00 16 103 00 17 103 00 18 103 00 19 103 00 20 103 00 21 103 00 22 7 1030011 2 102 0011 102 00 12 EEN EE 020024 102 00 25 102 00 26 103 00 27 103 00 33 103 00 28 1033 00 29 103 00 30 WK D 103 00 31 Quantity N N 24 AMP Instruction Manual Pos Description Quantity EN Hose HYPALON 103 00 32 Driver JA 15 Driver Roller support 102 01 06 Roller support 3 rollers 102 01 13 7 shim o w Shim 3 rollers P 102 01 14 Roller washer 102 01 10 25 AMP Instruction Manual AA mmm
5. aging materials are recyclable 4 2 Storage The pump should be in a resting position The hose should not be compressed Avoid areas open to harsh weather or excessive humidity For storage periods of longer than 60 days protect the coupling surfaces clamps reducers motors with adequate anti oxidant products Spare hoses should be stored in a dry place away from direct light 11 AMP Instruction Manual el gf mmm 5 Assembly and Installation 5 1 Ambient conditions Assembly is to be carried out in the following order If the pump has to be installed outdoors then it is to be equipped with protection against sunlight and weather influences When positioning the pump ensure that sufficient room for access is provided for all types of maintenance work Limit values for hose temperature and pressure Material Min Temp C Max Temp C Min Temp C Nap Hose Feed chemical Feed chemical Environment Bar 80 OT At max T3 the life of hose is drastically reduced Please contact with Boyser or authorized distributor for high T application lu EE 5 2 Correct installation of the pump 5 2 1 Suction side The pump is to be positioned as near as possible to the liduid container so that the suction side is kept as short and straight as possible The suction line must be absolutely airtight and made of a suitable material so that it is not squeezed together under vacuum The diameter must corre
6. an be actuated AMP Instruction Manual ll ea E In addition as the hose has an indeterminate life and due to the possibility of its breakage or deterioration the user is responsible for the prevention of a possible although most unlikely incorporation of particles form the hose into the product being pumped This can be achieved e g by means of filtration a hose rupture alarm or other means suitable for the respective process CIP cleaning In the event of CIP cleaning it is necessary to obtain information from the manufacturer about correct installation of the pump a special installation is required as well as regarding the compatibility of the cleaning agents with the pump hoses and the hydraulic connections Cleaning should be undertaken at the recommended maximum temperature Direction of rotation flow direction Possible consequence Material damage right through to destruction of the unit The pumps direction of rotation in relation to the desired flow direction must be checked prior to every start Disconnect the pump from the mains Possible consequence Personal injury You may only carry out work on the pump after it has previously been switched off and disconnected from the mains AMP Instruction Manual el ee E Environmental influences Possible consequence Material damage right through to destruction of the unit The device is not suitable for outdoor operation Take suitable measures to
7. cal safety The instructions of this manual whose inobservance compromises the correct working of the pump are identified with this symbol 1 2 Users qualifications Pumps are machines that due to their functioning under pressure and moving parts can present dangers Improper use Removing the protections and or disconnecting the protection device AMP Instruction Manual The lack of inspections and maintenance They can cause serious damage or injury The person in charge of safety should therefore guarantee that the pump is transported installed put in service used maintained and repaired by qualified personnel who should therefore possess Specific training and sufficient experience Knowledge of the technical standards and applicable laws Knowledge of the general national and local safety standards and also of installation Any work carried out on the electrical part of the pump should be authorized by the person responsible for safety Given that the pump is destined to form part of an installation it is the responsibility of whoever supervises the installation to guarantee absolute safety adopting the necessary measures of additional protection AMP Instruction Manual elle E 2 Safety and Responsibility 2 1 General safety information Live parts Possible consequence Fatal or very serious injuries Measure The device must be disconnected from the power supply before it is opened Isolat
8. ck that the optional electrical components are connected and are working properly Install a manometer in the pressure line if the back pressure value is unknown Check the operating instructions in order to ensure that the flow values pressures and power consumption of the motor do not exceed the rated values Install a pressure relief valve in the pressure line in order to protect the pump in the event that a valve is unintentionally closed off or the line is blocked in another way 18 AMP Instruction Manual 7 Maintenance repair malfunctions disposal and spare parts 7 1 7 2 Lubrication Check that the rollers and the hose are sufficiently lubricated o Check every 300 operating hours Gear reducer o The lubrication is permanent Is not necessary any servicing Exchanging the pump hoses 7 2 1 Exchanging the pump hoses dismantling oa POND gt N Close off all valves in order to prevent leakage of the feed chemical Dismantle the pump pipes from both discharge and suction sides Remove the front cover Remove a roller the roller that is not touching the pump hose Mount the front cover Turn the rotor vvith the help of the motor so that the remaining roller is not pressing against the pump hose Dismount the front cover Remove the press flange from the pump housing Remove the pump hose to be exchanged Dismantle the hydraulic connections from both pump hose ends Exchanging the pump hoses in
9. e damaged faulty or manipulated devices from the mains in order to de energise Emergency stop switch Possible consequence Fatal or very serious injuries An emergency stop switch is to be connected for the entire plant This should enable the entire plant to be shut down in the event of an emergency in such a way that the overall plant can be brought into a safe condition Unauthorized access Possible consequence Fatal or very serious injuries Measure Ensure that there can be no unauthorized access to the unit Hazardous media contamination of persons and equipment Possible consequence Fatal or very serious injuries material damage Ensure that the pump hoses are resistant against the media being conveyed Always observe the safety data sheets for the media to be conveyed The system operator must ensure that these safety data sheets are available and that they are kept up to date The safety data sheets for the media being conveyed are always decisive for initiating countermeasures in the event of leakage to the media being conveyed gt gt gt gt AMP Instruction Manual PR mmm Observe the general restrictions in relation to viscosity limits chemical resistance and density Always switch the pump off before exchanging the pump hose Correct and proper use Possible consequence Fatal or very serious injuries The unit is not intended to convey or regulate gases or solid media Do not exceed th
10. e rated pressure speed or temperature for the pump The unit may only be used in accordance with the technical data and specifications provided in these operating instructions and in the operating instructions for the individual components The system is not designed for use in areas of risk from explosion Only switch the pump on if it has been properly fastened to the floor Only switch the pump on if it the front cover has been attached Do not carry out any maintenance operations or dismantle the pump without first making sure that the pipes are not under pressure and are empty or isolated In the case of the hose becoming stuck during extraction or fitting it is necessary to reverse the direction of the pump relubricate and then repeat the operation As the peristaltic pump is volumetric and its functioning is positive displacement it is necessary to prevent a possible overload of pressure due to for example the accidental closure of a valve For this reason it is advisable to fit a safety device such as a safety valve pressure limiter etc Operational lifetime of the pump hoses Possible consequence Fatal or very serious injuries The operational lifetime of the pump hoses cannot be precisely specified For this reason the possibility of fracture and consequential leakage of liquids must be accounted for If the hose rupture alarm optional is fitted then the pump can be stopped and or an electrical valve c
11. essive squeezing increased wear and tear to pump and hose The shims are fitted in the factory You can adapt the number of shims to the actual operating conditions according to the following table 14 AMP Instruction Manual 5 3 1 AMP 10 B Model Number of shims of 0 5 mm thickness a NR NBR EPDM HYPALON NR A and NBR A 1 min Factoring default setting if working pressure is not informed b Norprene 1 min Amin o O 80 99 a e j Q fs 19 2 0 15 15 15 5 NB Factoring default setting if working pressure is not informed 5 3 2 AMP 13 B Model Number of shims of 0 5 mm thickness a NR NBR EPDM HYPALON NR A and NBR A 1 min os 12039 langa at laog paa gg mm e em 20 E o Factoring default Sr if working pressure is not informed b Norprene 1 min a EE 20 39 40 59 SE E EE EE Factoring default setting if working pressure is not informed 15 AMP Instruction Manual 5 3 3 AMP 16 C Model Number of shims of 0 5 mm thickness a NR NBR EPDM HYPALON NR A and NBR A 1 min Factoring default setting if working pressure is not informed b Norprene 80 99 Fa N 20 19 19 19 19 19 _ Factoring default setting if vvorking pressure is not informed 5 3 4 AMP 19 C Model Number of shims of 0 5 mm thickness a Norprene and Tygon 1 min Amin o 80 99 w Ses j j fs fs 20 5 15 15 GG Factoring default setting if workin
12. eter on the suctions Insufficient diameter on the suction side side as far as possible Air introduction in the suction Check connections and accessories for air connections tightness 20 AMP Instruction Manual Tighten connections and accessories High pulsation on suction Mount antipulsation equipment Reconsider application speed etc The pipes are not correctly fastened Fasten pipes correctly e g wall brackets Pump speed too high Reduce pump speed Vibrations on pumps and Insufficient nominal width of the pipes Increase nominal width pipelines Pump base plate loose Fasten base plate Pulsation dampers insufficient or Install pulsation dampers on suction and missing or discharge side Check the compatibility of the hose with Reduced flow or pressure Chemical exposure the liquid being conveyed the cleaning fluid and the lubricant High pump speed Reduce pump speed z High conveying temperature Reduce product temperature hort operational lifetime of the High operating pressure Reduce operating pressure hoses SS e Pump cavitation Check the suction conditions Abnormal elevation of temperature Check rollers shaft mounting Unsuitable lubricant Use lubricant BOYSER Insufficient quantity of grease Top up lubricant High inlet pressure gt 3 bar Reduce inlet pressure Pump hose Pump hose filled with deposits Clean or replace the pump hose pulled into the mee Holder press flange insufficiently ump housin S pum
13. g pressure is not informed 5 3 5 AMP 22 Model Number of shims of 0 5 mm thickness a NR NBR EPDM HYPALON NR A and NBR A 80 99 2 ja ao 1 1 20 la 2 la 22o EE 16 AMP Instruction Manual el gf mmm Factoring default setting if working pressure is not informed b Norprene 1 min Amin o 20 39 40 59 80 99 Factoring default setting if working pressure is not informed 17 AMP Instruction Manual el gf mmm 6 Commissioning 6 1 Testing prior to commissioning the pump The following tests are to be carried out Ensure that the pump has not been damaged during transportation or storage Immediately report any damage to the supplier Check that the mains voltage is suitable for the motor Ensure that the hose is suitable for the fluid to be conveyed and that it is not damaged Make sure that the temperature of the liquid does not exceed the recommended temperature range Only switch the pump on if it the front cover has been properly attached Check that the rollers are correctly fitted and fastened Check that the drive pump and the inner of the rollers are correctly greased The specially formulated grease can be obtained from BOMBAS BOYSER S L or from the authorized distributor Check that the thermal overload protection not included in the delivery scope corresponds to the value specified on the motor type plate Check whether the direction of rotation is correctly adjusted Che
14. iver 1 19 Ball bearing roller 113 00 31 Lip seal roller 113 00 32 1 8 Short stud 102 00 14 1 1 30 AMP Instruction Manual 9 Declaration of Conformity Original EC Declaration of Conformity We hereby declare BOMBAS BOYSER GL CI Narcis Monturiol 24 Pol Ind Can Magre 08187 Sta Eulalia de Roncana Barcelona Spain That the following designated product complies with the pertinent fundamental safety and health reduirements of the EC Directive in terms of its design and construction and in terms of the version marketed by us This declaration loses its validity in the event of a modification to the product not agreed with us Description of the product Peristaltic pump BOYSER AMP Product type AMP 10 B AMP 13 B AMP 16 C AMP 19 C AMP 22 Serial no Refer to nameplate on the device Pertinent EC Directives CE Declaration of Conformity Ann Il A 2006 42 CE The pump is conform to the safety requirements according to the 2006 42 CE norms and amendments Manufacture Declaration Ann Il B 2006 42 CE The pump cannot be operated before the machine in which is assembled the pump will be declared in conformity with the safety requirements according to the 2006 42 CE norms and amendments gt zz JB Signature Details of the signatory Technical Manager 31 AMP Instruction Manual 10 Guarantee We guarantee against all manufacturing defects and guarantee the materials tha
15. p g tightened Re tighten holder press flange Insufficient grease Top lubricant Insufficient motor performance Check motor and replace if necessary Insufficient output from frequency The frequency converter must match the The pump does converter motor not start up Check voltage Start occurs at minimum Blockage in the pump 10 Hz AA AA Check if the suction or discharge side is 9 Pasia blocked Rectify blockage 21 AMP Instruction Manual AA mmm 8 Spare parts 8 1 Spare parts exploded AMP 10 B and AMP 13 B Model 22 AMP Instruction Manual 8 1 1 AMP 10 B Model wesch mk 3 4 5 1 10 1 A 15 16 1 Description Casing Rotor Rotor 3 rollers Roller shaft Roller ball bearing Roller 35 Long stud Short stud Front cover Gasket front cover Connection S S BSP Connection PP BSP Connection PVDF BSP Connection S S NPT Connection PP NPT Connection PVDF NPT Connection DIN NW 10 Connection SMS Connection TRI CLAMP 1 2 Press flange standard Press flange thermoplastic hose Base plate Base plate S S Press pommel Press pommel blind Hose NR Hose NR A Hose NBR Hose NBR A Hose EPDM Hose NORPRENE Hose HYPALON Driver Roller support Roller support 3 rollers Shim Quantity Reference 102 01 01 102 01 03 102 01 11 102 01 04 102 01 02 102 01 09 102 00 07 102 00 14 102 01 08 102 01 05 102 00 10 102 00 15 102 00 16 102
16. spond to the rated diameter of the pump hose A larger diameter is recommended in the event of viscose liguids The pump is self priming and does not reduire an admission valve The pump is reversible and the suction connection can therefore comprise of one of AMP Instruction Manual lle aa kel two options Normally the option is selected which is best suited to the physical conditions of the installation It is recommended to use a flexible transition between two fixed pipes and the hydraulic connection of the pump in order to avoid the transmission of vibrations 5 2 2 Discharge side The discharge line is to be kept as straight and short as possible in order to avoid performance reduction The diameter must correspond to the rated diameter of the pump hose A larger diameter is recommended in the event of viscose liquids It is recommended to use a flexible transition between two fixed pipes and the hydraulic connection of the pump in order to avoid the transmission of vibrations 5 3 Adjusting the roller pressure The peristaltic pump is equipped with shims in order to adjust the precise pressure distance to the roller dependent on speed and operating pressure Fig 2 1 Roller 2 Shims 13 AMP Instruction Manual N aa Fig 3 Squeezing the hose 1 Hose in normal shape 2 Insufficient squeezing back flowing media in the cavity will destroy the hose within a short period of time 3 Perfect squeezing 4 Exc
17. stallation Clean the interior surfaces of the pump housing Lubricate the internal surfaces of the pump housing at the contact surfaces to the pump hose with original silicon grease 3 Check the rollers Ensure that the roller surfaces are not damaged 4 Attach the hydraulic connections at both hose ends with the help of the press flange 19 AMP Instruction Manual 7 3 OO N O A 9 Lay the pump hose into the pump housing Fasten the press flange to the pump casing Mount the front cover Turn the rotor with the help of the motor so that the remaining roller presses against the pump hose Dismount the front cover 10 Re attach the second roller with shims back onto the rotor 11 Lubricate the pump hose and the rollers 12 Attach the front cover to the pump housing 13 Mount the pipes from both discharge and suction sides 14 Open all of the valves Troubleshooting temperature Pump hose has no lubricant Lubricate pump hose Increased pump Increased product temperature Reduce product temperature pressure Insufficient or poor suction conditions Check suction line for blockages Valves on discharge and or suction side Sit ne ag produd kata Reduced flow or Insufficient product quantity in storage Fill h HEEN ill storage container or exchange pump Suction line too long Shorten the suction line as far as possible High viscosity of medium Reduce viscosity as far as possible Increase the diam
18. t compose the electro pump BOYSER for one year from the date of delivery This guarantee does not include the hose or the lubricant as these are elements that have a normal function wear irrespective of their duration This guarantee is valid as long as the equipment functions within the parameters indicated in the technical information card supplied with every pump or on subsequent changes authorized by BOMBAS BOYSER S L This guarantee includes materials and work but not the transportation of materials to or from our warehouses in Santa Eulalia de Roncana Barcelona being necessary to do so arising from the necessities of the client the corresponding costs of displacement and expenses will be charged 32
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