Instruction handbook - PRP Systems

Doc. Nr. 823403

Version 1.21

Instruction handbook

2611-4-1 / 2611-4-2

POMTAVA S.A. [email protected] Metering gear pumps

Instruction handbook for pumps type 2611-4-1 and 2611-4-2 2/23

Table of contents

CHAPTER 1 GENERAL ................................................................................................................................... 4

1.1 INTRODUCTION ........................................................................................................................................... 4 1.2 APPLICATION FIELDS .................................................................................................................................. 4 1.3 COPYRIGHT ................................................................................................................................................. 4 1.4 MANUFACTURER ......................................................................................................................................... 4

CHAPTER 2 TECHNICAL DATA .................................................................................................................. 5

2.1 STRONG POINTS OF PUMP TYPE 2611-4-1 AND 2611-4-2 ............................................................................ 5 2.2 DIMENSIONS OF THE PUMP .......................................................................................................................... 6

2.2.1 Dimensions for pump 2611-4-2 (also available for 2611-4-1) ............................................................ 6 2.3 TECHNICAL DATA ....................................................................................................................................... 6

2.3.1 Technical data for pump 2611-4-1 and 2611-4-2 ................................................................................ 6 2.3.2 Options for pump 2611-4-1 and 2611-4-2 ........................................................................................... 6

2.4 OTHER DATA ............................................................................................................................................... 7 2.4.1 Available outputs ................................................................................................................................. 7 2.4.2 Acceptable output pressure ................................................................................................................. 7 2.4.3 Rotation speed ..................................................................................................................................... 7 2.4.4 Dosing accuracy .................................................................................................................................. 7

2.5 LIFESPAN..................................................................................................................................................... 7

CHAPTER 3 SAFETY ....................................................................................................................................... 8

3.1 GENERAL SAFETY ....................................................................................................................................... 8 3.1.1 Certificates .......................................................................................................................................... 8

CHAPTER 4 TRANSPORT .............................................................................................................................. 9

CHAPTER 5 DESIGN AND FUNCTION ..................................................................................................... 10

5.1 PUMP ELEMENTS ....................................................................................................................................... 10 5.1.1 Elements of a 2611-4-1 pump ............................................................................................................ 10 5.1.2 Elements of a 2611-4-2 pump ............................................................................................................ 11

5.2 GENERAL DESCRIPTION OF OPERATIONS .................................................................................................. 12

CHAPTER 6 PUMP ASSEMBLY .................................................................................................................. 13

6.1 GENERAL INFORMATIONS ......................................................................................................................... 13 6.2 INSTALLATION OF THE PUMP .................................................................................................................... 13

CHAPTER 7 STARTING THE PUMP .......................................................................................................... 14

7.1 GENERAL INFORMATION ........................................................................................................................... 14 7.2 FLUSHING .................................................................................................................................................. 14 7.3 BREAKING IN THE PUMP ............................................................................................................................ 14 7.4 SEALING CHECK ........................................................................................................................................ 14 7.5 LIQUID BARRIER TEST ............................................................................................................................... 14

CHAPTER 8 OPERATION ............................................................................................................................ 15

8.1 GENERAL INFORMATION ........................................................................................................................... 15 8.2 SAFETY MEASURES ................................................................................................................................... 15 8.3 TROUBLESHOOTING .................................................................................................................................. 15

CHAPTER 9 MAINTENANCE ...................................................................................................................... 16

9.1 SAFETY ..................................................................................................................................................... 16 9.2 GEAR PUMPS ............................................................................................................................................. 16 9.3 MAINTENANCE AND REPAIRS.................................................................................................................... 16

9.3.1 General .............................................................................................................................................. 16 9.3.2 Tool set .............................................................................................................................................. 17

9.4 CLEANING ................................................................................................................................................. 17



9.5 DISASSEMBLY AND RE-ASSEMBLY OF A 2611-4-1 AND A 2611-4-2 PUMP ................................................18 9.5.1 Disassembly .......................................................................................................................................18 9.5.2 Re-assembly .......................................................................................................................................21

9.6 DISASSEMBLY AND RE-ASSEMBLY OF SEALING ........................................................................................23



Chapter 1 General

1.1 Introduction

This maintenance manual (referred to as IH from here) is especially intended to help maintenance

personnel in utilizing POMTAVA S.A. dosing gear pumps in the best possible manner as well as

perform the technical maintenance correctly. It is therefore, recommended that this manual be read

before starting the pump. Pomtava declines all responsibility for any damages incurred if these

recommendations are not followed and no request for repair or exchange under warranty will be

considered.

In case of problems, please refer to POMTAVA S.A. customer services and/or to the supplier of the

whole installation.

POMTAVA S.A. reserves the right to modify the specifications and the text here in and declines all

responsibilities for damages (of any kind) incurred after using this manual, including typographic

errors and other possible errors in this publication.

1.2 Application fields

This type of pump is mainly fitted to meter paints with strong deposit that normally provokes seizing

of the idler shaft.

The flushing of the pump is optimum and allows savings of flushing time and products.

1.3 Copyright

It is absolutely forbidden to copy in any way this document, whether in part or in its entirety without

the explicit written consent of POMTAVA S.A.

© 2014 POMTAVA S.A.

1.4 Manufacturer

POMTAVA S.A. Tel. +41 (0)32 481 15 14 Pompes et systèmes de dosage Fax. +41 (0)32 481 48 18

Nonceruz 2 E-mail : [email protected]

CH-2732 Reconvilier Net: www.pomtava.com



Chapter 2 Technical data

2.1 Strong points of pump type 2611-4-1 and 2611-4-2

All parts are in tempered stainless steel

Reduction of “dead zones” allowing for a better flushing

New sealing technology combining lip seals and liquid barrier

Strong, coated drive shaft, held in place with 2 bearings and a axial thrust

Centering pins making pump assembly easier and increasing its accuracy

Sealing options quickly interchangeable

Possibility to mount a bypass system (for type 2611-4-2)

Type : 2611-4-1 Type : 2611-4-2

A POMTAVA S.A. metering pump is made up of high precision elements. The center plate and

gears are created on special machines and the manufacturing norms consider them already as

standard for others to refer to, according to DIN standards.

It is therefore obvious that all parts must be handled with extreme care, and that the good functioning

of the pump could be compromised if parts came to hit each other.

In order to obtain maximum life span, the pump specifications must be respected. Also, correct

assembly of the pump, together with accurate axial alignment of the drive shaft contribute to a longer

life span. A radial drive is definitely not recommended.

Several options make it possible to get the best performance out of your pump according to the

product to be metered. A careful choice is therefore necessary. POMTAVA S.A. technical

department is available to advise you on this. A loaded viscous product (abrasive) cannot be metered

in the same way as a very thin product.

When referring to the direction of the rotation of the pump (to the right, to the left, clockwise,

counter clockwise), the pump is viewed with the drive shaft facing the reader or more simply from

the drive motor side.



2.2 Dimensions of the pump

2.2.1 Dimensions for pump 2611-4-2 (also available for 2611-4-1)

* Bypass system (only with 2611-4-2)

** Stand H=40mm

Output (cc/rev) 1.2 2.4 3.0 6.0 10.0

X (mm) 41.2 45.4 47.5 58 72.0

2.3 Technical data

2.3.1 Technical data for pump 2611-4-1 and 2611-4-2

Sealing : Lip seals and liquid barrier

Rotation speed : From 10min-1 to 200min-1 ; depend of the product

Standard rotation direction : Clockwise (A)

Temperature : Max. 135°C

Output pressure : Max. 15 bars

Input / Output : 2 holes Ø 6mm on the body of the pump.

Delivers with a G1/4’’ connecting block.

Drive shaft diameter : Ø 12mm with a 4mm key

Drive shaft height : H = 51 mm

2.3.2 Options for pump 2611-4-1 and 2611-4-2

(T2) Entirely treated with ADLC

(H40) Stand H = 40mm

(Z) Counter clockwise rotation

(AZ) Clockwise and counter clockwise rotation

(W) Connecting block for 2 pressure sensors M28x1.5

(BB) Block bypass (for type 2611-4-2)

(AB38) Connecting block G3/8’’

Connections on demand



2.4 Other data

2.4.1 Available outputs

1.2 cc/rev 2.4cc/rev 3.0cc/rev 6.0 cc/rev 10.0 cc/rev

2.4.2 Acceptable output pressure

Max. 15 bars

2.4.3 Rotation speed

From 10min-1 up to 200min-1, depending on the product involved.

Optimal output stands between 30 min-1 and 80 min-1.

2.4.4 Dosing accuracy

The dosage accuracy of a new pump is ± 2% in the following working conditions:

Speed of rotation 30-80 rpm

Oil viscosity 25s DIN4 by 20°C

Delta P ± 2 bar between input and output

2.5 Lifespan

The normal life span under optimal conditions is 1 year - counting 8hr/day – 5days/week.

This may vary considerably depending on the product involved.



Chapter 3 Safety

3.1 General safety

The pump must be installed according to assembly instructions and all necessary precautions must be

taken when handling the pump or any of its elements. Installation, maintenance and repairs must be

performed only by qualified personnel.

If the product to be metered can be hurtful to the people working on the installation, adequate

protection must be provided for the skin and the eyes. In that case, it is mandatory to follow the

product manufacturer’s recommendations.

The user agrees to use the pump in a clean environment.

Modifications of the pump causing lowering of safety standards are forbidden.

Maintenance or repair will be done only if the pump is off.

CAUTION

Before disassembling the pump, rinse thoroughly with the proper solvent and ensure that there is no

pressure anywhere.

Always read and follow instructions given in the product manufacturer’s documentation regarding

the wearing of protective gears (goggles, gloves, etc.) as well as any other safety measures.

After performing repairs, adjustments or cleaning with polluting products, please dispose of these

products in an ecological manner.

3.1.1 Certificates

The following documents are included with each pump delivery:

1 certificate of control

1 manufacturer’s certificate



Chapter 4 Transport

The transport of one or several pumps can be done by various methods (trucks, train, etc.). Packing is

done preferably with recyclable material. The pumps are precision units and during transport, the

various components must be well protected so as to avoid hitting against each other.

In order to avoid deposits inside the pump during transport, input and output openings as well as

sealing systems must be plugged.

The pumps or their components must be stored in a dry place, protected from dust. Before

assembling a pump, it is important to store it first in a place at the same temperature at which it will

be later used, in order to avoid any possible seizing.

Any possible damages incurred during transport must be reported in writing immediately to

POMTAVA S.A.



Chapter 5 Design and function

5.1 Pump elements

5.1.1 Elements of a 2611-4-1 pump

Nr. REF Quantity Description

1 1 Stainless steel body

2 1 Center plate and gears

4 1 Rear cover

5 2 Centering pin

6 6 Plate mounting screw

15 2 O-Ring

20 1 Connecting block

22 2 Connecting block screw

23 2 PTFE ring

30 1 Stand

50 1 Sealing system 26KA (see doc. N° 843101)



5.1.2 Elements of a 2611-4-2 pump

Nr. REF Quantity Description

1 1 Stainless steel body

2 1 Center plate and gears

4 1 Rear cover

5 2 Centering pin

6 6 Plate mounting screw

15 2 O-Ring

20 1 Connecting block

22 2 Connecting block screw

23 2 PTFE ring

30 1 Stand

41 1 Middle plate for bypass block (option)

42 1 Bypass block (option)

46 2 Bypass block screw (option)

47 1 Valve 400 (option)

50 1 Sealing system 26KA (see doc. N° 843101)



5.2 General description of operations

Two gears are located in the central plate (2) which is placed between a rear cover (4) and the body

of the pump (1). The rotation of the pump is given by the position of the decompression hole, on the

side of the output on the cover (4).

The link with the leading gear is done by the driving shaft and its driving pin.

The input/output openings are located on the top of the body (1). The product to be metered is

pushed from the input opening all the way to the gears. The gear teeth fill up and bring the product to

the output. The gear teeth empty out by the gear action and push the product out.

The product enters in the pump through the input path and goes through the pump by following the

outer teeth of the gears (rear view):



Chapter 6 Pump assembly

6.1 General informations

A thorough cleaning of the pump is recommended before starting assembly. The inputs/outputs must

be free of any impurity which could block the openings. Manually turn the drive shaft to check the

rotation. Please note the direction of the rotation, as well as the input/output openings, which are

engraved on the small plaque mounted on the pump. Rotating the pump in the wrong direction can

cause serious damage and even destroy the pump. It is also advised NOT to run the pump dry.

6.2 Installation of the pump

The pump must be properly and firmly mounted on its stand. A perfect alignment of the drive shaft

of the pump and the drive shaft of the motor is absolutely mandatory. The minimum distance allowed

between the pump drive shaft and the motor drive shaft is of 2mm but they must never touch each

other. A radial pressure on the drive shaft can damage the pump.

Check the feeding hoses front and back of the pump. If there are any impurities at the entrance of the

pump or if the product to be metered is not perfectly clean, the installation of a filter will be

necessary.

For perfect sealing of the fittings, sealing washers in PTFE should be used instead of Teflon strips.

Nothing must come in contact with the pump and adequate ventilation must be provided.



Chapter 7 Starting the pump

7.1 General information

When installing the pump on the machine, it is absolutely critical to ensure that no foreign body is

present underneath the pump. A careful cleaning of the feeding hoses is necessary. A filter can be

recommended by the machine manufacturer if the product to be metered is impure or is susceptible

to be polluted during transferring.

Please check the correct direction of the rotation of the pump and that the inputs/outputs are

connected correctly according to the direction of the rotation (a pump with reduced play “F” can be

destroyed in a few rotations)

7.2 Flushing

It is necessary to rinse the pump with a solvent before turning it on. It is important to erase all traces

of any matter (grease, oil, etc.) used during assembly. The flushing should take as little time as

possible due to the lack of lubricant in certain solvents. The speed of rotation during flushing should

not exceed 40min-1.

7.3 Breaking in the pump

Although the pumps are tested and controlled at POMTAVA S.A., it is necessary to gently break in

the new pump with the product to be metered before turning it on. The procedure to follow is:

Run the pump at 20-30 min-1 with a product having an input pressure of no more than 3 bars and an

output pressure of 0 bar for one hour (in closed circuit if possible).

At the same rate of speed, increase the output pressure to 5 bars and run for 30 minutes. Then

increase steadily the output pressure, always keeping 30 minutes between levels, until the maximum

pressure acceptable is reached (max. 15 bars).

During these steps, a flow check of the pump is possible in order to discover the output curb under a

specific product and to, in this way, compensate for any possible leakage by adjusting the rotation of

the pump.

7.4 Sealing check

By turning on the pump, the sealing between plates is automatically checked. If any of the liquid

metered appears between any of the plates, please check if the mounting screws (6) are tight enough

(see Chapter 9 for proper tightening).

If leakage persists, the pump will have to be dismantled. After a careful cleaning of all the elements,

the pump will again be assembled, with special care given to the cleanliness of the surfaces of the

plates and of the body of the pump. Only clean and dry surfaces guarantee a perfect sealing.

7.5 Liquid barrier test

See document N° 843101 “Instruction handbook - Sealing 16KA and 26KA for pumps type

1610, 1611, 2610 and 2611”.



Chapter 8 Operation

8.1 General information

The metering pump is designed to operate continually but can also be run intermittently. During

short pauses, no particular servicing or maintenance is necessary. The bearings are lubricated by the

metered product and for that reason it is not recommended that the pump be run dry.

8.2 Safety measures

Starting and running the pump are of course subject to rules and regulations of local safety.

8.3 Troubleshooting

The following list is not limitative and the information is given in order to assist the local

maintenance people in case of problems. This information is of a general nature. It is impossible to

list here all the possible problems and repairs since many of those are directly tied to the metered

product. It is therefore advised to contact the supplier’s service department or POMTAVA S.A.

Problem Cause Solution

Leakage of the sealing at the

drive shaft

Sealing worn Disassemble + check. Change parts

needed.

Wrong choice of sealing of product

and/or of pressure used

Contact POMTAVA customer

service

Leakage near the center plate,

rear cover and body

Impurities between the plates.

Exceeding authorized pressure.

Disassemble and clean the pump.

Check that the screws are tight.

Decrease pressure.

Very liquid product (leak by

capillarity)

Contact POMTAVA customer

service

Metering not accurate Wearing out of parts. Take apart and check all parts and

Impurities in I/O lines feeding I/O lines.

Pressure too low. Measure I/O pressure.

Inadequate play for the type of Check product viscosity.

product. Error in assembly.

No output (pump doesn’t run) Motor doesn’t turn. Check motor and its plugs.

The coupling is broken or missing. Check coupling and driving pins.

No output (pump runs) I/O poorly connected or plugged. Check I/O connections.

Check feeding line.

Disassemble and check pins and

gears.

Driving pin for gear is broken. No

product on the Input side of pump.



Chapter 9 Maintenance

9.1 Safety

During maintenance, please refer to Chapter 3 safety instructions which are to be followed

methodically. The pump will last longer if the maintenance is performed correctly and regularly.

It is obvious that the wear and tear of the pump is directly tied to the work settings, applications and

products metered. Therefore, the frequency of maintenance and trouble-shooting will vary and an

appropriate maintenance plan should be instated.

WARNING

The pump must be off and unplugged when making any repairs or doing any maintenance. Any

work on the pump must be done by authorized and qualified personnel.

9.2 Gear pumps

The pump is made up of the following elements: a body, a front friction plate, a center plate and

gears, a drive shaft, an idler shaft, a rear cover and a stand. According to a pre-set program, it is

important, may be even necessary to periodically check the flow. The different of the results

comparing to the new pump control tests is an indication of its wear and tear. It is sometimes

possible to compensate any decrease in output by an increase of the rotation speed. This solution is

however limited and it might become necessary to take the pump apart. Obviously any and all

elements showing a severe wear and tear are to be replaced. It is very important to use original

POMTAVA S.A. spare parts when doing repairs or maintenance.

When ordering spare parts, please indicate the pump serial number and any other pertinent

information to ensure that the correct parts are ordered.

9.3 Maintenance and repairs

9.3.1 General

Any work done on a pump must be done so by authorized and qualified personnel. All necessary

precautions must be taken to ensure the safety of the personnel and that of the environment. It is also

mandatory to refer to the local safety rules applying to the installations on which the pump is

mounted. If any of the pump elements become defective and need to be replaced, it is imperative to

use original POMTAVA S.A. parts.



9.3.2 Tool set

The following tools are necessary to perform any repair or maintenance:

1 3 / 4mm wrench (dynamometric)

1 3 / 4 / 5mm wrench

1 plastic mallet

1 N° 2 screwdriver

1 N° 4 screwdriver

1 indelible felt-tip pen

Paper or cloth, lint free

1 emery cloth – grain 1600

1 fine grain oil stone - (800 - 1000)

Solvent or diluting agent, compatible with product in the pump

1 hard bristle brush

Protective gear (as requested by product manufacturer)

9.4 Cleaning

IMPORTANT

The elements must be soaked in the solvent appropriate for the product to be metered. The elements

must never be banged or damaged during this procedure. The parts will be dipped in the

container with care. No metallic tool (screwdrivers, knives, chisels) must ever be used. In order not

to mix elements from different pumps, the pumps will be cleaned one at a time.

The cleaning of a pump is often tedious. This procedure is however, of major importance in order the

later analyse properly the wear and tear and to guarantee a proper assembly, which in turn ensures a

good functioning of the pump.



9.5 Disassembly and re-assembly of a 2611-4-1 and a 2611-4-2 pump

Drawing 1 – The parts of a 2611-4-2 pump

9.5.1 Disassembly







9.5.2 Re-assembly





9.6 Disassembly and re-assembly of sealing

See document N° 843101 “Instruction handbook - Sealing 16KA and 26KA for pumps type

1610, 1611, 2610 and 2611”.

If you have problems with the assembly or the disassembly of the pump please contact POMTAVA

customer care at [email protected] or by phone (see page 4).

© 2014 POMTAVA S.A.

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