PONNDORF P high pressure 65 User manual

Hose Pump
Type
P_high pressure 65
Operation Manual

PONNDORF Gerätetechnik GmbH
Leipziger Strasse 374
D - 34123 Kassel
Operation manual
Hose Pump type
P_high pressure 65
Page 1 of 26
Version 002_GB / 05.2017
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
2.6 Adjustment of pressure ........................................................................................5
3. Safety
3.1 Marking of details in the operation manual ..........................................................6
3.2 Safety instructions for operating the pumps in hazardous locations......................7
3.3 Intended use .....................................................................................................7/8
3.4 Qualification and training of personnel..................................................................8
3.5 Dangers in case of non-observance of the safety instructions...........................8/9
3.6 Safety-conscious working.....................................................................................9
3.7 Safety instructions for the operator/user...............................................................9
3.8 Safety instructions for maintenance / inspection / assembly............................9/10
3.9 Unauthorized modifications or use of unoriginal parts ........................................10
3.10 Unauthorized operation methods........................................................................10
4. Transport, storage and disposal
4.1 Transport............................................................................................................11
4.2 Storage ..............................................................................................................11
4.3 Disposal.............................................................................................................12
5. Description of pump and accessories ......................................................................13
5.1 Detector for hose leakages.................................................................................14
5.2 Diagram of the leakage detector.........................................................................15
6. Installation / connection / operation
6.1 Installation of pumps in hazardous locations......................................................16
6.2 Electrical connections....................................................................................16/17
6.3 Mechanical connections.....................................................................................17
6.4 Installing / changing the pump hose ..................................................................18
6.5 Installing / changing the pump hose (work steps)..........................................19-22
7. Repairs / maintenance
7.1 Changing the pump hose ...................................................................................23
7.2 Maintenance...................................................................................................... 23
7.3 Cleaning ............................................................................................................24
7.4 List of spare parts...............................................................................................24
7.5 Drawing of spare parts .......................................................................................25
8. Characteristic curve....................................................................................................26
9. Accompanying documents.........................................................................................26

PONNDORF Gerätetechnik GmbH
Leipziger Strasse 374
D - 34123 Kassel
Operation manual
Hose Pump type
P_high pressure 50
Page 2 of 28
Version 002_GB / 05.2017
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 (operation without
pumping media) 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_high pressure 65
Page 3 of 26
Version 002_GB / 05.2017
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_high pressure 65
Page 4 of 26
Version 002_GB / 05.2017
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_high pressure 65
Max. flow rate:
[l/h H2O]
approx. 32.000
Max. pressure (pmax):
a) motor capacity 3 / 5,5 / 9,2 kW
b) motor capacity 4 / 7,5 / 11 kW
[bar]
a) 7,5 1)
b) 15 1)
Max. suction height:
[m H2O]
8
Max. viscosity of pumping media:
[mPas]
35.000
Motor power (depending on
pressure and speed):
[kW]
3,0 - 11,0
Max. Speed:
[n/min]
80
Weight:
pump head only (0)
with gear motor (GM)
with variable speed drive (RST)
[kg]
approx. 586 2)
approx. 847 2)
approx. 937 2)
Hose material:
Natural rubber, EPDM,
Perbunan (NBR), according to 21 CFR of
FDA
1) Exception: with pump hose material Perbunan (NBR): limited to pmax = 10 bar
2) Weights refers to basic versions of the pumps with coupling drive and max. driving
power. Differences of weights (i.e. because of special models) are not considered.

PONNDORF Gerätetechnik GmbH
Leipziger Strasse 374
D - 34123 Kassel
Operation manual
Hose Pump type
P_high pressure 65
Page 5 of 26
Version 002_GB / 05.2017
2.6 Adjustment of pressure
Ponndorf hose pumps provide the opportunity to change the gap width between the shoes
and the inner surface of the pump housing. At applications with lower required discharge
pressures we recommend to enlarge the gap width in order to achieve a longer hose-
lifetime. On the other hand at high discharge pressures the gap width has to be reduced,
i.e. the contact pressure on the hose has to be increased.
The adjustment of the gap width is being effected by the shims included in delivery. The
shims between the rotor and the shoes have to be assembled or disassembled, always
depending on the required discharge pressure. In the following table you will find the
recommendations for the necessary quantity of shims to be installed, depending on the
discharge pressure.
For assembly and disassembly of the shims the lubricant bath and the casing cover have
to be removed. Each shim is fixed to the rotor by one screw. This screw must be loosened
just a little bit to enable assembling or disassembling of the shims.
Pump type
Pressure
Gap width in mm
Shims per shoe
P_high
pressure 65
0-7,5 bar
33,25
1 piece at 0,75 mm
up to 8 bar
32,5
2 pieces at 0,75 mm
up to 12 bar
31,75
3 pieces at 0,75 mm
up to 15 bar
31
4 pieces at 0,75 mm
Note: The above-mentioned quantities of shims per shoe are guideline values.
Depending on varying application conditions (pipework, varying properties of the
medium to be pumped etc.) it may be necessary to use one shim more or less at
each shoe!
Following pressure limits must be considered for the different hose materials:
Hose material
max. pressure
Natural rubber - NR
15 bar
EPDM
15 bar
Perbunan –NBR
10 bar
In case of change of the used hose material a corresponding adjustment of pressure must
be made (see above).
The casing cover may only be removed when the drive is switched off and
the power supply is interrupted (remove fuses).

PONNDORF Gerätetechnik GmbH
Leipziger Strasse 374
D - 34123 Kassel
Operation manual
Hose Pump type
P_high pressure 65
Page 6 of 26
Version 002_GB / 05.2017
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_high pressure 65
Page 7 of 26
Version 002_GB / 05.2017
3.2 Safety instructions for operating the 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_high pressure 65
Page 8 of 26
Version 002_GB / 05.2017
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 internal space of the pump casing is filled sufficiently
with Ponndorf Special Lubricant Bath 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_high pressure 65
Page 9 of 26
Version 002_GB / 05.2017
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_high pressure 65
Page 10 of 26
Version 002_GB / 05.2017
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_high pressure 65
Page 11 of 26
Version 002_GB / 05.2017
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)
•
When lifting the complete pump aggregate (pump head with mounted
drive and base plate) the corresponding lifting tool must only be fixed at
the holes for lifting the pumps at the base plate! The ring bolts on pump
head and drive must only be used for lifting the separate components
while installation and disassembling.
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 shoes!
CAUTION
Holes for lifting the pump
These holes can be used for balancing when lifting
the pump

PONNDORF Gerätetechnik GmbH
Leipziger Strasse 374
D - 34123 Kassel
Operation manual
Hose Pump type
P_high pressure 65
Page 12 of 26
Version 002_GB / 05.2017
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:
- 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.
CAUTION

PONNDORF Gerätetechnik GmbH
Leipziger Strasse 374
D - 34123 Kassel
Operation manual
Hose Pump type
P_high pressure 65
Page 13 of 26
Version 002_GB / 05.2017
5. Description of pump and accessories
Depending on the construction of the pump the pump head is connected with the drive by
a coupling. Pump head and drive are completely mounted on a base plate.
Construction "XXX" means that the pump head is supplied with bare shaft extension
Construction
Description
- XXX
- pump head with bare shaft extension, without drive
Pump with coupled drive
- GMC
- GMC-TF
- GMC-FF
- GMC-I1/I3
- GMC-V1/V3
- pump with gear motor
- pump with gear motor incl. 3 thermistors for frequency converter use
- pump with gear motor incl. 3 thermistors and forced fan
- pump with gear motor with integr. frequency converter
- pump with gear motor, forced fan and integr. frequency converter
-BDC
- pump with variable speed drive
P_high pressure 65
Material of pump casing:
Grey cast iron (cover: steel)
Material of base plate:
steel (standard)
Paint of the complete pump:
RAL 5003 (standard)

PONNDORF Gerätetechnik GmbH
Leipziger Strasse 374
D - 34123 Kassel
Operation manual
Hose Pump type
P_high pressure 65
Page 14 of 26
Version 002_GB / 05.2017
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 sensor of the leakage detector must be screwed in non-flush into the thread of the screw cap
and should extend approx. 3 - 5 mm into the cap.
When the sensor extends more than 5 mm into the cap it may occur that the detector alerts even
without any hose leakage.
This sensor is prohibited for use in hazardous locations.
For such operating conditions a special leakage detector is available
Leuchte
Horn
pump
sensor
light
horn

PONNDORF Gerätetechnik GmbH
Leipziger Strasse 374
D - 34123 Kassel
Operation manual
Hose Pump type
P_high pressure 65
Page 15 of 26
Version 002_GB / 05.2017
5.2 Diagram of the leakage detector
Part 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 “EX”
B1 –capazitive sensor „EX“
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
S1 –double push button

PONNDORF Gerätetechnik GmbH
Leipziger Strasse 374
D - 34123 Kassel
Operation manual
Hose Pump type
P_high pressure 65
Page 16 of 26
Version 002_GB / 05.2017
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_high pressure 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_high pressure 65
Page 17 of 26
Version 002_GB / 05.2017
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).
fig. 6.3.1
WRONG
fig. 6.3.2
WRONG
fig. 6.3.3
WRONG
fig. 6.3.4

PONNDORF Gerätetechnik GmbH
Leipziger Strasse 374
D - 34123 Kassel
Operation manual
Hose Pump type
P_high pressure 65
Page 18 of 26
Version 002_GB / 05.2017
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 !
6.4 Installing / changing the pump hose
The assembly of the pump hose is described on the pages 20 - 23.
This description is material to following cases:
Case
Situation
Necessary work
steps
Delivery of a new hose pump
Pump hose is not built in yet
(standard!) and has to be installed
Chapter 6.5,
Steps 6) to 13)
Pump must be put out of
operation over a longer
period (> 5 days)
Pump hose must be dismantled
Chapter 6.5,
Steps 1) to 4)
Pump should be reactivated
after a longer period
Pump hose must be installed
Chapter 6.5,
Steps 6) to 13)
Hose damage / leakage
Pump hose must be dismantled
and must be replaced by a new
hose
Chapter 6.5,
Steps 1) to 13)
Remove power from the pump by removing the main fuses before doing
any maintenance operations!

PONNDORF Gerätetechnik GmbH
Leipziger Strasse 374
D - 34123 Kassel
Operation manual
Hose Pump type
P_high pressure 65
Page 19 of 26
Version 002_GB / 05.2017
6.5 Installing / changing the pump hose (work steps)
1)
Unscrew drain plug to remove the
lubricant bath and collect the liquid.
2)
Unscrew counter flanges on suction
and discharge side.
3)
For installed pump hose if necessary
use lifting screws.
4)
Switch on the drive to remove the
hose.
The rotating pump pushes out the
pump hose.
CAUTION: Do not put your hands into
the pump casing!!
CAUTION: SWITCH ON THE DRIVE ONLY WHEN THE CASING COVER IS MOUNTED!