BA-M300-GB/10.19 Peristaltic Series M300 Series T300

Operating and Installation Instructions Installation, Operation and Maintenance

www.cranechempharma.com ELRO® Peristaltic Pumps Series M300 / T300

This is the translation of the original declaration of conformity for ELRO® peristaltic pumps series M300 / T300.

2 ELRO® Peristaltic Pumps Series M300 / T300

EC Declaration of Conformity

in compliance with the Machinery Directive 2006/42/EC We hereby declare, that the units manufactured in series production

Designation: ELRO Peristaltic Pump and ELRO peristaltic pump heads with/without mounting frame

Series: M300, T300

Manufacturer: Crane Process Flow Technologies GmbH Heerdter Lohweg 63 - 71 40549 Düsseldorf

Serial number: (see identification plate) in the version delivered by us, is in compliance with the following applicable regulations:

EC directives: Machinery Directive 2006/42/EC EMC Directive 2014/30/EU

Harmonized standards: EN ISO 12100:2011-03, EN ISO 13857:2008-06, EN 809:2012-10

Mr. Ralf Rennwanz is authorized to compile the technical documents.

Crane Process Flow Technologies GmbH Heerdter Lohweg 63 - 71 40549 Düsseldorf

Place, date: Düsseldorf, 31.10.2019

Signature of manufacturer:

Information on signatory: Hans-D. Ptak, Managing Director

3 ELRO® Peristaltic Pumps Series M300 / T300

II 2G Ex h IIB T3 Gb EU Declaration of Conformity in accordance with directive 2014/34/EU for equipment intended for use in potentially explosive atmospheres

The manufacturer Crane Process Flow Technologies GmbH, Heerdter Lohweg 63-71, 40549 Düsseldorf,

declares that the pump units manufactured in series production

Description: ELRO – Peristaltic Pump

Series: M300 including drive and accessories

Pump materials: NBR, CSM, NR all are electrically conductive

Connecting ports: Stainless steel, bronze; PP electrically conductive Base frame: Fire fighter frame high-grade steel or galvanized steel Pulsation damper: High-grade steel with CSM diaphragm electrically conductive Suction/pressure hoses: electrically conductive Barrels and suction accessories: Stainless steel

Drives: All drives have their own declaration of conformity issued by the supplier

Installed electrical components: all electrical units have their own declaration of conformity issued by the supplier

in the version delivered by us, is in compliance with the following applicable regulations:

EC Directive: Directive 2014/34/EU for equipment authorised for use in poten- tially explosive environments.

Conformity assessment procedures: Equipment group II, category 2G, explosion group IIB temperature class T3, equipment protection level (EPL) Gb

Harmonised standards: DIN EN 1127-1:2011-10 DIN EN ISO 80079-36:2016-12 DIN EN ISO 80079-37:2016-12

Place, date: Düsseldorf, Germany, 26/09/2019

Signature of manufacturer:

Information on signatory: Hans-Dieter Ptak, Managing Director

4 ELRO® Peristaltic Pumps Series M300 / T300

Table of contents Page

1.0 Introduction...... 7

1.1 Warranty...... 7 1.2 Transport, storage...... 8 1.3 Principle of function...... 8

2.0 Safety...... 10

2.1. General information...... 10 2.2 Intended use...... 11 2.2.1 Unintended use 2.3 Operation of pump...... 11 2.4 Conversions and alterations to the pump...... 12 2.5 Symbols and safety notes...... 12 2.6 Maintenance work...... 12 2.6.1 Health and safety information on electric equipment...... 13 2.6.2 Health and safety information on lines under pressure...... 14 2.6.3 Regulations and instructions on lubrication...... 14 2.7 Noise emissions...... 15 2.8 Use of pumps in potentially explosive environments...... 15

3.0 Notes on installation and use...... 16

3.1 Installation instructions for peristaltic pump heads...... 16 3.2 Points to be observed before use...... 16 3.2.1 Pump suction line...... 16 3.3 Installation...... 16 3.4 Equipotential bonding / Earthing...... 17 3.5 Distance for vibration...... 17

4.0 Operating instructions...... 18

4.1 To be considered before commissioning...... 18 4.2 Commissioning...... 18 4.3 Decommissioning...... 18

5.0 Maintenance...... 19

5.1 Cleaning...... 21 5.2 Replacement of the pumping hose...... 21 5.3 Replacement of separating part...... 24

5 ELRO® Peristaltic Pumps Series M300 / T300

5.4 Replacement of abutment...... 24 5.5 V-belt drive...... 25 5.5.1 Axial safety of the belt pulleys...... 25 5.5.2 Checking the V-belt tension ...... 25 5.6 Lubricant change...... 25 5.6.1 Pump housing...... 25 5.6.2 Gearbox...... 25 5.6.3. Lubricant types...... 25 5.7 Shaft bearing...... 25

6.0 Spare parts...... 26

6.1 Stock keeping of spare parts ...... 26 6.2 Ordering spare parts...... 26

7.0 Troubleshooting...... 27

8.0 Appendix I ...... 30

Noise emissions...... 30

9.0 Appendix II ...... 31

Recommendations for use...... 32

6 ELRO® Peristaltic Pumps Series M300 / T300

1.0 Introduction chapter ”Safety” before starting work. This is too late once work ELRO® Peristaltic pumps M300/T300 are dimen- has started. This applies especial- sioned as pumps in accordance with chapter 1, ly for persons who work on the article 1, section (2), paragraph (j), point (ii) of the pump only occasionally, e.g. for pressure equipment directive and are therefore maintenance and cleaning work. no pressure equipment as defined by the EC pressure equipment directive 2014/68/EEC. Each pump is subject to stringent inspections and function tests before leaving the factory. You should always bear in mind that a correct function, a long lifetime and optimal opera- tional reliability of the pump mainly depend on n correct installation n correct commissioning n and proper maintenance. Enquiries concerning service, spare parts or repairs should be addressed to the manufac- turer or an authorized dealer. Fig. 1: Exemplary installation for peristaltic pumps Always provide the following information: The following instructions refer only to the peri- n Pump type staltic pumps M300 and T300. n Serial number of pump Since the pumps will be used in combination with other assem- This information is stamped on the identifica- blies, such as combustion engines tion plate on the base of the pump. Caution! and electric motors, you must also strictly observe and comply with When returning pumps or pump parts to the operating and maintenance the manufacturer or an authorized dealer instructions for these components for repair or overhaul, the delivery must be as well as the corresponding accompanied by a certificate stating that the notes on safe and reliable opera- pump is free of product or other aggressive tion. or hazardous substances (see page 37). These instructions contain information for in- 1.1 Warranty stallation, operation and maintenance of peri- staltic pumps ELRO M300 and T300. The correct function of each ELRO peristaltic pump is checked in the factory before ship- You should therefore thoroughly read these ment. The manufacturer assumes warranty instructions before use and always follow the for his product as specified in the effective information contained therein. terms of sales and delivery. Faults resulting All personnel involved in activities from the non-compliance with the aforemen- on pump or equipment must have tioned regulations and notes can only be Caution! read this manual, especially the rectified at the cost of the customer.

7 ELRO® Peristaltic Pumps Series M300 / T300

1.2 Transport, storage In order to avoid any problems you should n check the delivered goods against the delivery note for completeness and cor- rectness, n make sure that for pumps with electric motor, combustion engine, water tur- bine, hydraulic motor or pneumatic mo- tor the respective operating instructions for the drive are available. Be careful when unpacking the pump and proceed as follows: Fig. 2 - Attaching the lifting ropes n Examine the packaging for transport damage. 1.3 Function n Take the pump carefully out of the pack- aging. n Examine the pump for any visible dam- 3 age. n Remove all plugs from the pump ports. Saugseite n Make sure that accessories, such as seals and flushing lines, are free of damage. Consider the indicated weight before attempting to lift the 2 Caution! pump. Use only lifting gear of appropriate capacity. 1

Do not step or stand under sus- Fig. 3 1 Rotor 2 Abutment pended loads. 3 Separating part

Fasten the lifting gear so that the pump (or The priming properties of the peristaltic pump with drive unit) can be safely lifted pump are based on the vacuum backed (see example). restoring force of its hose. Due to its special design a vacuum is permanently generated inside the hose on the suction side of the pump. This vacuum always restores the hose to its original size. This way the pump achieves maximum pumping power.

8 ELRO® Peristaltic Pumps Series M300 / T300

The abutment 2 (Fig. 3) is an part and is installed in the pump section where the hose is squeezed to maximum extend. At the same time this abutment protects the 7 4 7 4 7 4 7 pump housing against damage caused by solid particles in case of a hose breakage. 5 In case of wear the abutment can be easily replaced. 3 6 The separating part (Pos. 3, Fig. 3) sepa- 6 rates the suction area from the inside of the 1 pump and protects the pumping hose. In case of hose breakage it additionally pro- tects the rotor (Pos. 1, Fig. 3) against dam- Fig.4 1 Rotor 5 Inside area age caused by abrasive or coarse particle 3 Separating part 6 Hose chamber 4 Suction area 7 Pressure area product. The separating part can be re- placed by simply unscrewing two screws. The rotor 1 rotates inside the separating part 3, which is tightly bolted to the housing. The pump is filled with 1-2 litres of glycerine This separates the suction area 4 from the or silicone, which works as lubricant, barrier inside of the pump 5. and coolant. The vacuum gauge (Fig. 3a), which is con- nected with the suction room (Pos. 4, Fig. 4) not only shows the current suction head of the pump, but also serves as warning ele- ment in case of possible defects. If the vac- 7 uum gauge does not indicate any vacuum 4 7 4 7 4 7 during operation, the pump most certainly 5 needs servicing. Maintenance can be carried out without any 3 6 special tools. 6 1

Fig. 5 4 Suction area 7 Pressure area

1 The sliding tube of the rotor enlarges the volume of the suction area (4). At the same time the pressure area (7) is decreased and the air is forced out through a channel in the pump cover.

Fig. 3a 1 Vacuum meter

9 ELRO® Peristaltic Pumps Series M300 / T300

2.0 Safety

2.1 General information Make sure that the pump is installed in com- 7 4 7 4 7 4 7 pliance with all applicable national safety 5 regulations. Always observe all applicable accident prevention instructions and implementing 3 6 6 regulations. 1 Transfer of media of Explosion Group IIA and IIB is only permit- ted outdoors or in well ventilat- Fig. 6 4 Suction area 7 Pressure ed rooms. The following precautions must be applied As the rotor rotates further the suction area before performing maintenance work. If becomes bigger. The fast rotation of the ro- the product to be pumped is a hazardous tor generates a permanent vacuum of down or noxious substance, the system must be to -1 bar (Fig. 6). neutralized and vented. Danger of burning! Depending on operating con- Caution! ditions the pump may reach temperatures too high to touch. You should therefore switch off 7 4 7 4 7 4 7 the pump and let it cool down before touching it. 5 ■ Disconnect main drive unit and pump from the electric power supply (e.g. pull 3 6 out the mains plug). 6 ■ 1 Depressurize the pump head. ■ It is not permitted to run the pump after removing the pump cover. When clean- Fig. 7 6 Hose chamber ing the pump manually make sure that 7 Pressure area all necessary precautions have been applied. Since the hose chamber Pos. 6 remains constant, the pressure area Pos. 7 is All incorrectly installed, unprofessionally decreased by rotation of the rotor, which operated or insufficiently serviced machines results in a volumetric pumping process and pumps are potential safety hazards. (Fig. 7). The non-observance of relevant safety measures may cause injury to operating personnel or damage to the pump.

10 ELRO® Peristaltic Pumps Series M300 / T300

On pump systems with protective covering the product comes into contact and guards these must be properly assem- with the silicone or glycerine lubri- bled again before restarting. cant. The pump must be shut down or should not When changing the delivery me- be restarted if any defects are found which dium, make sure that no chemical could affect the operating safety and reliabil- Danger! reactions can occur with existing ity of the pump. residual fluid. When changing delivery media in 2.2 Intended use Explosion Groups IIa and IIB, for The peristaltic pumps of series M300 and safety reasons install a new deliv- T300 are designed for mobile use and for ery hose. short-time operation (up to max. 5 hours). Pumped products which lead to Check the pumping capabilities chemical reactions on contact with of the medium (freezing point) Danger! aluminium may on no account be Danger! before commissioning. pumped with a peristaltic pump.

Pumps without explosion pro- 2.2.1 Unintended use tected drive must not be used The operating safety and reliability of the sup- Danger! in explosive environments. plied pump can only be assured if it is used for the purpose it is intended for. The limits men- Temperatures tioned in the technical data sheet must not be The permissible ambient temperature range exceeded under any circumstances. is -20 °C to +40°C. It is prohibited to operate the pump without a Pumps with glycerine lubricant sufficient quantity of lubricant. For the neces- sary fill quantities, refer to Ch. 5.6. Not permitted to be pumped or stored in the same room: Substances which react se- Temperature of pumped product:- verely up to explosively with glycerine. max. permissible 80°C Warning! Speed of drive shaft n2 max.: Examples: 2303 min-1 • Calcium hypochloride -1 • Chlorine Speed n2 max.: 1920 min . It is • Chromium trioxide prohibited to operate the pump for • Potassium permanganate more than 0.5 h without delivery • Sodium peroxide medium. • Phosphorus pentoxide • Phosphorus triiodide 2.3 Operation of pump • Nitric acid The pump must only be operated by trained, • Sulphuric acid instructed and authorized persons. Any re- • Hydrogen peroxide sponsibilities must be clearly appointed before starting operation and should always be com- Please check before using the plied with. peristaltic pump that no chem- Danger! ical reactions can occur when

11 ELRO® Peristaltic Pumps Series M300 / T300

Strictly observe the operating instructions Operating safety of equipment for the drives in chapter “Appendix”. at risk. The non-observance of this note affects the operation- al reliability and can lead to 2.4 Conversions and alterations to pump damage. the pump Attention! In this manual the Attention Conversions and alterations to the pump symbol precedes all safety are strictly prohibited. notes referring to instructions, However, this does not include minor regulations or work sequenc- changes that do not affect safety and re- es, which must be strictly liability, or measures that even enhance complied with. the safety. Safety installations must not be Danger of explosion: Special made ineffective or changed or used in a instructions apply when han- way contradicting their purpose. dling explosive products or in an explosive environment. 2.5 Symbols and notes on safety 2.6 Maintenance work Note on danger, which, if not observed, may lead to sever applies particularly for all work on electric, Danger! injury or even death. hydraulic and pneumatic equipment. Keep unauthorized persons away from the Note on danger, which, if not pump. observed, may lead to sever Warning! injury or even death. Mechanical and electrical repairs and maintenance work must only be carried Note on danger, insecure hand- out by qualified specialists. The profes- ling and working procedures sional execution of this work must be Caution! may cause injury or extensive examined and approved by a highly skilled damage to equipment and and responsible ”Inspector”. property. Before starting repair and maintenance Warning – dangerous electric work the equipment must be switched off voltage. and shut down and secured against unin- Contact with live parts can tended or unauthorized restarting. cause immediate death. Doors and covers (e.g. hoods and Before starting work on electrical systems lids) marked with this sign and equipment make sure that the system must only be opened by ”spe- is reliably de-energized. cialists or/and instructed persons” after the respective Apart from this the pump/system must be operating voltage (input termi- reliably secured against unexpected re- nal voltage, operating voltage starting. or external input voltage) has been switched off.

12 ELRO® Peristaltic Pumps Series M300 / T300

■ Pull out the mains plug. Always wear safety boots if there is a risk of heavy objects tipping over, slipping or The customer (or an ”authorized person” coming loose for any other reason, thereby appointed by him) is responsible for the causing danger for your feet. compliance with all accident prevention instructions applicable at the place of use. 2.6.1 Health and safety information on As a measure to avoid injury all mainte- electric equipment nance, adjustment and repair work should only be carried out using permitted and Depending on the version, the pumps may appropriate tools and working aids. be equipped with electric accessories (con- trols, motor drives). Blown fuses must not be repaired or bridged and may only be replaced by fuses of the Severe damage to health and property can same type. be caused by: n Cooling facilities, such as ventilation slots or unauthorized removal of covers fans, must not be covered or made perma- n inappropriate use of pump nently ineffective. n inadequate maintenance Rotating or moving parts must be reliably stopped before starting work. It must be as- Before starting installation work on electrical sured that these parts will not start to move equipment this equipment must be reliably while work is in progress. zero potential. Do not touch rotating parts and always keep Cover non-insulated live power lines and a safe distance to avoid clothing or hair plug connections against unintended con- being caught. tact. Always wear protective clothing suitable for Electric components stored and not used for the job and the related dangers. a longer period of time should be carefully inspected before use, to ensure that the This applies especially to cleaning, main- insulation is still intact. tenance and repair work. Depending on the type of work to be performed sufficient On wet electric assemblies or components protection can be provided by e.g. wearing parts, which would be perfectly zero poten- the following protective clothing: protective tial in dry condition, may still be live. goggles, ear defenders, working boots, Before touching damp or wetted electric safety gloves, etc. components check by measuring whether Protective clothes should be of tight fit. parts that could be touched are still live. If your face may get in contact with chem- Never attempt to insert any objects through icals, metal splinters or dust during work, the openings on the pump or attached you should wear a full face protection with equipment. This may cause short circuits safety goggles. and electric shocks with danger to limb and life.

13 ELRO® Peristaltic Pumps Series M300 / T300

2.6.2 Health and safety information for cation instructions for these assemblies and work on lines under pressure components (see chapter “Appendix”). Always relieve the pressure before starting The complete system must generally be work on pressure lines. switched off and secured against unintend- ed and unauthorized restarting before start- n Close shut-off alvesv ing lubrication work. n Vent lines (Exception: Lubrication work that can only Be careful when checking for be performed when the system is running). leaks on lines under pressure. As a measure to avoid injury all lubrication Caution! Fluids or air escaping under work should only be carried out using per- pressure can penetrate clothes mitted and appropriate tools and working and skin. aids. Be careful when loosening or Rotating or mobile parts must be shut down changing pressure lines; lines and reliably secured against restarting be- mixed up by mistake may re- fore starting work. verse the function. Do not touch rotating parts and always keep Take care when handling hazardous (caus- a safe distance to avoid clothing or hair tic, harmful) fluids. being caught. n Always wear your personal protective Strict cleanliness is of utmost importance outfit (e.g. gloves, goggles, tight fitting during initial filling and when topping up or clothes). changing lubricant so that no foreign matter n In case of skin contact, inhalation of will enter through the lubrication point. harmful vapours or eye injury you should n Overflowing and spilling of oil must be immediately contact a physician. avoided. n 2.6.3 Regulations and instructions on Wipe off excessive and emerging lubrication grease. Lubrication work must only be carried out by n Avoid skin contact with oils and grease, authorized personnel. The professional ex- wear protective clothes. ecution of this work must be examined and approved by a highly skilled ”Inspector”. With certain lubricants, e.g. low flamma- bility hydraulic fluids, the special safety Unauthorized persons must not be permit- instructions for these substances must be ted to work on machines or units or in their observed. vicinity. (See notes on packaging and instructions of Lubricants and oils must not come in con- manufacturer). tact with naked flames or glowing parts. When working on assemblies and compo- nents (e.g. motor, gearbox) you must also consider the specific instructions and lubri-

14 ELRO® Peristaltic Pumps Series M300 / T300

2.7 Noise emissions 2.8 Use of pumps in potentially In a room with several pumps you may explosive environments experience an extreme development of When using pumps in explosive environ- noise. Depending on the sound pressure ments or when pumping combustible liq- level the following measures must therefore uids, you must check that the unit is suitable be applied: according to the declaration of conformity in below 70 dB (A): No special measures terms of the 94/9 EC directive (ATEX) for the intended area of use. above 70 dB (A): Persons who are permanently in the room The chapter “Equipotential bonding/earth- must wear ear defenders. ing” and “Vibration distance” must be ob- above 85 dB (A): Room with dangerous served when installing the pumps. noise level! Each door Earthing of the pump by means of earthing must have a clearly screw or discharging hoses must take place noticeable warning sign to before bringing the pump into the explosion warn persons from entering endangered area. the room without ear defenders. All connected pipelines, components and hoses must be electrically conductive (spe- Measured sound pressure level as per cific volume resistivity <1 MΩm; surface appendix I on page 32. resistance <1 GΩm). All M300/T300 pumps with motor delivered by the manufacturer have been subjected to a sound pressure measurement according to EC-directive 200/14/EC.

e.g. sample sticker

15 ELRO® Peristaltic Pumps Series M300 / T300

3.0 Notes on installation To prevent frictional heat and protect the delivery hose, the pump must be filled and use as standard using silicone oil M 350 or, as requested, glycerine DAB10; 99.9% 3.1 Installation instructions for ignition temperature 400 °C. Other an- peristaltic pump heads ti-friction fluids have not been approved For the installation of peristaltic pumps by the manufacturer. ELRO M300 without drive the following For the fill quantities, refer to Ch. 5.6) conditions must be met, so that the pump can be properly assembled together with Before using the peristaltic components to a complete machine, without pump you should make sure affecting the health and safety of persons. Danger! that your pumped product will not cause any chemical reaction 1. Before installation of the pump the when coming into contact with supplied ventilation valve (Fig. 12, part- the glycerine or silicone, in case no. 1012) must first be mounted to the of a hose damage. elbow in the pump cover. 3. Check the pump arrangement to ensure that suction lift and discharge head are 2. Fasten the pump head in its place by not exceeded. observing the specified suction side and sense of rotation (see sticker). The pump must only be operated in upright 3.2.1 Pump suction line position with suction and pressure ports If the fluid to be pumped contains solid par- pointing up. ticles with a size of more than 8 mm, a filter, e.g. flat suction box, suction strainer should 3. Max. drive speed nmax = 2800 rpm be used. This filter must be permanently Min. drive torque Mmin = 7 Nm monitored and cleaned when necessary. Max. drive torque Mmax = 116 Nm 3.3 Installation 3.2 Points to be observed before use The pump unit must be placed on a level The pump must only be used by profession- base of sufficient load bearing capacity for als and in compliance with the safety regula- the weight of the pump. tions (see chapter 2). Because the pump is a positive 1. Before start-up make sure that pump displacement pump it must be and drive unit are in perfect condition. Caution! assured that no shut-off ele- The pump must only be operated in ments are installed in the pres- upright position with suction and pres- sure side. Components reducing sure ports pointing up. Pipe lines must the cross-section of the piping be routed in a way that the weight of the or instable hoses which could pipes does not rest on the pump. cause blockage of the piping 2. The pump is delivered ready for opera- system must not be used. tion. The pump is fitted with Camlock quick cou- plings DN 50 (male part) for the connection

16 ELRO® Peristaltic Pumps Series M300 / T300

of hoses. Camlock couplings DN 50 (female 3.4 Vibration distance part) with 2” external thread should be used When installing and operating, a distance as matching parts. It is recommended to con- of a minimum of 10 cm between pump and tinue with a 2” elbow each, in order to avoid other components, excluding connections, buckling of suction and pressure hoses. must be adhered to. Couplings normally used by the customers, such as ■ fire fighting couplings C (system Storz) (DIN 14307), 3.5 Equipotential bonding / Earthing In principle, pumps and accessories must be ■ screw couplings DN 50 (DIN 11851) or earthed or provided with equipotential bond- ■ tank truck couplings VK or MK 50 (DIN ing if there is the possibility of electro-static 28450) can then be connected to these charging and for use in potentially explosive elbows. environments. All connecting parts are available made of the following materials as standard: Aluminium (AIMgSi), red brass (copper zinc alloy), conductive plastic (PP), stainless steel (1.4571). Pumps with electric drive motors are deliv- ered from the factory with motor circuit break- er and connecting plug. The necessary connecting line must be fitted with a matching socket. Electrical installations and con- nections must only be made by a Warning! qualified electrician. Pumps and drives with combus- tion engines must only be start- ed up by following the operating instructions of the engine manu- facturer (see chapter Appendix).

17 ELRO® Peristaltic Pumps Series M300 / T300

4.0 Operating instructions Check the lubrication of the drive unit. Make sure that all safety features are fas- 4.1 Points to be observed before tened and fully functional. commissioning Please check: Attention! Camlock couplings must not be used without being locked (ad- n whether the pump is correctly installed ditional locking pins or O-ring). and connected. The peristaltic pump must un- n whether the sense of pump rotation is der no circumstances be op- correct. The sense of rotation is “clock- erated against closed shut-off wise” (when viewed from the pump valves. head cover). An arrow on the pump housing marks the sense of rotation. The drive unit is to be started up in accord- ance with the respective operating instruc- n that a pump without explosion protected tion. drive will be under no circumstances used in an explosive environment. 4.3 Taking out of service n whether the pumping hose inside the Attention! Always observe the safety in- pump is suitable for the product to be structions in chapter 2 in this pumped. manual and the operating in- n whether the pump is properly earthed to structions for the drive unit in avoid electro-static charging. the chapter “Appendix”. The shut-down procedure for maintenance, 4.2 Commissioning installation or cleaning work must only be The pump must only be operated in upright performed by authorized and trained per- position with suction and pressure ports sonnel. pointing up. 1. Switch off the electric power supply or The vacuum gauge mounted to the pump the respective drive and secure against housing shows the vacuum on the suction unintended restarting. side. After a short time running the vacuum 2. Close shut-off alvesv on suction and gauge should indicate vacuum. discharge side. The vacuum indicated by the vacuum meter 3. Relieve the pressure in suction and depends on suction head and pumped prod- pressure lines. uct. This vacuum meter must show at least -0.7 bar to achieve max. pumping capacity. This can be achieved by placing the pump at a more distant point and thus lengthening the hose. If no vacuum is reached, check pump and couplings for leak tightness (see chapter maintenance and troubleshooting).

18 ELRO® Peristaltic Pumps Series M300 / T300

Fluids escaping under pressure 5.0 Maintenance can cause severe injury. Danger! Take care when loosening pres- Attention! Always observe the safety reg- sure fittings, wear protective ulations in chapter 2 when per- clothing. forming maintenance work!

Be extremely careful when han- Before working on the pump, it dling hazardous fluids. must be removed from the po- You should immediately consult tentially explosive area to a safe a doctor if you had contact with working area. such substances. No work on the pumps in the 4. Loosen suction and pressure fittings Danger! EX-area. carefully. The system may still be under pressure or tension. Regularly check all lines and fittings for signs of leaks and external damage! 5. Disconnect suction and discharge lines Repair any damage immediately! from the pump and disassemble the rinsing line (if present). Handling peristaltic pumps M300/T300 re- quires special safety measures and reliable If wear symptoms are detected when in- maintenance after each application! specting the pump, the respective parts must be replaced. Explicit reference is made to the test and operating regulations in accordance with Ordinance on Hazardous Substances (Gef- stoffV) and the Industrial Safety Regulations (BetrSichV). Fundamentally, before starting maintenance work, the pump must be switched off and disconnected from the electric supply. General maintenance is limited to a profes- sional visual inspection. During this inspec- tion, pay special attention to affected com- ponents, loose connecting parts or electrical connections! ■ Check the equipment plug and con- necting cable for secure connection and damage. ■ Defective cables and equipment plugs

19 ELRO® Peristaltic Pumps Series M300 / T300

can only be replaced by the manufactur- We recommend the operator of the peri- er. staltic pump to maintain an application and ■ operation logbook, to provide evidence of Loose connections and damaged parts the operating hours of the pump and pump- must be tightened and damaged parts ing hose. must be replaced (designation see spare parts list). During general maintenance, check to see ■ whether the pumping hose must be replaced Repair corroded components. for safety reasons (refer to maintenance ■ Make sure that the pump is thoroughly instructions). flushed and the pumped product com- Explicit reference is made to accident pre- pletely drained (refer to Chapter 4.3: vention regulations (UVV). Decommissioning).

Spare parts kit

Consists of the following positions: 1 x Pumping hose M 300 connected with 2 x Connecting sockets 1 x l silicone or glycerine 1 x Set of O-rings (incl. 1 x O-ring for pump cover and 2 x O-rings for connecting sockets)

Description Quantity Article-No. Hose material Lubricant

Connection socket ALUMINIUM Nitrile - NBR Silicone 1 Set ESK-M-ABS Nitrile - NBR Glycerine 1 Set ESK-M-ABG Hypalon - CSM Silicone 1 Set ESK-M-ACS Hypalon - CSM Glycerine 1 Set ESK-M-ACG - NR Silicone 1 Set ESK-M-ANS Natural rubber - NR Glycerine 1 Set ESK-M-ANG

Connection socket Nitrile - NBR Silicone 1 Set ESK-M-KBS Nitrile - NBR Glycerine 1 Set ESK-M-KBG Hypalon - CSM Silicone 1 Set ESK-M-KCS Hypalon - CSM Glycerine 1 Set ESK-M-KCG Natural rubber - NR Silicone 1 Set ESK-M-KNS Natural rubber - NR Glycerine 1 Set ESK-M-KNG

Connection socket BRONZE Nitrile - NBR Silicone 1 Set ESK-M-RBS Nitrile - NBR Glycerine 1 Set ESK-M-RBG Hypalon - CSM Silicone 1 Set ESK-M-RCS Hypalon - CSM Glycerine 1 Set ESK-M-RCG Natural rubber - NR Silicone 1 Set ESK-M-RNS Natural rubber - NR Glycerine 1 Set ESK-M-RNG

Connection socket HIGH-GRADE STEEL Nitrile - NBR Silicone 1 Set ESK-M-SBS Nitrile - NBR Glycerine 1 Set ESK-M-SBG Hypalon - CSM Silicone 1 Set ESK-M-SCS Hypalon - CSM Glycerine 1 Set ESK-M-SCG Natural rubber - NR Silicone 1 Set ESK-M-SNS Natural rubber - NR Glycerine 1 Set ESK-M-SNG

20 ELRO® Peristaltic Pumps Series M300 / T300

Pumps with electric drive must Always wear protective clothing generally be switched off and when working with solvents or disconnected from the electric Caution! cleansing agents. power supply before starting Housing, cooling fins, openings and covers maintenance work! on equipment components are very often not On pumps with combustion en- just protections, but have additional functions gines the spark plug socket must such as cooling, insulation, noise reduction, Life be pulled off after the engine has splash protection, etc. hazard! been shut down. Some of these functions can be impaired or Danger of cauterization! may become totally ineffective by excessive deposits of dirt. If the pump is used for aggres- Caution! sive, caustic or toxic media, the Here some advice on how to remove dirt. pump must generally be flushed with a neutral agent before open- Danger of injury! ing the pump housing. Loose dirt should not fall on ro- Caution! tating parts, from which it could Danger or burning! be thrown away. Depending on operating condi- Non-observance may cause Caution! tions the pump may reach tem- injury to persons or damage to peratures too high to touch. You property. should therefore switch off the pump and let it cool down before Do not touch pump or pipes. touching it. Danger or burning! Always wear your personal pro- 5.1 Cleaning tective outfit when handling Caution! chemicals. The following generally applies: Always flush the system thor- Wherever possible mechanical cleaning oughly after. procedures should be preferably used, rather than cleaning with chemical aids. Always observe the applicable regulations when storing or Pumps for use in explosive are- handing out chemicals. as must always be kept clean of dust deposits. 5.2 Replacment of the pumping hose After each use, the pump should only be (see also Fig. 10-13, page 25) stored with completely empty and clean Peristaltic pumps may be fitted with hoses of pumping hose. This can be carried out by us- various qualities, depending on the applica- ing appropriate hose cleaning balls or small tion. cloths.

21 ELRO® Peristaltic Pumps Series M300 / T300

The following materials are available: fastening screw into the forcing bore M 10 (Fig. 10). Colour code 7. Loosen and remove both holding clamps Natural rubber (NR) yellow and pumping hose (Fig. 11). Nitrile rubber (NBR) red Hypalon (CSM) black 8. Pull the pumping hose on the pressure side back into the housing, then pull it back on the suction side and take it out Before installing a new hose you should (Fig. 12 and Fig. 12). make sure that the hose material suits the intended application (see appendix: 9. The connection ports are firmly attached Materials for pumping hoses). If the hose to the hose using metal bands. We inside the pump has not been damaged by recommend bonding using a bonding normal mechanical wear, but by chemical device, or bonding at the factory. Alterna- influences, you should use a hose of tively, special hose clamps are available. different material. The hose must be pushed onto the sock- et, so that the end of the hose touches 1. Completely empty the pumping hose, the collar around the complete circumfer- for this purpose lay the pump on its side ence. Each socket is fastened with one with the pressure side down. hose clamp. 2. Stand the pump with the pump cover After assembly the strap must be parallel facing forward. to the end of the hose, on side of the 3. Place a container to collect the sliding loop (buckle) must be flush with the end fluid. of the hose. Please make sure that the loops of the socket fastening on a hose 4. Loosen and unscrew four nuts (part- are on the same side. In the pump the no.1016, Fig. 8) from the pump cover. sockets must be assembled in such a Take off the washers. way, that the loops are always furthest 5. Take the pump cover carefully off, let away from the rotor. the lubricant flow into the container. Notes on the correct use of the hose assembly unit can be found in the Attention! If the pumping hose is damaged, pumped product respective operating instructions. and lubricant will have mixed. In this case the inside of pump housing and cover must be cleaned. After changing the hose the lubricant must be refilled. 6. Unscrew the rotor retaining screw (part- no. 1018, Fig. 8). If necessary force the rotor off by turning the

22 ELRO® Peristaltic Pumps Series M300 / T300

Fig. 10 Disassembly of rotor Fig. 12 Disassembly of pumping hose

Fig. 11 Disassembly of holding claws Fig. 13 Disassembly of pumping hose

10. Slide the O-rings over both The O-rings at the hose ends connecting sockets. must be properly in their grooves. The pumping hose 11. Install the new pumping hose into the must not be twisted around its housing. longitudinal axis. 12. Place the pump with the pump head Attach and tighten both holding facing upward. Fill the housing with 1-2 brackets. Assemble and tighten the litres of lubricant. Attach the pump cover rotor. If lubricant has been loss, top with the new O-ring and fasten it with up the same quantity. Close the pump washers and nuts. cover and tighten the screws crosswise.

23 ELRO® Peristaltic Pumps Series M300 / T300

2 2

1

Fig. 14 1 Separating part Fig. 15 1 Abutment 2 Holder for separating part 2 Abutment fastening screws

5.3 Replacement of separating part 3. Tighten by hand to allow the separating The installed separating part has the part to align itself. function of creating the vacuum in the pump Fasten the holder only after the pump housing and provides a protective layer cover has been assembled. between rotor and pumping hose. When changing a hose the separating part should Important: always be examined for possible damage. The separating part must rest This should be done before installing the properly against pump cover hose. If damaged it must also be replaced. and back wall of housing. 1. After removing the pumping hose loosen both hexagon screws (part-no. 5.4 Replacement of abutment 1019, Fig. 8) on top of the pump so When replacing the hose you should also far that the split separating part can be examine the abutment for damage. taken out of the holder. If the (PUR) hose (no longer 2. Insert the new separating part into the available) is replaced with a hose of holder with the gearing towards the different material, the abutment must also inside (Fig. 14). be changed. Make sure that the separating part Please note that abutments are available neatly rests against the housing wall with two different dimensions, i.e the and is flush at the joint. abutment for the PUR hose is approx. 5 mm thicker than the abutment for all other hose materials. 1. Remove both side plates (if present). 2. Unscrew both abutment fastening

24 ELRO® Peristaltic Pumps Series M300 / T300

screws (part-no.1020, Fig. 8) and lift the 6. Reassemble the side plates. abutment out of the housing (Fig. 15). Clean the housing thorough- 5.6 Lubricant change, lubricant ly before assembling the new qualities abutment. 5.6.1 Pump housing Do not forget to assemble the The pump housing is filled with 1-2 litres of lu- abutment fastening screws with brication fluid. Due to the ageing of the oil, the copper washers. oil should be changed at intervals of 3 years.

5.5 V-belt drive The filling quantity depends on the pump type:

Depending on the version the pump may be Type Fill quantity driven by a V-belt. M5 2 litres The installed V-belt has been designed for a M10 1,5 litres power transfer of up to 3 kW under perma- M15/M20/M21/T300 1 litre nent operation.

5.5.1 Axial safety of the belt- pulleys 5.6.2 Gearbox In order to prevent the grub screws from The gearbox is lifetime lubricated by 0.25 loosening, install using thread adhesive litres of low viscosity oil. Loctite 243 or Tuflok 180. The oil only needs to be changed in case of an oil loss. 5.5.2 Checking the V-belt tension If the V-belt tension slackens (V-belt can be depressed for more than 1 cm), the V-belt 5.6.3 Lubricant types needs to be tightened. We recommend using following lubricants: EL420-001-BG 1. Remove both side plates from the pump Pump: Silicone EL430-001-BG (if present). Glycerine oil 2. Loosen four fastening screws on the Gearbox: Renolyn CLP100 motor foot. Fuchs Europe GmbH 3. Loosen the counter nut on the V-belt tensioning device and tighten the ten- 5.7 Shaft bearings sioning screw until the correct V-belt The shaft bearings are designed for an ex- tension is achieved. pected lifetime of at least 15.000 hours. 4. Lock the tensioning screw with the After this time, the bearings must be replaced. counter nut. 5. Tighten the fastening screws on the mo- tor foot and make sure that the V-belt is properly aligned.

25 ELRO® Peristaltic Pumps Series M300 / T300

6.0 Spare parts

6.1 Spare parts storage Since the extent of the recommended spare parts storage depends on the period of use and the different operating conditions for the pumps, you should consult the manufactur- er or an authorized dealer.

6.2 Ordering spare parts Please state the following when ordering spare parts: ■ Pump type ■ Construction year and serial number ■ Spare parts article number

Should subsequent material changes for dif- ferent parts of the pump have taken place, this information is mandatory. The required spare parts and their article numbers can be found in the spare parts lists. These can be found under www.cranechempharma.com.

Liability when using non-genuine spare parts: Installation and/or use of non-original spare parts or accessories can negatively alter and consequently impair the design-related features of the peristaltic pump. For damage caused by the use of non genuine spare parts and accessories on pump, system or product all liability and warranty is excluded.

26 ELRO® Peristaltic Pumps Series M300 / T300

7.0 Troubleshooting

Fault Possible cause Remedy

No pump flow Pressure and suction valves Open valves closed

Wrong direction of rotation Reverse direction of rotation, Check supply line (phase)

Suction line blocked Remove blockage

Leaks in suction pipe Check for leaks (entering of air) and seal

Suction lift too high Change pump arrangement

No operating voltage Connect voltage supply

Pump looses Excessive counter-pressure Change pump arrangement, if necessary suction capacity, use different hose cross-sections or pumping capacity too low Leaks in suction pipe Find and eliminate leaks

Speed too low Check speed and electric wiring

Suction line blocked Remove blockage

Insufficient suction pressure Change pump arrangement

Pump parts worn Replace these parts

Dosing valve open Close dosing valve

not enough sliding fluid Fill up sliding fluid in the pump

Pump makes Pump worn Examine and replace noises or defective

Drive heats up or A certain amount of heating with Replace parts, if necessary is overloaded electric motors is normal Check current input for safety reasons

Discharge pressure too high Change pump arrangement

27 ELRO® Peristaltic Pumps Series M300 / T300

Fault Possible cause Remedy

Pump looses suction abilities Leaks in suction line Find and seal leaks

Suction head too high or air Increase suction pressure, degas or gas in fluid fluid

Pump worn Examine, if necessary replace parts

Speed too low Increase speed

Pump makes noises Cavitation Increase suction pressure

Pump worn or Examine, if necessary replace de- defective fective parts

Air or gas in fluid Degas fluid

Solids in fluid Install dirt catcher in suction line

Drive heats up or A certain amount of heating Check the current consumption is overloaded with electric motors is normal to be sure

Discharge pressure too high Reduce the pressure, check the pressure gauge

Fluid more viscose than Install a stronger motor intended

Speed too high Drehzahl reduzieren (depending on type of pump)

Pump parts eroded or stick Examine and release, as necessary, replace

Motor incorrectly connected Check connection and change, if necessary

Suction or ventilation pipes Reseal or renew leaking or squashed

28 ELRO® Peristaltic Pumps Series M300 / T300

Fault Possible cause Remedy

Pumping hose service life Chemical attack. Hose swollen Check chemical compatibility of insufficient or peeling hose material on the basis of the resistance list, if necessary contact the authorized dealer or manu- facturer.

Too high speed Reduce speed (depending on type of pump)

Too high pumping pressure Raise the hose service life by chan- ging the pressure side conditions (reduction).

Abrasive solids-containing Check pumping hose and, if medium necessary, reduce speed, as necessary, change material of hose.

Washouts in pump hose as necessary, reduce product return, delivery pressure.

Pumping hose defective on Pump operated against closed shut- pressure side (pressure stop) off valve.

Pumping hose burnt Too little or wrong lubricating fluid. externally

29 ELRO® Peristaltic Pumps Series M300 / T300

8.0 Appendix I

Type Noise emission [dB] LpA LWA 5 E 67 80 7,5 E 67 80 10 E 67 80 10 Ex 67 80 10 EW 71 84 15 E 67 80 15 EX 67 80 15 R 67 80 20 E 67 80 T300 E 67 80 21 E 67 80 21 EX 67 80 15 D 91 104 20DF 91 104 20 D 91 104 20HD 91 104 20 B 83 96 T300 B 83 96 20 H 71 84 20 W 71 84 20 L 101 114

30 ELRO® Peristaltic Pumps Series M300 / T300

9.0 Appendix II Please observe also the operating instructions for the respective drive unit. M300 pump series: Electric motor Electric motor explosion protected Gasoline engine Diesel engine Water turbine Hydraulic motor Pneumatic motor

31 ELRO® Peristaltic Pumps Series M300 / T300

Recommendations for use

Rubber materials for pumping hoses

Designation Properties chemically dependent not thermally Recommendation resistant1 resistant2 resistant usable

Natural rubber Natural material diluted acids and concentrated - 20 to + 80°C Sewage plants, NR high-polymeric alkaline solutions, acids and treatment plants isoprene: alcohols, warm water. alkaline tenacious - solutions, elastic, mineral oil, cold resistant. fuel.

Hypalon Elastomer, re- acids and alkaline Gasoline, - 20 to + 80°C Fire brigades CSM sulting from solutions, alcohols, benzene. Use with hazardous polymerization of paints foaming agents, fuel oil, substances chlorosulfonated hot water, steam up to gear oil. ethylene: 120°C. - wear resistant, electr. conductive, chemically resi- stant. Mineral oil Nitrile rubber Copolymer mineral oil, alcohols, Benzene, - 10 to + 80°C industry NBR from butadiene gasoline kerosene acids and and acrylonitrile: fuel oil, gear oil, water alkaline wear resistant, up to 100 °C. solutions, oil resistant - ester, solvents.

1 The chemical resistances only apply for a product temperature of up to 20°C. 2 Conditionally resistant means: sufficient for pumping quantities up to min. 403 m .

Please observe also the detailed compatibility information for the individual media in the compatibility list. If necessary, please contact the authorised dealer or manu- facturer for checking and advice.

32 ELRO® Peristaltic Pumps Series M300 / T300

Note on Declaration of no Objection

We want to protect our employees against dangers through contaminated devices and allow the timely handling of your return.

Please understand for this reason that we can only accept your shipment upon submission of our declaration of no objection including return number.

When returning goods to our plant in Düsseldorf please contact our contact person at the following phone number before shipping the goods: 0211 / 5956-218 or [email protected].

Here you can obtain the declaration of no objection necessary for a return shipment as well as a return number assigned to your shipment.

Please affix the same then to the package readily visible from the outside.

33 ELRO® Peristaltic Pumps Series M300 / T300

34 ELRO® Peristaltic Pumps Series M300 / T300

This is the translation of the original operating and installation ® instructions for ELRO peristaltic pumps series M300 / T300. For the original version in German, please refer to www.cranechempharma.com

35 ELRO® Peristaltic Pumps Series M300 / T300

Crane Process Flow Technologies GmbH P.O.Box 11 12 40, D-40512 Düsseldorf Heerdter Lohweg 63-71, D-40549 Düsseldorf Phone +49 211 5956-0 Fax +49 211 5956-111 [email protected] www.elropumps.com www.cranecpe.com

We reserve the right to change all technical information.

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