PONNDORF P classicplus 15 User manual

Hose Pump
Type P_classicplus
Operation Manual

PONNDORF Gerätetechnik GmbH
Leipziger Strasse 374
D - 34123 Kassel
Operation Manual
Hose Pump type P_classicplus
Page 1 of 25
Version 002_GB / 04.2017
Table of contents Page
1. Table of contents................................................................................................1
2. General
2.1 Service address .........................................................................................2
2.2 General information.................................................................................2/3
2.3 Labelling.....................................................................................................3
2.4 Guarantee..................................................................................................4
2.5 Technical data............................................................................................4
3. Safety
3.1 Marking of details in the operation manual ...............................................5
3.2 Safety instructions for operating the pumps in hazardous locations...........6
3.3 Intended use ........................................................................................... 6/7
3.4 Qualification and training of personnel.......................................................7
3.5 Dangers in case of non-observance of the safety instructions................ 7/8
3.6 Safety-conscious working ..........................................................................8
3.7 Safety instructions for the operator/user ....................................................8
3.8 Safety instructions for maintenance / inspection / assembly...................8/9
3.9 Unauthorized modifications or use of unoriginal parts................................9
3.10 Unauthorized operation methods...............................................................9
4. Transport, storage and disposal
4.1 Transport.................................................................................................. 10
4.2 Storage .................................................................................................... 10
4.3 Disposal ..............................................................................................10/11
5. Description of pump and accessories............................................................ 11
5.1 Detector for hose leakages ......................................................................12
5.2 Diagram of the leakage detector.............................................................. 13
5.3 Diagram of the leakage detector for operating the pumps in
hazardous locations.................................................................................14
6. Installation / connection / operation
6.1 Installation of pumps in hazardous locations............................................15
6.2 Electrical connections ......................................................................... 15/16
6.3 Mechanical connections......................................................................16/17
6.4 Installing the pump hose .....................................................................18-20
7. Repairs / maintenance
7.1 Changing the pump hose......................................................................... 21
7.2 Maintenance............................................................................................. 22
7.3 Cleaning...................................................................................................22
7.4 Drawing of spare parts.............................................................................23
7.5 List of spare parts..................................................................................... 23
8. Characteristic curves.................................................................................. 24/25
9. Accompanying documents.............................................................................. 25

PONNDORF Gerätetechnik GmbH
Leipziger Strasse 374
D - 34123 Kassel
Operation Manual
Hose Pump type P_classicplus
Page 2 of 25
Version 002_GB / 04.2017
2. General
2.1 Service address
PONNDORF GERÄTETECHNIK GmbH
Leipziger Strasse 374
D - 34123 Kassel
Tel. [phone] - 0
Fax: [phone] - 88
E-Mail: [email protected]
2.2 General information
Ponndorf Hose Pumps are a self-priming positive displacement pumps without any glands
or valves. The pumping medium only comes in contact the inner surface of the pump hose,
but not with the moving parts of the pump. Therefore the pumps are particularly suitable
for pumping aggressive, abrasive and viscous liquids, but as well for pumping liquids
containing coarse-grained solids and sensitive materials which require to be pumped
gently.
Priming and pumping of combustible gases or fumes is prohibited.
Start up and close down operations which require this should only be rarely
and kept as short as possible. A dry run of the pump has to be avoided
generally. Appropriate measures have to be taken by operator.
Hose pumps are only intended to pump free-flowing liquids but not to pump
gaseous pumping media.
The functioning of a hose pump can lead to abrasion on the pump hose. For
applications in which the possible abrasion is intermittent or not permissible,
appropriate filter technology must be provided by the customer.
To guarantee the tightness and chemical compatibility of the pump hoses, the
manufacturer of the hose pump must be consulted in case of possible
changes of the pumping media unless this information does not appear from
available documents.

PONNDORF Gerätetechnik GmbH
Leipziger Strasse 374
D - 34123 Kassel
Operation Manual
Hose Pump type P_classicplus
Page 3 of 25
Version 002_GB / 04.2017
To avoid blockages of the pumps and/or any other damages of pumps or
pump hoses, the operator must guarantee that no hose damaging objects can
invade the hoses (e.g. sharp-edged or too big and not pumpable objects). A
suitable strainer may be used as protection.
2.3 Labelling
1. Pump Type
2. Maximum Pressure
3. Pump Number and Year of Manufacture
4. ATEX Coding (optional)
5. Ambient Temperature Limit in EX-Zone (optional)
6. Customer Number –Order Number Ponndorf
The data specified on the name plate refer to the delivery status of the Ponndorf Hose
Pump. Any modification of the pump can result in a change of the specified data and the
request of a new name plate for the Ponndorf Hose Pump could be necessary.
When requesting spares, the model and serial number should always be quoted.
1
6
5
4
3
2

PONNDORF Gerätetechnik GmbH
Leipziger Strasse 374
D - 34123 Kassel
Operation Manual
Hose Pump type P_classicplus
Page 4 of 25
Version 002_GB / 04.2017
2.4 Guarantee
The guarantee for defects of any goods delivered by us is stated in our Terms and
Conditions of Sale.
We do not assume any liability for defects and damages which are caused by non-
observance of the instructions of the operation manual.
Furthermore we assume no liability for defects or damages which are caused by changing
the operating conditions (use not in accordance with the intended use), e.g. use of a
different pumping medium for which the pump hose is not suitable for, higher temperature
which exceed the maximum permissible or line losses caused by media with a too high
viscosity.
2.5 Technical data
P_classicplus
15
P_classicplus
27
P_classicplus
35
Max. flow rate:
[l/h H2O]
500
2.500
5.500
Max. pressure:
[bar]
4
Max. suction height:
[m]
8
Max. viscosity of
pumping media:
[mPas]
35.000
Max. motor power:
[kW]
0,37
0,55
1,5
Weight:
construction XXX
construction GMC
construction BDC
[kg]
7,0
35,5
40,5
14,0
45,5
54,5
26,0
max. 93,7
max. 90,7
Hose material
Natural rubber

PONNDORF Gerätetechnik GmbH
Leipziger Strasse 374
D - 34123 Kassel
Operation Manual
Hose Pump type P_classicplus
Page 5 of 25
Version 002_GB / 04.2017
3. Safety
These instructions contain basic recommendations that should be followed during
installation, operation and maintenance. Therefore the operation manual has to be read by
the fitter and qualified personnel/operator before installation and operation and must
always be available at the location of the machine/facility.
Not only the general instructions of safety mentioned in chapter - Safety - have to be
observed. The more specific safety instructions mentioned in other chapters must be
observed, too.
3.1 Marking of details in the operation manual
Non-observance of the safety instructions of this operation manual can endanger people.
Those instructions are particularly marked with the following general danger signs:
Safety sign according to DIN 4844 - W 9
Safety sign according to DIN 4844 - W 8
when warning of electrical hazards
This sign is used to mark instructions of the manual which are safety
relevant when operating the pumps in hazardous locations.
In case of safety instructions which can cause dangers for the machine
or its performance the term CAUTION is interpolated.
Signs directly fixed to the machine, e.g.
• arrows which indicate the flow rotation
• signs for fluid connections
have to be observed and must be kept in a readable condition.
CAUTION

PONNDORF Gerätetechnik GmbH
Leipziger Strasse 374
D - 34123 Kassel
Operation Manual
Hose Pump type P_classicplus
Page 6 of 25
Version 002_GB / 04.2017
3.2 Safety instructions for hose pumps in hazardous locations
•
Explosive gas mixture or dust concentration can cause serious or even
fatal injuries in conjunction with hot, voltaged, pressurized and moved
parts of the pump
•
•
Only qualified technical personnel is authorized to effect installation,
connection, operation as well as maintenance and repair works in
consideration of
- provided instructions
- danger signs and/or decal information
- every other provided instructions for the user
- the system-dependent regulations and requirements
-the currently valid regulations concerning explosion protection and
safety as well as rules for accident prevention
The pump in connection with the mobile base plate only fulfils the
ATEX directive (EC Directive 94/9/EC) in a stationary condition.
In case of moving the pump the operator has to make sure that no
explosive environment exists!
3.3 Intended use
•
Ponndorf Hose Pumps are intended for use in commercial facilities and
are only permitted for use in accordance to the information of the
technical documentation and of the nameplate.
They comply to the currently valid standards and regulations and meet
the requirements of the European directive 94/9/EC.
•
If a pump is coupled to a drive unit, the operating manual of the drive
and other provided components must be observed, too.

PONNDORF Gerätetechnik GmbH
Leipziger Strasse 374
D - 34123 Kassel
Operation Manual
Hose Pump type P_classicplus
Page 7 of 25
Version 002_GB / 04.2017
Before placing the pump into operation the operator must make sure that
•
the pump and all other components were not damaged during the
carriage.
•
the information on the nameplate concerning equipment group and
category, zone, temperature class and explosion group accords with
the permissible use in the particular hazardous location.
•
the air temperature of the ambience of the pump is observed.
•
the maximum temperature of the pumping media is not exceeded.
•
there is a sensor of the leakage detector assembled which meets the
ATEX requirements.
•
pump hose, clamping rings and connecting sockets are mounted
properly and the pump hose is greased sufficiently with Ponndorf
special grease (as described in chapter 6.4).
In case of any discrepancies the pump must not be placed into operation!
While placing the pump into operation the characteristics (pump speed, pressure) which
are prescribed in the manual and on the nameplate must not be exceeded.
3.4 Qualification and training of personnel
The technical personnel responsible for operation, maintenance, inspection and
installation must be qualified for this work. Fields of responsibility, competencies and the
supervision of the personnel have to be exactly regulated by the operator. If the personnel
is inadequately skilled it must be trained and instructed. If necessary, this may be effected
by order of the operator by the manufacturer/supplier.
Furthermore the operator has to make sure that the personnel did absolutely catch the
contents of the operation manual.
3.5 Dangers in case of non-observance of the safety instructions
Non-observance of the safety instructions can endanger people, environment and
equipment and can result in losing any claim for damages.

PONNDORF Gerätetechnik GmbH
Leipziger Strasse 374
D - 34123 Kassel
Operation Manual
Hose Pump type P_classicplus
Page 8 of 25
Version 002_GB / 04.2017
In detail non-observance can for instance result in the following dangers:
•
failure of important functions of the machine/facility
•
failure of methods prescribed for maintenance
•
threat to people because of electrical, mechanical and chemical effects
•
danger to the environment because of leakage of hazardous substances
3.6 Safety-conscious working
The safety instructions of this manual, the existing national rules for accident prevention as
well as potential instructions of the operator for work, operation and safety have to be
observed.
3.7 Safety instructions for the operator/user
•
If hot or cold machine parts cause dangers, the operator is responsible
for a protection against contact.
•
The protection against contact of moving parts of machines in
operation (e.g. coupling) must not be removed.
•
Leakages of hazardous pumping media (e.g. explosive, toxic, hot) have
to be discharged in a way which guarantees that no gangers to people
and environment arise. Legal regulations have to be observed.
•
Dangers caused by electrical power have to be eliminated.
(Please see also regulations e.g. of the VDE (in Germany) or of the
local power supply companies.)
3.8 Safety instructions for maintenance / inspection / assembly
The operator has to make sure that all maintenance, inspection and installation works will
be effected by authorized and qualified technical personnel, which is familiar with the
contents of the operating manual.
Basically all works may only effected during shutdown periods. The proceeding to
shutdown the machine described in the operating manual must be strictly observed.
Pumps or aggregates which convey harmful media have to be cleaned.

PONNDORF Gerätetechnik GmbH
Leipziger Strasse 374
D - 34123 Kassel
Operation Manual
Hose Pump type P_classicplus
Page 9 of 25
Version 002_GB / 04.2017
When works are finished all safety installations and protectors must immediately be refitted
or be put into operation.
The articles of chapter 6 (Installation / Connection / Operation) have to be observed before
reconnection.
3.9 Unauthorized modifications or use of unoriginal parts
Modifications of the machine are only permissible after prior consultation of the
manufacturer. Original spare parts and accessories authorized by the manufacturer serve
the safety. Use of other parts can repeal the liability for any consequences.
3.10 Unauthorized operating methods
The reliability of the supplied machine is only guaranteed in case of intended use in
accordance to chapter 2 - General - of the operating manual.
The limit values stated in the data sheet must not be exceeded in any way.

PONNDORF Gerätetechnik GmbH
Leipziger Strasse 374
D - 34123 Kassel
Operation Manual
Hose Pump type P_classicplus
Page 10 of 25
Version 002_GB / 04.2017
Holes for lifting the pump
(resp. to fix the base plate of stationary pumps)
4. Transport, storage and disposal
4.1 Transport
•
When choosing lifting tools and separate lifting accessories the weight
of the pump must be took into consideration. The corresponding
accident prevention regulations have to be observed.
(In Germany: UVV "Lastaufnahmeeinrichtungen im Hebezeugbetrieb",
BG 9a)
4.2 Storage
The pump has to be protected against humidity when stored
In case of longer standstill before placing the pump into operation do not
assemble the pump hose, during longer shutdown periods remove the
hose from the pump. Otherwise the hose could be warped by the constant
compression of the rollers!
4.3 Disposal
With prolonged use, pump parts can get contaminated by poisonous or
radioactive pumped liquids to such an extent that cleaning may be
insufficient.
Risk of poisoning and environmental damage by the pumped liquid!
Use suitable personal protective equipment when carrying out any work
on the pump.
Prior to disposal of the pump:
CAUTION
CAUTION

PONNDORF Gerätetechnik GmbH
Leipziger Strasse 374
D - 34123 Kassel
Operation Manual
Hose Pump type P_classicplus
Page 11 of 25
Version 002_GB / 04.2017
- Remove and dispose grease in accordance with local regulations.
- Dispose any leaking pumped liquid in accordance with local
regulations.
- Neutralize residues of pumped liquid in the pump.
Dispose of the pump unit and associated parts in accordance with
statutory regulations.
5. Description of pump and accessories
The pump head is connected with the drive by a coupling. Pump head and drive are
completely mounted on a base plate. Construction "0" means that the pump head is
supplied with bare shaft extension.
Construction
Description
- XXX
- pump head with bare shaft extension, without drive
- GMC
- GMC-TF
- GMC-FF
- GMC-I1/I3
- GMC-V1/V3
- pump with gear motor
- pump with gear motor incl. thermistors for frequency converter use
- pump with gear motor incl. thermistors and forced fan
- pump with gear motor with integr. frequency converter
- pump with gear motor with integr. frequency converter and forced fan
-BDC
- pump with variable speed drive
P_classicplus 15
P_classicplus 27
P_classicplus 35
Material of pump casing:
Aluminium alloy
Material of base plate:
Steel (standard)
Paint of the complete pump:
RAL 5003 (standard)
Diameter of shaft:
Fit:
15 mm
H7/k6
15 mm
H7/k6
25 mm
H7/f7

PONNDORF Gerätetechnik GmbH
Leipziger Strasse 374
D - 34123 Kassel
Operation Manual
Hose Pump type P_classicplus
Page 12 of 25
Version 002_GB / 04.2017
5.1 Detector for hose leakages
The hose leakage detector is for a continuous monitoring in order to avoid unnoticed hose
leakages.
Functional description
In case of a hose leakage the pump can be switched off and an alarm (horn/signal lamp)
can be activated. This is only possible when using a motor contactor.
The following mentionned detectors for hose leakages are available:
art.-no. 93-000-055
Detecor for hose leackages for operating the pumps in non-hazardous locations and for
electrically conductive media.
art.-no. 93-000-009
Detector for hose leackages for operating the pumps in hazardous locations and for
electrically non-conductive media.
art.-no. 93-000-045
Detector for hose leackages with SPC sensor for operating the pumps in non-hazardous
locations.
pump
horn
light
sensor

PONNDORF Gerätetechnik GmbH
Leipziger Strasse 374
D - 34123 Kassel
Operation Manual
Hose Pump type P_classicplus
Page 13 of 25
Version 002_GB / 04.2017
5.2 Diagram of the leakage detector for operating the pumps in non-hazardous
locations (art.-no. 93-000-055)
The following diagram is only valid for the leakage detector consisting of:
• sensor for leakage detector (make Ponndorf, standard)
• switch amplifier (make: Disibeint, type DNSA)
The connections must only be made by qualified and authorized
personnel!
The standard detector for hose leakages is not suitable for use in
hazardous locations and non-conductive media.
drive
pump
B2
=
Level control, type DNSA
B1
=
sensor
F1
=
fuse
F2
=
motor fuse
F3
=
motor overloads
H1
=
run light
H2
=
signal horn, signal lamp
K1
=
motor contactor
K2
=
flasher (0,5 sec.)
M
=
motor (pump drive)
S1
=
push button

PONNDORF Gerätetechnik GmbH
Leipziger Strasse 374
D - 34123 Kassel
Operation Manual
Hose Pump type P_classicplus
Page 14 of 25
Version 002_GB / 04.2017
5.3 Diagram of the leakage detector for operating the pumps in non-hazardous
locations (art.-no. 93-000-009)
The following diagram is only valid for the leakage detector consisting of:
• capacitive proximity switch (make: Rechner)
• switch amplifier (make: Rechner)
The switch amplifier must not be used in hazardous locations.
It has to be strictly installed outside of these areas.
The connections must only be made by qualified and authorized
personnel!
A1 –switch amplifier type N-132/1-01
B1 –capazitive sensor (2-wire NAMUR)
F1 –control fuse
F2 –motor fuse
F3 –motor protection relais
H1 –control lamp-operation
H2 –signal horn, signal lamp
K1 –motor contactor
K2 –flasher relais 0,5 sec.
M–motor –pump drive
S 1 –double push button

PONNDORF Gerätetechnik GmbH
Leipziger Strasse 374
D - 34123 Kassel
Operation Manual
Hose Pump type P_classicplus
Page 15 of 25
Version 002_GB / 04.2017
6. Installation / Connection / Operation
Installation
The installation of the pump depends on the pump type and can be made stationary or
movable (on wheels).
6.1 Installation of pumps in hazardous locations
•
When pumps have to be installed in hazardous locations the
instructions in chapter 3.2 must be strictly observed.
•
Ponndorf Hose Pumps of series P_classicplus for hazardous location
use (optional!) meet the construction requirements of equipment
group II, category 2G. They are intended for use in zone 1.
•
Hose pumps for hazardous location use in construction “0”
(see chapter 5 - Description of pump and accessories -)1)
•
are in accordance with temperature class T4.
•
are intended for use at an ambient temperature between +2°C and
+40°C (permissible temperature of place of installation).
•
are suitable for pumping media with a maximum temperature of:
• +60°C in continuous operation
• +80°C in short-time operation
•
fulfill the requirements for non-electrical devices of the type of
protection C - protection by constructional safety - according to EN
13463-1 and EN 13463-5.
•
are allowed for the explosion group IIB.
1) The explosion protection for complete aggregates can diverge! The details of the
enclosed declaration of conformity are relevant!
6.2 Electrical connection
The connections must only be made by qualified and authorized
personnel!
The connections must be made according to the wiring diagram in the
terminal box.
For instructions to effect the electrical connection please see the attached
manual of the pump drive!
The pump must be protected by fuses and a protective motor switch
according to the nominal current of the motor.

PONNDORF Gerätetechnik GmbH
Leipziger Strasse 374
D - 34123 Kassel
Operation Manual
Hose Pump type P_classicplus
Page 16 of 25
Version 002_GB / 04.2017
The pumps must be integrated in the equipotential bonding of the whole
plant. For example this can be made by grounding the base frame by using
the grounding terminal in the terminal box of the motor.
6.3 Mechanical connection
The nominal width of the tubing at the suction and the discharge side
should be approx. 25 % bigger than the nominal width of the pump hose.
The size of the hose pump is concurrent to the width of the pump hose.
The tubing on the suction side must be vacuum proof (reinforced) and the tubing on the
discharge side must withstand the maximum pressure of the pump. By using a pole
changing switch the tubing on suction and discharge side must withstand the maximum
pressure of the pump.
Always use flexible tubing to connect
the pump with the pipework of your application.
The length of the tubing should be
at least 1 m. (see fig. 6.3.1).
The standard way of connection is flexible tubing (fitting the connecting sockets of the
pump), fixed with hose band clamps. Other options (e.g. threaded connections, Kamlok
couplings, standard flanges) are available on request.
In order to avoid pressure peaks, which can cause damages of the pump hose, there
should no pipe bends or 90° elbows be installed directly after the pump on the discharge
side (please see fig. 6.3.2 and 6.3.3).
Furthermore the cross section of the pipework on the discharge side should not be
reduced (please see fig. 6.3.4).
CORRECT
fig. 6.3.1
fig. 6.3.4
fig. 6.3.3
fig. 6.3.2
WRONG
WRONG
WRONG

PONNDORF Gerätetechnik GmbH
Leipziger Strasse 374
D - 34123 Kassel
Operation Manual
Hose Pump type P_classicplus
Page 17 of 25
Version 002_GB / 04.2017
Important notice for the conveyance of media containing solids
There is a risk of sedimentation of solids which can settle in the pump while the pump is stopped.
Hereby a lump of solids can be formed in the upper section of the hose.
If the upper connecting socket of the pump is the outlet (discharge side), the lump blocks the pump
when it is restarted (please see pic. 6). This may cause damages to the pump.
To avoid any damages we recommend to reverse the direction of rotation of the pump and to
connect the discharge line to the lower, horizontal connecting socket.
To get a further advantage a flexible hose should be used to to connect the pump and a kind of
trap should be created in which the solids settle out (please see pic. 7).
In case of longer downtimes it is also recommended to flush the complete piping including the
pump sufficiently.
Hose pumps are positive displacement pumps which must not convey
against closed fittings (e.g. valves). In case of exceeding the maximum
permissible pressure, the pumps or other parts of the facility can be
damaged. Therefore a protection against pressure exceedance must be
integrated in the pipework on the discharge side (e.g. an overflow valve or
a burst disk).
When using overflow valves or burst disks it must be observed that the
overpressure always will be discharged in a safe direction.
I.e., neither people nor tangible assets may be endangered because of
emissions of the pumping medium.
If flammable liquids or gases may leak, the affected area of emission must
be free of ignition sources !
Pic. 6
Pic. 7

PONNDORF Gerätetechnik GmbH
Leipziger Strasse 374
D - 34123 Kassel
Operation Manual
Hose Pump type P_classicplus
Page 18 of 25
Version 002_GB / 04.2017
6.4 Installing the pump hose
The outer surface of the pump hose must be lubricated sufficiently with
Ponndorf Special Grease before assembling it.
Remove power from the pump by removing the main fuses before doing
any cleaning / maintenance / assembly operations.
6.4.1
Pump with assembled
connecting sockets
6.4.2
Unscrew the flanges on
suction and discharge side
of the pump.
6.4.3
Lubricate the pump hose
with Ponndorf Special
Grease.
6.4.4
Switch on the drive.
The rotating pump pulls in
the pump hose.
When the hose appears on
the other side of the casing
switch the drive off again
and interrupt the power
supply.
CAUTION

PONNDORF Gerätetechnik GmbH
Leipziger Strasse 374
D - 34123 Kassel
Operation Manual
Hose Pump type P_classicplus
Page 19 of 25
Version 002_GB / 04.2017
6.4.5
Put the clamping ring onto
the end of the hose.
CAUTION:
The outer edge of the
clamping ring must be
flush with the end of the
hose.
6.4.6
WRONG!
6.4.7
Put the connecting socket
into the end of the hose.
CAUTION:
Keep taking care of proper
seat of hose and clamping
ring.
6.4.8
WRONG!
6.4.9
Put the flange over the
connecting socket and
tighten it with screws.
6.4.10
Fix the clamping ring and
the connecting socket at
the second end of the
hose.
CAUTION:
Keep taking care of proper
seat of hose and clamping
ring.
6.4.11
Put the flange over the
connecting socket and
tighten it with the screws.
6.4.12
Pump with properly
mounted flange.
Pump is now ready for operation!
Do not wear gloves during these operations because they may be
pulled in!