Barnant Company PK15, PK25, PK50, PK40, PK65 Operating Manual

OPERATING MANUAL

BARNANT/PONNDORF
HOSE PUMPS

Ponndorf PK hose pump

Model Numbers:

PK15, 25, 40, 50, 65

Cole-Parmer Instrument Co.

1-800-MASTERFLEX (627-8373) (U.S. and Canada only)
11 [phone] (Outside U.S.) • [phone] (Local) • www.masterflex.com

Barnant Company

1-800-637-3739 (U.S. and Canada only)
11 [phone] (Outside U.S.) • [phone] (Local) • www.barnant.com

A-1299-1027

Edition 02

Barnant/Ponndorf

2

Barnant/Ponndorf

TABLE OF CONTENTS

Title Page

SAFETY PRECAUTIONS ............................................................................................................3

Safety......................................................................................................................................3

Precaution Icons......................................................................................................................3

Operator Qualifications and Training ......................................................................................3

Dangers of Ignoring the Instructions ......................................................................................3

Safety Awareness at Work......................................................................................................3

Safety Instructions for the Operator ........................................................................................3

Safety Instructions for Maintenance, Inspection, and Assembly ............................................4

User Modification or Manufacturing of Spare Parts ................................................................4

Unauthorized Operation..........................................................................................................4

Warnings and Cautions ..........................................................................................................4

INTRODUCTION ..........................................................................................................................5

DESCRIPTION OF PUMPS AND SPECIFICATIONS ..................................................................5

INSTALLATION AND SETUP ......................................................................................................8

Mechanical Connection ..........................................................................................................8

Installation/Change of the Pump Hose....................................................................................8

Adjustment of Discharge Pressure Capability ......................................................................10

MAINTENANCE / REPAIR..........................................................................................................11

Cleaning ................................................................................................................................11

Inactive Periods ....................................................................................................................11

Replacement Parts................................................................................................................11

Model and Serial Number Location ......................................................................................11

TRANSPORT AND STORAGE ..................................................................................................12

Lifting ....................................................................................................................................12

Transit Storage......................................................................................................................12

WARRANTY................................................................................................................................13

PRODUCT RETURN..................................................................................................................13

TECHNICAL ASSISTANCE........................................................................................................13

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SAFETY PRECAUTIONS

Safety

These instructions contain basic recommendations that should be followed during installation, set up, operation and
maintenance. Therefore, these operating instructions must be read by the installer, operators, and other personnel
before assembly and operation. These instructions must be available at all times to the operator. The customer must
consult the motor operating manual for additional instructions and safety precautions.

Precaution Icons

Those safety recommendations in the operating instructions, which must be followed to avoid personal injury and/or
damage to the pump, are marked with the appropriate precaution icons.

Instructions written on the pump assembly must be followed at all times and kept in a readable condition.
For example:

g

Direction of rotation arrows,

g

Marking for fluid connections.

Operator Qualifications and Training

Personnel responsible for operation, maintenance, inspection, and assembly must be suitably qualified for this work.
The customer must be responsible for the competence and supervision of staff. If suitably qualified personnel are not
available, training must be provided. Training can be provided by the Manufacturer or Distributor, for a fee, at the
request of the customer. The customer must ensure that the operating instructions are fully understood by all staff.

Dangers of Ignoring the Instructions

Ignoring the safety instructions can endanger people, the environment, and equipment. Ignoring these instructions will
also invalidate the warranty.

Not following the safety instructions can lead to:

g

Machinery failure,

g

Personal injury caused by electrical, mechanical, or chemical hazards,

g

Endangering the environment through leakage of hazardous materials.

Safety Awareness at Work

The safety instructions contained in the operating manual must be observed, in addition to any national or local codes
and regulations for the prevention of accidents and the customer’s own safety regulations.

Safety Instructions for the Operator

g

Guards which cover moving parts (e.g. coupling) must not be removed while the machine is in operation.

g

Any electrical hazard must be avoided (refer to local electrical codes). Do not use the pump in damp or wet locations.
Do not use damaged cords or plugs. Do not handle plug with wet hands. Use only properly grounded power outlets.

g

Do not operate the pump in the presence of flammable liquids or gases to avoid creating a fire or explosion.

g

Do not operate the pump when you are tired, ill, or under the influence of alcohol, drugs, or medication.

g

Always wear safety glasses or similar eye protection.

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4

Safety Instructions for Maintenance, Inspection, and Assembly

g

The customer must ensure that all maintenance, inspection, and assembly are carried out by fully trained personnel
who have read fully and familiarized themselves with the operating manual.

g

As a basic rule, the pump must be taken out of operation before any maintenance work is carried out, and the
procedures in the operating manual for taking the pump out of operation must be followed.

g

Pumps or systems used for liquids which are hazardous to health must be decontaminated before maintenance.

g

Immediately after completion of any work, all safety and protective devices must be refitted.

g

Before restarting the pump, follow the instructions for commissioning a pump for the first time.

User Modification or Manufacturing of Spare Parts

Modification to the pump should be made only after consultation with the Manufacturer. Those modifications to
the pump will not be covered under warranty. Use only original spare parts, hose, and fittings approved by the
Manufacturer. Use of hoses or parts, other than those supplied by the Manufacturer, shall invalidate the warranty
and may cause damage to the pump and/or personal injury.

Unauthorized Operation

The instructions contained in this SAFETY PRECAUTIONS section must be followed to reduce the risk of damage to the
pump and/or personal injury . Under no circumstances are the performance limits shown on the data sheet to be exceeded.

Warnings and Cautions

Look for the following symbols and safety precautions throughout this Operating Manual. The symbols are used to
highlight particular precautions at various points in the Operating Manual. The safety precautions must be observed to
reduce the risk of personal injury and/or damage to the pump.

WARNING: Disconnect the pump from the main power source before performing any type of assembly or

maintenance operation, including but not limited to hose installation, hose connection, shim
installation, spare part installation, and cleaning.

WARNINGS: Keep hair, gloves, loose clothing, jewelry, and fingers away from openings and moving parts.

The casing cover must be in place, and hands must not be put into the pump casing, unless
the drive is stopped and the power is disconnected.

Before operating the pump, all valves in the pipe work must be opened. If this is not done, a
hazardous bursting condition could develop and/or excessive pressure could damage the
pump and hose and may cause harm to personnel.

CAUTIONS: Positive displacement pumps should always be fitted with a relief valve on the discharge.

Otherwise, the pump could be damaged if the maximum pressure is exceeded.
When lifting the pump system or a component of the pump system, the proper attachment points

and lifting equipment must be used. The lifting equipment must have an adequate weight rating
and the proper attachment points must be utilized to prevent failure of the lift and/or attachment
points.

When storing the pump for extended periods (longer than five days) remove the hose to
prevent permanent deformation from the shoes.

Use only recommended hose with Ponndorf pumps to ensure optimum performance.
Use of other hose may void applicable warranties.

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INTRODUCTION

Ponndorf Hose Pumps are self-priming rotating positive-displacement pumps without seals or valves. The liquid
comes into contact with only the interior of the hose and not with the moving parts of the pump.

This makes them particularly suited to pumping aggressive, abrasive, and high viscous mediums, as well as pumping
liquids with a high percentage of solids and shear-sensitive fluids.

DESCRIPTIONS OF PUMPS AND SPECIFICATIONS

The PK Series Hose Pumps are baseplate mounted and driven by motor via a gearbox and coupling. Various
configurations are shown below.

The Hose Pumps are supplied with a sealed container of special Ponndorf oil bath lubricant and shims that change
the discharge pressure capability. A hose and connecting sockets are required for operation, but they are ordered and
supplied separately.

General environment:

■ Operating temperature: 32 to 104° F (0 to 40° C)

■ Storage temperature: –49 to 149° F (–45 to 65° C)

■ Humidity (non-condensing): 10% to 90%

■ Altitude: Less than 2000 m

Units that are supplied with motors:

■ For most motors, the wiring diagram is found inside the conduit box attached to the motor or on the motor

nameplate. For all other motors, consult the motor manufacturer.

■ Power supply voltage must be within 10% of the rating on the nameplate.

■ See motor nameplate for frame size and output speed.

■ Refer to the gearmotor manual for detailed information on motor current, motor torque, motor speed, and

gearmotor maintenance.

Pump head coupled to gearmotor

Pump head coupled to variable speed drive

Pump head with base plate only, without gearmotor, riser,
or coupling guard

Customers who purchase only the pump head are responsible for selecting the proper motor, coupling, and coupling
guard and for assuring proper alignment of the motor shaft, coupling, and pump shaft.

The casing material of the pump is aluminum alloy, and the baseplate material is steel.
PK Series Hose Pump parameters:

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PK15 PK25 PK40 PK50 PK65

Maximum flow rate

l/h 700 2,100 7,700 15,500 32,000

at 90 rpm
Maximum pressure bar 7 15 15 15 15

at 90 rpm psi 100 220 220 220 220
Maximum suction lift, m 8 8 8 8 8

water, at 90 rpm ft 26 26 26 26 26
Maximum viscosity mPas 35000 35000 35000 35000 35000
Approx. weight, kg 26 57 150 220 586

pump/base only lb 58 126 331 485 1292
Approx. weight, kg 41 109 255 334 847

gearmotor configuration lb 90 240 562 736 1867
Approx. weight, kg 57 124 285 366 937

mechanical variable speed lb 126 273 628 807 2066

Maximum pump speed . rpm 90 90 90 90 90
Oil bath volume required

liters 1 3 8 15 25

for operation

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Reference dimensions (for gearmotor and variable speed drive models; in inches):

* Gearmotor version ** Variable-speed belt drive version

m1

m2

b

c

c

od

e

f

g h

n

j

i

l

ok

**
*

abc d e f gh

PK15 16.54 14.96 13.66 .433 7.56 16.32 6.10 9.13
PK25 23.62 22.05 18.50 .551 9.25 22.05 7.64 10.83
PK40 39.37 37.01 29.84 .709 15.94 30.83 11.81 15.94
PK50 39.37 37.01 33.15 .709 18.39 34.17 14.76 18.39
PK65 49.21 46.06 40.94 .866 22.64 43.31 18.35 22.05

i j k l m1 m2 n

PK15 3.09 8.94 .79 2.17 28.03 26.46 10.47
PK25 3.82 10.87 1.22 2.60 38.31 38.86 13.39
PK40 6.97 17.95 2.01 3.35 44.13 48.03 13.86
PK50 7.40 22.01 2.40 3.54 48.58 50.98 16.30
PK65 7.91 29.45 2.64 3.54 57.95 60.43 22.05

INSTALLATION AND SETUP

Mechanical Connection

The inside diameter of the suction and discharge hoses should be approximately 25% greater than that of the pump
hose. The nominal pump hose diameter is determined by the pump type. For example, a PK15 pump uses a hose
with a nominal diameter of 15 mm.

The suction hose must not collapse from 100% vacuum, and the discharge hose must be able to withstand the maximum
pressure of the pump.

There must always be a flexible hose of at least one meter between the pump and any rigid system piping. (Standard
connections are hose barb type.) Threaded connections, flanged connections, and Sanitary Tri-Clamp fittings are also
available. Contact the factory for details.

CAUTION: Positive displacement pumps should always be fitted with a relief valve on the discharge.

Otherwise, the pump could be damaged if the maximum pressure is exceeded.

Installation/Change of the Pump Hose

WARNING: Disconnect the pump from the main power source before performing any type of assemb ly or

maintenance operation, including but not limited to hose installation, hose connection, shim
installation, spare part installation, and cleaning.

WARNINGS: Keep loose hair, gloves, loose clothing, jewelry, and fingers away from openings and

moving parts.
The casing cover must be in place, and hands must not be put into the pump casing,

unless the drive is stopped and the power is disconnected.

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Barnant/Ponndorf

1) Unscrew drain plug to remove the

Ponndorf special lubricant bath. Collect
the liquid in a suitable basin.

2) Unscrew the connecting sockets and
remove them from the hose.

3) Start the motor to remove the hose.

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WARNINGS: Keep hair, gloves, loose clothing, jewelry, and fingers away from openings and moving parts.

The casing cover must be in place, and hands must not be put into the pump casing, unless
the drive is stopped and the power is disconnected.

4) The hose comes out of the pump
automatically.

Remove
Screws

5) Stop the motor and disconnect the
power. Unscrew and remove the casing
cover from the pump. Clean the casing
inside and install the cover again.

6) Grease the new hose with Ponndorf
special lubricant. Start motor and
insert hose into the casing opening.

7) The rotor pulls in the hose automatically
as it rotates. Stop the motor immediately
as soon as the end of the hose juts out of
the casing approximately 40 mm. Unplug
the power.

5-10mm

8) Put the clamping ring onto the hose as
shown above. Approximately 5 to 10
mm of the hose should jut out of the
clamping ring.

9) Put the connecting socket into the hose
and tighten it by tightening the screws.
Take care that the socket is inserted in
the hose up to the flange.

10) Start the motor once
again briefly until the
hose juts out of the
other opening
approximately 40
mm. Stop and
unplug the motor,
and install the
connecting socket
as described in the
previous steps.

The pump is now ready for operation.

WARNINGS: Before operating the pump, all valves in the pipe work must be opened. If this is not done, a

hazardous bursting condition could develop and/or excessive pressure could damage the
pump and hose and may cause harm to personnel.

Adjustment of Discharge Pressure Capability

The discharge pressure capability of the pump depends on the gap between the gliding shoe and the pump casing.
This gap is changed by inserting or removing shims between the gliding shoe and the rotor. More shims will allow
higher pressures. Fewer shims will decrease the power requirement and maximize the tubing life.

Insert or remove shims under each of the two shoes to achieve the desired maximum pressure capability, according
to the following table:

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0 bar 2 bar 5 bar 7 bar 10 bar 15 bar

(0 psi) (30 psi) (75 psi) (100 psi) (145 psi) (220 psi)

PK15 no shim 1 shim 3 shims 4 shims N/A N/A
PK25 no shim ----- 1 shim ----- 2 shims 2 shims
PK40 no shim ----- 1 shim ----- 2 shims 3 shims
PK50 no shim ----- 2 shims ----- 3 shims 4 shims
PK65 no shim ----- 2 shims ----- 3 shims 4 shims

11) The pump with completely mounted
connecting sockets.

12) Pour the Ponndorf special
lubricant bath into the pump
casing.

13) The casing must be filled to the middle
of the inspection glass.

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Shim insertion/removal is achieved as follows:

WARNING: The casing cover must be in place, and hands must not be put into the pump casing, unless

the drive is stopped and the power is disconnected.

MAINTENANCE / REPAIR

Cleaning

When pumping materials that are likely to leave deposits, rinse the hose after use. When changing the hose, clean
any contamination from the pump casing.

Inactive Periods

If the pump is not going to be used for periods longer than five days, the hose must be removed to prevent permanent
deformation caused by continuous pressure from the rollers and hardening of the hose.

Replacement Parts

Contact the Manufacturer listed on the front of this manual to obtain information on replacement parts.

Model and Serial Number Location

The pump model and serial number are embossed on the nameplate. Example pump model: "PK15." The "PK" indicates
that the pump is a PK Series pump. The "15" indicates that the pump uses tubing that has an inside diameter of 15 mm.

1) Loosen the shoe with a flat wrench.

2) Insert/remove shim(s) and retighten
the shoe.

TRANSPORT AND STORAGE

CAUTIONS: When lifting the pump system or a component of the pump system, the proper attachment points

and lifting equipment must be used. The lifting equipment must have an adequate weight rating
and the proper attachment points must be utilized to prevent failure of the lift and/or attachment
points.

Lifting

Use the lift attachment points below when using a hoist or other equipment to lift the pump system or components of
the pump system. Do not use eyebolts A or B for lifting purposes except according to the lifting configurations
sketched below.

Transit Storage

The pump must be stored in an environment that is 10% to 90 % humidity (non-condensing).

CAUTION: When storing the pump for extended periods (longer than five days) remove the hose to

prevent permanent deformation from the shoes.

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Eyebolt A

Eyebolt B

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WARRANTY

Use only recommended hoses and replacement parts with Ponndorf pumps to ensure optimum performance. Use of
hoses or parts, other than the Manufacturer’s authorized replacement parts, may void applicable warranties.

This product is warranted against defects in material or workmanship, and at the option of the manufacturer or distributor,
any defective product will be repaired or replaced at no charge, or the purchase price will be refunded to the purchaser,
provided that: (a) the warranty claim is made in writing within the period of time specified on the warranty card, (b) proof of
purchase by bill of sale or receipted invoice is submitted concurrently with the claim and shows that the product is within
the applicable warranty period, and (c) the purchaser complies with procedures for returns set forth in the general terms
and conditions contained in the manufacturer's or distributor's most recent catalog.

This warranty shall not apply to: (a) defects or damage resulting from: (i) misuse of the product, (ii) use of the product in
other than its normal and customary manner, (iii) accident or neglect, (iv) improper testing, operation, maintenance, service,
repair, installation, or storage, (v) unauthorized alteration or modification, or (b) post-expiration dated materials.

THIS WARRANTY IS THE EXCLUSIVE REMEDY OF THE PURCHASER, AND THE MANUF ACTURER AND DISTRIBUT OR
DISCLAIM ALL OTHER WARRANTIES, WHETHER EXPRESS, IMPLIED, OR STATUT ORY, INCLUDING WITHOUT
LIMIT ATION, WARRANTIES OF MERCHANT ABILITY AND FITNESS FOR A PARTICULAR PURPOSE. NO EMPLOYEE,
AGENT, OR REPRESENTATIVE OF THE MANUFACTURER OR DISTRIBUTOR IS AUTHORIZED T O BIND THE
MANUFACTURER OR DISTRIBUT OR TO ANY OTHER W ARRANTY. IN NO EVENT SHALL THE MANUFACTURER
OR DISTRIBUTOR BE LIABLE FOR INCIDENT AL, INDIRECT, SPECIAL OR CONSEQUENTIAL DAMAGES.

The warranty period for this product is noted on the Warranty Card.

PRODUCT RETURN

Products may be returned under the following conditions:
a. Manufacturer’s written approval has been obtained and a return goods authorization number (RGA #) is issued.
b. Full credit towards specific exchange items will be allowed only if products being returned are in good, re-stockable,

saleable condition, in original unaltered packages, are current models and regular stock items.

c. Credit for returns will be based on purchase price, less any refurbishment or repair costs for making the product

re-stockable. The customer agrees to pay the invoice for the differential in credit allowed or accept a reduced
quantity of exchanged merchandise.

d. Products not returned in a saleable condition within the Warranty term will be returned to the customer freight

prepaid or scrapped at the option of the customer and no credit issued.

e. A purchase order to substitute an assortment of products of equal value must accompany returns in order for credit

to be allowed.
f. Transportation charges to Manufacturer, unless otherwise provided in writing, are to be paid by the customer.
g. No credit can be allowed if the products returned are in unsaleable condition, used, damaged, obsolete or of

special design or private label.

TECHNICAL ASSISTANCE

If you have any questions about the use of this product, contact the Manufacturer or authorized seller. See the front
cover for contact information.