instruction handbook - prp systems
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Version 1.21
Instruction handbook
2611-4-1 / 2611-4-2
POMTAVA S.A. info@pomtava.com 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
POMTAVA S.A. info@pomtava.com Metering gear pumps
Instruction handbook for pumps type 2611-4-1 and 2611-4-2 3/23
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
POMTAVA S.A. info@pomtava.com Metering gear pumps
Instruction handbook for pumps type 2611-4-1 and 2611-4-2 4/23
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 : info@pomtava.com
CH-2732 Reconvilier Net: www.pomtava.com
POMTAVA S.A. info@pomtava.com Metering gear pumps
Instruction handbook for pumps type 2611-4-1 and 2611-4-2 5/23
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.
POMTAVA S.A. info@pomtava.com Metering gear pumps
Instruction handbook for pumps type 2611-4-1 and 2611-4-2 6/23
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
POMTAVA S.A. info@pomtava.com Metering gear pumps
Instruction handbook for pumps type 2611-4-1 and 2611-4-2 7/23
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.
POMTAVA S.A. info@pomtava.com Metering gear pumps
Instruction handbook for pumps type 2611-4-1 and 2611-4-2 8/23
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
POMTAVA S.A. info@pomtava.com Metering gear pumps
Instruction handbook for pumps type 2611-4-1 and 2611-4-2 9/23
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.
POMTAVA S.A. info@pomtava.com Metering gear pumps
Instruction handbook for pumps type 2611-4-1 and 2611-4-2 10/23
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)
POMTAVA S.A. info@pomtava.com Metering gear pumps
Instruction handbook for pumps type 2611-4-1 and 2611-4-2 11/23
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)
POMTAVA S.A. info@pomtava.com Metering gear pumps
Instruction handbook for pumps type 2611-4-1 and 2611-4-2 12/23
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):
POMTAVA S.A. info@pomtava.com Metering gear pumps
Instruction handbook for pumps type 2611-4-1 and 2611-4-2 13/23
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.
POMTAVA S.A. info@pomtava.com Metering gear pumps
Instruction handbook for pumps type 2611-4-1 and 2611-4-2 14/23
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”.
POMTAVA S.A. info@pomtava.com Metering gear pumps
Instruction handbook for pumps type 2611-4-1 and 2611-4-2 15/23
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.
POMTAVA S.A. info@pomtava.com Metering gear pumps
Instruction handbook for pumps type 2611-4-1 and 2611-4-2 16/23
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.
POMTAVA S.A. info@pomtava.com Metering gear pumps
Instruction handbook for pumps type 2611-4-1 and 2611-4-2 17/23
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.
POMTAVA S.A. info@pomtava.com Metering gear pumps
Instruction handbook for pumps type 2611-4-1 and 2611-4-2 18/23
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
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Instruction handbook for pumps type 2611-4-1 and 2611-4-2 19/23
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Instruction handbook for pumps type 2611-4-1 and 2611-4-2 20/23
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Instruction handbook for pumps type 2611-4-1 and 2611-4-2 21/23
9.5.2 Re-assembly
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Instruction handbook for pumps type 2611-4-1 and 2611-4-2 22/23
POMTAVA S.A. info@pomtava.com Metering gear pumps
Instruction handbook for pumps type 2611-4-1 and 2611-4-2 23/23
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 service.technique@pomtava.com or by phone (see page 4).
© 2014 POMTAVA S.A.
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