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Alfa level LKH UltraPure-10, Instruction Manual

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Alfa level LKH UltraPure-10 Instruction Manual Download Page 14

4 Operation

Read the instructions carefully and pay special attention to the warnings!

4.1

Operation/control

Step 1

Always read the technical data thoroughly. See chapter 6 Technical data

CAUTION
Alfa Laval cannot be held responsible for incorrect operation/control.

Step 2

Never touch the pump or the pipelines when pumping hot liquids
or when sterilising.

Danger of burns!

3007-0015

Step 3

Never run the pump with both the suction side and the pressure
side blocked.

Danger of explosion!

!

3007-0016

!

!

See the warning
label!

Step 4

CAUTION

The shaft seal must not run dry.

CAUTION
Never throttle the inlet side.

Do not allow to

run dry

3007-0017

14

Summary of Contents for LKH UltraPure-10

Page 1: ...3007 0089 ESE01703 EN11 2018 02 Original manual Instruction Manual LKH UltraPure Centrifugal Pump ...

Page 2: ......

Page 3: ...eaning 17 5 Maintenance 18 5 1 General maintenance 18 5 2 Cleaning procedure 20 5 3 Dismantling of pump shaft seals 21 5 4 Assembly of pump single shaft seal 24 5 5 Assembly of pump double mechanical shaft seal 26 5 6 Assembly of flushing set if not supplied with pump 29 5 7 Adjustment of shaft 31 6 Technical data 33 6 1 Technical data 33 6 2 Relubrication intervals 34 6 3 Torque specifications 37...

Page 4: ...LKH UP 10 LKH UP 20 LKH UP 25 LKH UP 35 LKH UP 40 LKH UP 45 LKH UP 60 LKH UP 70 Type From serial number 10 000 to 1 000 000 is in conformity with the following directive with amendments Machinery Directive 2006 42 EC The person authorised to compile the technical file is the signer of this document Global Product Quality Manager Pump Valves Fittings and Tank Equipment Lars Kruse Andersen Title Nam...

Page 5: ...using the pump 2 1 Important information WARNING Indicates that special procedures must be followed to avoid serious personal injury CAUTION Indicates that special procedures must be followed to avoid damage to the pump NOTE Indicates important information to simplify or clarify procedures 2 2 Warning signs General warning Dangerous electrical voltage Caustic agents 5 ...

Page 6: ...Necessary precautions must be taken if leakage occurs as this can lead to hazardous situations Always handle lye and acid with great care Never use the pump for products not mentioned in Alfa Laval pump selection program The Alfa Laval pump selection program can be acquired from your local Alfa Laval sales company Maintenance Always read the technical data thoroughly See chapter 6 Technical data N...

Page 7: ...cause injuries to feet or fingers The pump should be supported underneath the adaptor when not installed in the process line Check the delivery for 1 Complete pump 2 Delivery note 3 Motor instructions 4 Instructions for flushing set IF ORDERED Step 2 Remove any packing materials from the inlet and the outlet Avoid damaging the inlet and the outlet 3007 0090 Remove packing materials Step 3 Inspect ...

Page 8: ...nstallation Step 4 Avoid damaging the flushing liquid connections if supplied Caution 3007 0092 Step 5 Always remove the shroud if fitted before lifting the pump Remove the shroud before ifting 3007 0093 8 ...

Page 9: ...3 Installation Step 6 ONLY LKH UltraPure 60 and LKH UltraPure 70 Do NOT use eyebolt in casing to lift the pump The eyebolt is for casing removal only 3007 0093 9 ...

Page 10: ...UTION Alfa Laval cannot be held responsible for incorrect installation WARNING Alfa Laval recommends the installation of lockable repair breaker If the repair breaker is to be used as an emergency stop the colours of the repair breaker must be red and yellow CAUTION The pump does not prevent back flow when intentionally or unintentionally stopped If back flow can cause any hazardous situations pre...

Page 11: ...7 0007 O I Step 4 1 Ensure that the pipelines are routed correctly 2 Ensure that the connections are tight Remember seal rings 3007 0008 Few bends Correct Step 5 Avoid stress on the pump Pay special attention to Vibrations Thermal expansion of the tubes Excessive welding Overloading of the pipelines Piping system must be self supported 3007 0009 Note In the event of leakage at the shaft seal the m...

Page 12: ...ction of rotation of the impeller before operation See the indication label on the pump 3 3 Pre use check Step 1 Never start in the wrong direction of rotation with liquid in the pump 1 Start and stop the motor momentarily 2 Ensure that the direction of rotation of the motor fan is clockwise as viewed from the rear end of the motor See the indication label 3007 0014 View from rear end of motor 12 ...

Page 13: ...the machine are replaced All metal parts should be sent for material recycling Worn out or defective electronic parts should be sent to a licensed handler for material recycling Oil and all non metal wear parts must be taken care of in accordance with local regulations Scrapping At end of use the equipment must be recycled according to relevant local regulations Beside the equipment itself any haz...

Page 14: ...ld responsible for incorrect operation control Step 2 Never touch the pump or the pipelines when pumping hot liquids or when sterilising Danger of burns 3007 0015 Step 3 Never run the pump with both the suction side and the pressure side blocked Danger of explosion 3007 0016 See the warning label Step 4 CAUTION The shaft seal must not run dry CAUTION Never throttle the inlet side Do not allow to r...

Page 15: ...iquid correctly 2 Regulate the water supply correctly O Outlet I Inlet Tmax 70 C 158 F Pmax LKHUP10 60 5 bar 72 5 psi Pmax LKHUP70 3 bar 43 5 psi 3007 0095 O I Step 6 Control Reduce the capacity and the power consumption by means of Throttling the pressure side of the pump Reducing the impeller diameter Reducing the speed of the motor 3007 0018 Throttling 15 ...

Page 16: ... Lamination of precipitates from the liquid Frequent cleaning Cavitation Damage Low inlet pressure Increase the inlet pressure Pressure reduction sometimes to zero High liquid temperature Reduce the liquid temperature Increasing of the noise level Reduce the pressure drop before the pump Reduce speed Leaking shaft seal Dry run Replace All wearing parts Incorrect rubber grade If necessary Change ru...

Page 17: ... 0 6 gal 100 l 26 4 gal Cleaning agent 33 NaOH water 2 0 5 by weight HNO3 at 70 C 158 F 0 7 l 0 2 gal 100 l 26 4 gal Cleaning agent 53 HNO3 water 1 Avoid excessive concentration of the cleaning agent Dose gradually 2 Adjust the cleaning flow to the process Sterilisation of milk viscous liquids Increase the cleaning flow Step 4 Always rinse well with clean water after using a cleaning agent NOTE Th...

Page 18: ...ectives Step 2 Never service the pump when it is hot Danger of burns 3007 0015 Step 3 Never service the pump with pump and pipelines under pressure CAUTION Fit the electrical connections correctly if they have been removed from the motor during service Pay special attention to the warnings Atmospheric pressure required 3007 0019 Step 4 Recommended spare parts Order service kits from the service ki...

Page 19: ...leakage and smooth operation Keep a record of the pump Use the statistics for planning of inspections Replace after leakage Complete shaft seal Replace when replacing the shaft seal Yearly inspection is recommended Replace complete bearing if worn Ensure that the bearing is axially locked See motor instructions Lubrication Before fitting Lubricate the Quad O rings with silicone grease or silicone ...

Page 20: ...r sanitary bristle pipe brush in and out of the hole for two minutes while submerged 4 Soak stub shaft 7 in acid sanitiser for 5 minutes then scrub blind tapped hole as described in step 3 above 5 Rinse well with clean water and blow dry the blind tapped hole with clean air 6 Swab test the inside of the tapped hole to determine cleanliness 7 Should the swab test fail repeat steps 2 to 6 above unti...

Page 21: ...t seal 5 3 Dismantling of pump shaft seals Step 1 Flushing set for double mechanical shaft seal 1 Remove flow meter 2 Remove flushing set 54 from pump casing 29 and lower tube 3007 0096 Step 2 Unscrew cap nuts 24 and remove washers 24a and pump casing 29 3001 0020_1 Step 3 Double mechanical shaft seal Unscrew tubes 42 using a spanner 3001 0021 21 ...

Page 22: ...Remove impeller 37 If necessary loosen the impeller by tapping gently on the impeller vanes 3 Remove the O ring 38 from the impeller Counterhold with a screwdriver 3001 0023 If necessary Step 6 1 Pull off the O ring 26 from back plate 25 2 Unscrew nuts 20 and remove washers 21 and the back plate 3007 0101 Step 7 1 Remove the stationary seal ring 11 2 Remove the O ring 12 from back plate 25 Use the...

Page 23: ...rings 14 and drive ring 52 from spring 13 3 Remove O rings 15 from rotating seal rings 14 3007 0027 Step 9 Double mechanical shaft seal 1 Remove stationary seal ring 51 from seal housing 40a 40b 2 Remove O ring 50 from stationary seal ring 51 3 Remove O ring 44 from seal housing 40a 40b 3007 0028 Step 10 Single shaft seal 1 Remove the complete shaft seal from stub shaft 7 2 Remove spring 13 and ro...

Page 24: ...e spring and the rotating seal ring on drive ring 10 CAUTION Ensure that the driver on the drive ring enters the notch in the rotating seal ring 3007 0031 Step 3 Fit the complete shaft seal on stub shaft 7 CAUTION Make sure that connex pin 8 on the stub shaft enters the notch in drive ring 10 3007 0032 Step 4 1 Fit O ring 12 on stationary seal ring 11 and lubricate 2 Screw the stationary seal ring...

Page 25: ...fit it in impeller 37 2 Lubricate impeller hub with silicone grease or oil 3 Screw the impeller onto stub shaft 7 4 Fit impeller screw 39 and tighten Torque values LKHUP10 60 20 Nm 15 lbf ft LKHUP70 50 Nm 37 lbf ft 3001 0036 Step 8 Fit safety guards 22 and screw 23 and tighten If pump is not supplied with flush connections the holes in the adaptor must be covered by the guard 3001 0037 Step 9 1 Fi...

Page 26: ... to place it correctly on the pump shaft 7 2 Fit the second rotating ring 14 on the other end of the spring 3 Place the parts on the stationary seal ring fitted in back plate 25 NOTE Ensure that both drive pins on the drive ring enter the notches in rotating seal rings Only LKHUP 70 TD239 007_1 Step 3 1 Lubricate O ring 44 and slide onto seal housing 40a 2 Lubricate O ring 50 and fit on stationary...

Page 27: ... 25 onto adaptor 16 3 Fit washers 21 and nuts 20 3001 0034 Step 7 Lubricate O ring 26 and slide it onto back plate 25 3001 0035 Step 8 1 Lubricate O ring 38 and fit it in impeller 37 2 Lubricate the impeller hub with silicone grease or oil 3 Screw impeller 27 onto stub shaft 7 4 Fit impeller screw 36 and tighten Torque values LKHUP10 60 20 Nm 15 lbf ft LKHUP70 50 Nm 37 lbf ft 3007 0105 Step 9 1 Wi...

Page 28: ...t 3001 0012 Step 12 Flushing set for double mechanical shaft seal 1 Fit membrane valve on drain on pump casing Ensure the bypass tube is in the right position see drawing 2 Fit lower tube to the needle valve 3 Fit pressure gauge to upper tube 4 Fit flow meter A C B 3007 0040 A Up B 26 mm 1 2 C 37 6 mm 1 48 Step 13 Adjustment of flushing set 1 Drain valve is used for draining the pump 2 Flushing wa...

Page 29: ...al shaft seal Step 2 1 Fit membrane valve on pump casing drain 2 Ensure the bypass tube is in the right position see section 5 5 Assembly of pump double mechanical shaft seal step 10 3007 0042 Step 3 1 Fit needle valve to bypass tube from membrane valve 2 Adjust the length of the bypass tube to ensure the outlet of needle valve is aligned with the inlet in the bottom of the flushing house 3007 004...

Page 30: ...seal Step 5 1 Fit Hex tube 140mm 5 5 to top hole of flush housing 2 Fit straight connection to HEX tube 3 Cut and fit 6mm 1 4 tube supplied in between straight connections 4 Fit flow meter to straight connection and fit elbow connection to other end of flowmeter 5 Connection or threaded outlet from flow meter to be connected to on site flush water installation 3007 0110 30 ...

Page 31: ...t and compression rings are applied with grease No grease on the motor shaft No grease on the inside diameter of the pump shaft Screws for the compression rings are applied with grease 3007 0046 Step 2 1 Push stub shaft 7 together with compression rings 5a 5b onto the motor shaft 2 Check that the clearance between the end of the stub shaft and the motor flange is 10 20 mm 0 39 0 78 inch 3007 0047 ...

Page 32: ...3007 0049 Step 6 1 Fit impeller 37 on stub shaft 7 2 Ensure that the clearance between the impeller and back plate 25 is correct 0 5 mm 0 02 inch for LKHUP 10 to 60 and 1 0 mm 0 039 inch for LKHUP 70 3 Tighten screws 6 evenly until the stub shaft 7 cannot move on the motor shaft LKHUP 10 to 60 0 5 mm 0 02 inch LKHUP 70 1 0 mm 0 039 inch 3007 0050 Step 7 1 Remove impeller 37 back plate 25 and drive...

Page 33: ...ts AISI 316L Other steel parts Stainless steel Finish Polished Product wetted seals EPDM standard Other O rings EPDM standard Alternative seals FPM and FEP Shaft seal Seal types External single or double mechanical seal Max temperature flush media 70 C NOTE When the pump is not in operation the flush housing can be sterialized up to 125 C Max water pressure LKHUP 10 60 DMS Normally atmospheric max...

Page 34: ...cated 3100h 2300h DE NDE 25g 15 Permanently lubricated 3100h 2300h DE NDE 25g 18 5 Permanently lubricated 3100h 2300h DE NDE 25g 22 Permanently lubricated 2600h 2000h DE NDE 42g 4000h 2200h DE NDE 42g 30 Permanently lubricated 4000h 2800h DE NDE 55g 8000h DE NDE 40g 37 Permanently lubricated 4000h 2800h DE NDE 55g 8000h DE NDE 40g 45 Permanently lubricated 2500h 1000h DE NDE 55g 8000h DE NDE 40g 5...

Page 35: ...manently lubricated 1 5 Permanently lubricated 2 2 Permanently lubricated 3 0 Permanently lubricated 4 0 Permanently lubricated 5 5 Permanently lubricated 7 5 Permanently lubricated 11 Permanently lubricated 15 Permanently lubricated 18 5 Permanently lubricated 22 10000 10000h DE NDE 18g 30 10000 10000h DE NDE 21g 37 10000 10000h DE NDE 21g 45 Not available 55 5000 5000h DE NDE 27g 75 5000 5000h D...

Page 36: ...cated These bearings should be replaced at least every 5 years for 8 hr day service or every 2 years for 24 hr day service Warning Bearing grease is Klüber NBU 15 DO NOT SUBSTITUTE Table 2 Baldor NEMA motors Motor RPM Frame Type of service Standard Severe 8 hrs day 16 hrs day 210 5500 hrs 2750 hrs 210 280 3600 hrs 1800 hrs 280 360 2200 hrs 1100 hrs 3600 360 449 2200 hrs 1100 hrs 210 12000 hrs 6000...

Page 37: ...alues Nm Ibf ft M8 13mm 0 51 20 15 M10 17mm 0 67 40 30 M12 19mm 0 75 67 49 M14 22mm 0 87 110 81 6 4 Weight kg Pump Type LKH UltraPure 90 100 112 132 160 180 200 250 Size 1 5 kW 2 2 kW 3 kW 4 kW 5 5 kW 7 5 kW 11 kW 15 kW 18 5 kW 22 kW 30 kw 37 kw 45 kw 55 kw 75 kw 10 53 55 70 75 20 55 57 72 77 94 108 25 81 98 112 171 185 35 81 98 112 171 185 40 115 174 188 206 225 45 82 99 113 172 186 60 102 116 17...

Page 38: ...5 82 MR 200 81 MR 300 82 GM 54 FM OS 61 The above LKH noise levels are the same for LKHPF LKHI LKH UltraPure LKH Evap and LKHex The above SolidC noise levels are the same for SolidC UltraPure The noise measurements have been carried out on the original motor and shroud at the approximate Best Efficiency Point BEP with water at ambient temperature and at 50 Hz Very often the noise level generated b...

Page 39: ...sts in the following sections 7 2 LKH UltraPure Product wetted parts 7 1 LKH UltraPure 10 20 25 35 40 45 60 70 3007 0112 US legs are different to the ones shown For further information see US spare parts 3007 0058 3007 0059 3007 0054_1 Double mechanical shaft seal Single shaft seal Only used for 3 kW Fitting of legs 39 ...

Page 40: ... 7 2 LKH UltraPure Product wetted parts 7 2 LKH UltraPure Product wetted parts 3001 0067 22 22 23 17 18 19 35a 35 1 31 32 30a 39 33 34 30b 7 5a 5b 9 6 6a 8 13 10 14 15 16 21 20 25 24a 24 12 26 36 38 37 29 28 11 2 3 46 47 48 49 42 44 51 50 40a 52 DMSS 13 56 LKHex UP 70 42 41 14 14 15 15 53 Product wetted steel parts Product wetted elastomer parts 40 ...

Page 41: ...o the parts lists in the following sections 7 2 LKH UltraPure Product wetted parts Parts list Pos Qty Denomination 20 2 Nut 21 2 Washer 24 6 Cap nut 24a 6 Washer 25 1 Backplate compl 26 1 Pump casing O ring 28 6 Bolt 29 1 Connections and drain 36 1 Impeller screw 37 1 Impeller 38 1 O ring impeller screw 41 ...

Page 42: ... 7 2 LKH UltraPure Product wetted parts 7 3 LKH UltraPure Motor dependent parts 3001 0065 22 22 23 17 18 19 35a 35 1 31 32 30a 39 33 34 30b 7 5a 5b 9 6 6a 8 13 10 14 15 16 21 20 25 24a 24 12 26 36 38 37 29 28 11 2 3 46 47 48 49 42 44 51 50 40a 52 DMSS 13 56 LKH UP 70 42 41 14 14 15 15 53 Product wettet steel parts Product wetted elastomer parts 42 ...

Page 43: ...pression ring with thread 5b 1 Compression ring without thread 6 6 Screw 6a 6 Washer 7 1 Shaft 8 1 Connex pin 9 1 Retaining ring 16 1 Adaptor 17 4 Screw for adaptor 18 4 Nut for adaptor 19 4 Washer for adaptor 22 1 Safety guard set 23 1 Screw for safety guard 30a 1 Support bar right 30b 1 Support bar left 31 4 Leg 32 4 Screw 33 4 Nut 34 4 Spring washer 35 4 Screw 35a 4 Washer 39 4 Nut 46 4 Distanc...

Page 44: ...ctions 7 2 LKH UltraPure Product wetted parts 7 4 LKH UltraPure Shaft seal 3001 0065 22 22 23 17 18 19 35a 35 1 31 32 30a 39 33 34 30b 7 5a 5b 9 6 6a 8 13 10 14 15 16 21 20 25 24a 24 12 26 36 38 37 29 28 11 2 3 46 47 48 49 42 44 51 50 40a 52 DMSS 13 56 LKH UP 70 42 41 14 14 15 15 53 Product wettet steel parts Product wetted elastomer parts 44 ...

Page 45: ...2338 9611922340 Service kit LKHUP 20 9611922357 9611922356 9611922358 Service kit LKHUP 25 35 45 9611922375 9611922374 9611922376 Service kit LKHUP 40 60 9611922393 9611922392 9611922394 Service kit LKHUP 70 9611920549 9611920550 9611920551 Service kit for double mechanical shaft incl Q doc Service kit LKHUP 10 9611922345 9611922344 9611922346 Service kit LKHUP 20 9611922363 9611922362 9611922364 ...

Page 46: ...is the responsibility of the user of this document to comply with all applicable intellectual property laws Without limiting any rights related to this document no part of this document may be copied reproduced or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise or for any purpose without the expressed permission of Alfa Laval Corporate AB Alfa Lava...

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