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GEA Hilge CONTRA I ADAPTA Operating Instructions Manual Download Page 93

11

Decommissioning

11.1

Special personnel qualification

The decommissioning personnel must be suitably qualified for this work. See also
Section 2.6, Page 15.

11.2

Safety instructions

Warning!

 

Pressure shock!
► Always close shut-off devices (gates, valves) slowly.
► A pressure shock is a sudden increase in pressure in the system. This
pressure increase may be triggered by quickly shutting off the flow in the
pressure pipe, in addition to other causes. If a pressure shock occurs, the
max. permissible pump pressure is briefly exceeded by a multitude.

Caution!

 

Sticking of the pump.
► Clean the pump suitably after decommissioning. See "Cleaning" section.

11.3

Temporary decommissioning

Warning!

 

Pressure shock!
► Always close shut-off devices (gates, valves) slowly.
► A pressure shock is a sudden increase in pressure in the system. This
pressure increase may be triggered by quickly shutting off the flow in the
pressure pipe, in addition to other causes. If a pressure shock occurs, the
max. permissible pump pressure is briefly exceeded by a multitude.

Perform the following steps:

1.

Close the pressure side shut-off valve.

2.

Switch off the pump.

3.

Close the suction side shut-off valve.

4.

Switch off the flushing.

5.

Make sure that the pump is depressurised.

6.

Depressurise the sealing system.
→ The pump has been temporarily decommissioned.

11.4

Disposal

Discard the pump or parts thereof in an environment-friendly manner: Use the
service of public or private disposal companies. If this is not possible, contact the
next GEA Hilge company or service centre.

Decommissioning

Special personnel qualification

BA.10A.ADY.001.GB_1

 

20.07.2018

93

Summary of Contents for Hilge CONTRA I ADAPTA

Page 1: ...Hygienic Pumps GEA Hilge CONTRA I II ADAPTA Operating instruction Translation from the original language BA 10A ADY 001 GB_1 ...

Page 2: ...ability and service life These instructions are aimed at users of the pump and are intended in particular for the operator and its operating and maintenance personnel It is mandatory for the operator and its operating and maintenance personnel to read these instructions prior to transport installation commissioning use maintenance repair disassembly and disposal of the pump The obligation to read ...

Page 3: ...ible that the illustrations do not exactly match the pump used by you The technical data and dimensions are not binding Claims cannot be derived from them The manufacturer assumes no liability for damages arising within the warranty period due to unintended operation and usage conditions insufficient maintenance improper operation incorrect installation incorrect or improper connection of electric...

Page 4: ...nt 1 Numbered list point 2 Handling instructions Handling instructions require you to do something Several consecutive steps result in a handling sequence that should be run in the specified order The handling sequence can be divided into separate steps Handling sequence 1 Handling sequence step 1 step 1 step 2 step 3 2 Handling sequence step 2 The subsequent handling sequence is the expected resu...

Page 5: ...Special personnel qualification for transport and storage 20 4 2 Safety precautions for transport and storage 20 4 3 Safety instructions for transporting the pump 20 4 4 Attachment points for lifting loads 20 4 5 Storage of the pump 20 4 6 Dimensions weights 21 4 7 Unpacking the pump 22 4 8 Disposal of packaging material 22 5 Technical data 23 5 1 Serial number 23 5 2 Performance data 23 5 3 Noise...

Page 6: ...lacement 48 9 4 5 Grease filling 49 Roller bearing greases 49 9 5 Maintenance of the motor 50 10 Malfunctions repairs 51 10 1 Special personnel qualification 51 10 2 Safety instructions 51 10 3 Malfunctions and remedies 52 10 4 Repair 53 10 4 1 Repair order 53 10 4 2 GEA Hilge assembly tool kit 55 Contents and use 55 10 4 3 Parts overview 56 10 4 4 Parts overview of ADAPTA bearing housing sizes 1 ...

Page 7: ...11 2 Safety instructions 93 11 3 Temporary decommissioning 93 11 4 Disposal 93 12 Appendix 94 12 1 Clearance certificate 94 BA 10A ADY 001 GB_1 20 07 2018 7 ...

Page 8: ...BA 10A ADY 001 GB_1 8 20 07 2018 ...

Page 9: ...and lists points Instructions Instructions that must be executed in a certain order are numbered according to the sequence For the marking of safety instructions please refer to Section 2 3 Page 13 Technical changes Versions technical data and spare part numbers are subject to technical change We reserve the right to implement changes due to technical progress 1 2 Manufacturer address GEA Hilge Ni...

Page 10: ...chinery Directive Applicable harmonized standards in particular EN 809 1998 A1 AC D EN ISO 12100 2010 Remarks We also declare that the relevant technical documentation for this machine has been prepared in accordance with Annex VII Part A and agree to submit the documentation on justified request of national authorities on a data carrier Person authorised for compilation and handover of technical ...

Page 11: ...m should be equal to or greater than the pump nominal diameters DNE suction side or DNA pressure side and the fittings to the pump should match exactly the type standard of the fixed mating connection part on the pump The suction line must be hermetically sealed and routed such that no air pockets can form Avoid tight bends and valves directly in front of the pump On the suction side a straight se...

Page 12: ...ant personnel or operator prior to installation and commissioning The operating instructions must always be available at machine system site In addition to the general safety precautions listed in this chapter on safety be sure to read also the other special safety precautions included Safety Safety precautions in these operating instructions BA 10A ADY 001 GB_1 12 20 07 2018 ...

Page 13: ...ant for the designated use and function of the product Description of the necessary action for proper operation of the product 2 4 Safety instructions for the company operator Follow the safety instructions contained in this operating manual the relevant national accident prevention regulations as well as any internal working operating and safety provisions of the operating company Warning Hot or ...

Page 14: ...aims for damages Failure to follow the instructions may entail the following hazards for example Failure of important functions of the machine system Failure of prescribed methods for repair and maintenance Exposure of persons to electrical mechanical and chemical hazards Environmental risks caused by leakage of hazardous substances 2 4 2 Safety conscious work behaviour Follow the safety instructi...

Page 15: ...and machine during all life phases of the pump cannot be fully ruled out The additional safety instructions in the individual chapters of this manual must therefore be carefully observed The residual risks that were ascertained during the risk assessment carried out for the product according to safety standard EN ISO 14121 Safety of Machines are mechanical hazards due to sharp sheet metal edges an...

Page 16: ...ontrol circuit or control loop incorrect assembly fracture during operation operating media or objects getting thrown out loss of stability personnel slipping tripping or falling Safety BA 10A ADY 001 GB_1 16 20 07 2018 ...

Page 17: ...0180A 0181 Fig 1 0107 Discharge casing 0153 Suction port 0156 Discharge port 0180 A Foot combi foot 0180 B Foot cast iron foot 0181 Pump stand vertical stand 0330 Bearing housing 0680 Shroud 0801 Flanged motor Description Pump overview BA 10A ADY 001 GB_1 20 07 2018 17 ...

Page 18: ...cooking oil etc Cleaning systems CIP 3 2 2 Hygienic design applications Due to the consistent hygienic design and the use of pore and porosity free materials the pump is ideally suited for use in the following areas pharmaceutical industry medical technology in biotechnology process plants Special applications arise in the area of ultrapure water delivery WFI as well as in equipment for the produc...

Page 19: ...P Motor rating Serial No Serial number n Speed Q Flow rate TAG No customer name H Delivery head YOM Year of manufacture Note The type plate may differ from the presented layout Description BA 10A ADY 001 GB_1 20 07 2018 19 ...

Page 20: ... Never fasten a rope to the pump housing or the suction discharge port For version with casing Remove the stainless steel casing before transport 4 4 Attachment points for lifting loads Fig 3 Attachment points 4 5 Storage of the pump Follow the following instructions for the storage of the pump The maximum storage period is two years In case of frost risk drain the pump completely Protect the pump...

Page 21: ...r number Installation combi foot simple mechanical seal WEG motor Weight kg CONTRA I ADAPTA Stages Motor output kW Motor size Weight 1 0 75 80 40 1 1 1 1 80 42 1 1 1 5 90S 49 1 2 1 5 90S 50 4 2 2 2 90L 49 4 2 3 0 100L 61 2 3 1 5 90S 51 7 3 2 2 100L 50 7 3 3 0 100L 62 5 3 4 0 112M 71 5 4 2 2 100L 52 4 3 0 100L 63 8 4 4 0 112M 72 8 4 5 5 132S 96 8 5 3 0 100L 65 1 5 4 0 112M 74 1 5 5 5 132S 98 1 6 3 ...

Page 22: ...laims for damages The transport risk passes to the customer once the shipment has left our warehouse 4 8 Disposal of packaging material The generation of waste should be avoided or minimized wherever possible Surpluses and packaging materials not suitable for recycling should be disposed of through an approved waste disposal company Packaging materials not suitable for recycling must always be dis...

Page 23: ...nd flow rate are explained in accordance with ISO 9906 2012 Grade 3B and documented with the acceptance report 5 3 Noise emissions Measured values in accordance with DIN EN ISO 3746 for pump units measuring uncertainty 3 DB A The noise emissions caused by a pump are influenced mainly by its application The values shown here should therefore be considered merely as a guide Noise emissions Lpfa dB A...

Page 24: ...8 60 7 5 59 59 61 5 4 Maximum operating temperatures Warning Exceeding the maximum temperatures Never exceed the specified operating temperatures Operating temperatures Version Temp C Normal version 95 Sterilisation SIP 140 Variations are possible at the above temperatures 5 5 Maximum operating pressure Warning Pressure overload of the pump Operate the pump according to the ordering data Never exc...

Page 25: ...material general operating temperature EPDM 40 135 C 40 275 F FKM 10 200 C 14 392 F Caustics up to 3 up to 80 C 176 F o Caustics up to 5 up to 40 C 104 F o Caustics up to 5 up to 80 C 176 F Caustics at more than 5 o Inorganic acids up to 3 up to 80 C 176 F Inorganic acids up to 5 up to 80 C 176 F o Inorganic acids up to 5 up to 100 C 212 F Water up to 80 C 176 F Steam up to 135 C 275 F o Steam app...

Page 26: ...ilms and caps from the connectors Caution Dry running of the mechanical seal The suction line must be hermetically sealed and laid such that no air pockets can form Avoid tight bends and valves directly in front of the pump They impair the incoming flow of the pump and the NPSH of the system The suction head of the system must not be larger than the suction head guaranteed by the pump The piping n...

Page 27: ...egulations Danger For motors with frequency converter tronic Electric shock by touching live parts Even if the power supply is switched off touching electrical parts may cause an electric shock Disconnect the power supply and wait at least four minutes before touching electrical components Warning Electric overload Compare the voltage indicated on the motor plate with the operating voltage The pow...

Page 28: ... direction of rotation For back to back arrangement ensure that the sealing pressure is at least 1 5 2 0 bar 22 29 psi above the maximum internal pressure of the pump Max internal pressure system pressure pumping pressure at Q zero Always keep the level in the liquid tank between the upper and the lower mark where applicable 6 1 3 Vertically installed pumps Warning Tipping tilting of the pump Fast...

Page 29: ...ller Contact the HILGE service If the impeller rotates freely 5 Reattach the motor fan cover 6 Reattach the motor shroud only for SUPER version The impeller has been checked for running smoothly 6 3 2 Setting up and aligning the pump unit The pump is designed for horizontal and vertical operation Fig 4 Permissible setups of the pump Aligning the pump 1 Level the unit via the machined planar surfac...

Page 30: ...ion P Pump M Motor 6 3 3 1 Space requirements Maintain the following minimum distances Pay attention to motor performance Horizontal installation 0 5 5 4 k W 5 5 kW 300 mm 1000 mm 300 mm Fig 6 Minimum distances in horizontal installation Assembly and installation Setup installation and connection BA 10A ADY 001 GB_1 30 20 07 2018 ...

Page 31: ... Foundation Vibration damping is best achieved if the pump is set up on a flat solid concrete foundation As a guideline the concrete foundation should be 1 5 times as heavy as the pump Vibration damper To avoid the transmission of vibrations to the building it is recommended to disconnect the pump foundation from parts of the building using vibration dampers Selecting the correct vibration damper ...

Page 32: ...um distance to the pump which is 1 1 5 times the nominal diameter of the piping This allows for an improved flow on the suction side of the pump as well as reduced pressure drop on the pressure side For connections with a size over DN 100 we always recommend compensators with length limiters The pipes must be started so that they can cause no strain in the compensators and in the pump Follow the m...

Page 33: ...y depending on other influences Particularly in the running in phase mechanical seals regardless of size type or design are subject to low leakage In individual cases it may be necessary to tolerate a low visible leakage or to counteract it with suitable measures Dry run The mechanical seal needs a lubrication film between the sliding surfaces for correct sealing If the lubrication film is missing...

Page 34: ...lastomers No contaminating of the pumped fluid Viscosity 5 mPas Water hardness 5 dH Demineralised water meets these requirements to a large extent 6 3 5 2 Double mechanical seals optional Pumps with double acting mechanical seals are equipped with a seal cartridge This seal cartridge holds the sealing or flushing fluid depending on the seal version The connections for flushing must be made as show...

Page 35: ...The sealing pressure should be at least 1 5 2 0 bar above the maximum internal pressure of the pump Max internal pressure system pressure pumping pressure at Q zero Obtain the delivery head at Q 0 from the test bench acceptance of your pump When operating with a frequency converter consider the varying delivery heads When using a closed sealing circuit with a supply reservoir regularly monitor the...

Page 36: ...ally or by means of level probes Also make sure that no pressure build up can occur in the flushing circuit Keep the reservoir open to the atmosphere Change the flushing fluid regularly when using critical media The maximum temperature of the flushing fluid must be 20 K below the boiling temperature of the flushing fluid at the outlet The temperature rise in the pump flushing chamber is normally l...

Page 37: ...e pump according to the ordering information The following figure shows the wiring diagram of the delta connection U1 V1 W1 W2 U2 V2 L1 L2 L3 Fig 13 Delta connection 6 3 6 3 Frequency converter operation All three phase motors can be connected to a frequency converter Frequency converter operation may subject the insulation of the motor to a higher load so that louder motor noise than in the norma...

Page 38: ...ces voltage peaks and thus noise or check whether the motor has a reinforced insulation Supply voltage 690 V and above Install a dU dt filter between the motor and the frequency converter and check whether the motor has a reinforced insulation Notice Incorrect operation of the frequency converter Follow the manufacturer s instructions to install and operate a frequency converter 6 3 6 4 Checking t...

Page 39: ...eve potential equalisation Earthing the motor Equipotential bonding for the motor is performed via the protective conductor connection in the terminal box Ground the assembly foot Equipotential bonding of the assembly is achieved via the screw connection to the motor Use toothed lock washer at corresponding position for grounding Assembly and installation BA 10A ADY 001 GB_1 20 07 2018 39 ...

Page 40: ... warming of the pumped fluid and pressure increase Do not exceed the permissible operating temperatures 7 3 Commissioning initial startup 7 3 1 Checking conditions of use Compare the information in the following documents with the intended conditions of use of the pump Order documents order confirmation Nameplate Operating instructions Test bench acceptance Make sure that the pump is operated only...

Page 41: ... pumped e g water is flowing out of the discharge valve 3 Close the discharge valve B The pump is vented 7 3 3 Commissioning of the pump Caution Hazard due to overheating and pressure overload Never pump for longer than 30 seconds against a closed shut off device Pumping against a closed shut off device leads to rapid warming of the pumped fluid and pressure increase Do not exceed the permissible ...

Page 42: ...p valve 12 Switch on the pump 13 Slowly open the pressure side stop valve This completes the commissioning If there is no increase of delivery head after commissioning 1 Switch off the pump 2 Again vent the pump system 3 Repeat steps 7 to 10 and follow Section 10 3 Page 52 7 3 4 Functional testing of the mechanical seal Perform the following steps 1 Inspect the pump and check whether liquid exits ...

Page 43: ...working temperatures and steps 8 1 Special personnel qualification The cleaning personnel must be suitably qualified for this work See also Section 2 6 Page 15 8 2 Safety instructions Warning Damage caused by cleaning agents Use only suitable cleaning agents Observe the safety instructions in the product descriptions of the cleaning agents Use always suitable personal protective equipment when han...

Page 44: ...rature Permissible pH Max permissible Cl content in the preparation water Max permissible contact time C F mg l h Alkaline NaOH 2 5 85 185 2 13 14 150 3 Acid H2SO4 H3PO4 HNO3 2 3 4 60 140 1505 6 1 C2H4O3 0 0075 90 194 150 0 5 C2H4O3 0 15 20 68 150 2 Iodophore 50 mg l act Iodine 30 86 3 150 3 Cleaning agents that contain hydrochloric acid HCl or hydrofluoric acid HF must not be used Consult the sup...

Page 45: ...s when using cleaning agents Wear safety glasses and gloves Dispose of cleaning agent properly Do not use a high pressure water jet to clean the pumps Regular manual external cleaning of the pump unit facilitates proper operation Always check the impermeability of the motor terminal box condensation water holes before each cleaning Clean the outside of the pump with a soft cloth or brush and use w...

Page 46: ...commends that regular visual inspections be carried out Special attention should be paid to the leak tightness and the correct functioning of the pump In order to ensure maximum operational safety of the pump wear parts such as the mechanical seal and O rings should be checked after 2000 hours of operation and replaced if necessary In any case all seals must be checked and if necessary replaced du...

Page 47: ... values Media at temperatures of 60 C to 130 C 140 F to 266 F approx every 3 months Media at temperatures of 60 C 140 F approx every 12 months 9 4 Maintenance of the ADAPTA bearing 9 4 1 Bearing housing design sizes 1 and 2 The bearing consists of two angular contact ball bearings They are paired and are installed as fixed bearings in an O arrangement to accommodate axial and radial forces from al...

Page 48: ...33 Mass g 31 25 Relubrication of bearings Lubricate the roller bearings according to the following table The listed values refer to normal operating conditions Notice Damage from incorrect lubrication Avoid over under lubrication Grease quantity for relubrication Bearing point Lubricating interval in operating hours Quantity g 0326 00 approx 1 000 11 0327 00 approx 3 000 10 9 4 3 Bearing replaceme...

Page 49: ...d 10 95 C Storage temperature 70 C 100 C Delivery fluid 96 C 190 C Factory filled grease UNIREX N3 OKS 4200 Basic oil type Mineral oil Polyalfaolefin Thickener Lithium complex soap Bentonite Continuous limit temperature approx 70 C approx 115 C Identification acc to DIN 51502 K3N 20 KHCF2R 10 Key to symbols Key to symbols Grease type for roller bearings according to DIN52825 K also permitted KP K ...

Page 50: ...motors with grease nipple the specifications for relubrication type of grease grease quantity and other information as applicable are given on the lubrication or type plate 1 2 3 4 5 6 7 8 Fig 15 Lubrication information plate of MGE motor example 1 Bearing on drive side 2 Type of grease 3 Ambient temperature 4 Ambient temperature 5 Bearing not drive side 6 Grease grade 7 Lubricating interval 8 Lub...

Page 51: ...al parts may cause an electric shock Disconnect the power supply and wait at least four minutes before touching electrical components Danger Liquids squirting out under high pressure Always depressurise the pump before troubleshooting Warning Hot system and pump parts Always allow the pump to cool before troubleshooting Warning Inadvertent switch on of the pump Be sure to secure the pump against a...

Page 52: ...er than stated in the order 5 Motor protection switch is not set properly 6 Motor runs on 2 phases 1 Open pump and eliminate malfunctions 2 Install pump without strain support piping by fixed points 3 Adjust operating point according to data sheet 4 If a lower power than specified is sufficient reduce the flow rate on the pressure side otherwise use a more powerful motor 5 Check the setting replac...

Page 53: ...d reduce or replace lubricants 3 Install pump without strain support piping by fixed points Check coupling alignment 4 Check the relief holes in the impeller and the split rings at the inlet 5 Check the setting replace the motor protection switch if necessary 6 Open pressure valve 10 4 Repair 10 4 1 Repair order Compliance with legal regulations on occupational safety requires all commercial compa...

Page 54: ...If despite careful emptying and cleaning of the pump safety precautions are required the necessary information must be given Malfunctions repairs Repair BA 10A ADY 001 GB_1 54 20 07 2018 ...

Page 55: ...lastic adapter Ø 28 2 Spray bottle 12d Mechanical seal mounting sleeve Ø 19 and Ø 22 5 Extractor for mechanical seal counter ring 12d Plastic adapter Ø 19 6 Klüber paste UH1 96 402 13a Impeller nut assembly device 7 Socket wrench a f 32 13b Impeller nut assembly device plastic 7 Socket wrench bit a f 27 13c Impeller nut assembly device 8 Optimol paste TA 13d Impeller nut assembly device plastic 9 ...

Page 56: ...asinga 1 0412 15 O ringa 1 0112 05 Diffusor casinga 1 0412 16 O ringa 1 0112 06 Diffusor casinga 1 0412 22 O ring seal 1 0162 00 Suction cover 1 0412 23 O ringa 1 0230 01 Impeller 1 0412 24 O ringa 1 0230 02 Impellera 1 0412 25 O ringa 1 0230 03 Impellera 1 0412 26 O ringa 1 0230 04 Impellera 1 0433 00 Axial face seal 1 0230 05 Impellera 1 0557 00 Seal spacer 1 0230 06 Impellera 4 0905 01 Connecti...

Page 57: ...Pcs Part no Designation Pcs Part no Designation 1 0211 00 Pump shaft 1 0900 00 Eyebolt 2 0326 00 Angular contact ball bearing 4 0901 04 Hex screw 1 0330 00 Bearing housing 1 0926 00 Locknut 1 0360 01 Bearing cover 4 0934 05 Spring washer 1 0507 00 Deflector 1 0940 00 Key 1 0507 02 Deflector V ring 1 0940 01 Key 1 0507 05 Deflector V ring 1 0970 00 Nameplate 4 0560 00 Round head grooved pin 4 1002 ...

Page 58: ...0686 00 Safety guard 2 0326 00 Angular contact ball bearing 1 0900 00 Eyebolt 1 0327 00 Cylindrical roller bearing 4 0901 03 Hex screw 1 0330 00 Bearing housing 4 0901 04 Hex screw 1 0360 00 Bearing cover 1 0932 00 Circlip 1 0360 01 Bearing cover 1 0932 02 Circlip 1 0504 00 Spacer ring 4 0934 05 Spring washer 1 0504 01 Spacer ring 4 0934 25 Spring washer 1 0507 00 Deflector 1 0940 01 Key 1 0507 02...

Page 59: ...00 Intermediate motor stool 1 0904 00 Set screw 4 0554 08 Washer 1 0904 01 Set screw 1 0680 00 Casing hood SUPER version 4 0904 05 Set screw 1 0801 00 Motor 4 0920 23 Hex nut 1 0840 00 Coupling 4 0920 09 Hex nut 1 0840 01 Coupling 4 0934 06 Spring washer 6 0867 02 Coupling insert 1 0940 01 Key 10 4 7 Disassemble the pump Disassembly of the pump is carried out in the reverse order of assembly For t...

Page 60: ... for damage and wear and replace if necessary Use only proper clean parts for installation Clean installation space and contact surfaces before installation 10 4 8 1 Cleaning the components before assembly Notice Hygiene risk food safety Contaminated components contaminate the pump and installation Use suitable chemical cleaning agents to remove impurities in the area of the impeller area the O ri...

Page 61: ...eplacing the bearings Do not use a mallet Fig 21 Shaft with roller bearing Fill the gaps of roller bearings 0326 00 100 with grease For details see Section 9 4 1 Page 47 Fig 22 Roller bearings Push the shaft 0211 00 into the bearing housing 0330 00 Fig 23 ADAPTA bearing housing Lightly grease the bearing cover 0360 01 on the inside Push the bearing cap over the shaft 0211 00 Fig 24 Bearing cover M...

Page 62: ...p onto the shaft 0211 00 so that the sealing lip contacts the bearing cover 0360 01 Fig 26 V ring Push the V ring 0507 02 with greased sealing lip onto the shaft 0211 00 so that the sealing lip contacts the bearing housing 0330 00 Fig 27 Position V ring Insert the key 0940 01 into the shaft 0211 00 Do not use a mallet The bearings could be damaged Fig 28 Key Malfunctions repairs Repair BA 10A ADY ...

Page 63: ...housing Fix the coupling half 0840 00 with the set screw 0904 00 torque 4 Nm Fig 30 Set screw Connect the bearing housing 0330 00 to the VA foot 0180 00 Base assembly may vary To do so use the hex head screws 0901 00 spring washers 0934 02 and hex nuts 0920 02 Fig 31 Stainless steel foot Insert the key 0940 01 into the motor shaft Fig 32 Key Malfunctions repairs Repair BA 10A ADY 001 GB_1 20 07 20...

Page 64: ...he motor shaft Loosely tighten the set screw 0904 01 Fig 34 Coupling half motor side Connect the motor to the bearing housing 0330 00 by plugging the coupling halves 0840 00 and 0840 01 into each other Fig 35 Connect coupling halves Connect the bearing housing 0330 00 and motor using the hex head screws 0902 06 spring washers 0934 06 and hex nuts 0920 09 torque M10 35 Nm torque M12 65 Nm Fig 36 Mo...

Page 65: ...0 01 with the set screw 0904 00 torque 4 Nm Fig 37 Feeler gauge Push the deflector 0507 00 onto the shaft 0211 00 During the further installation make sure that the deflector does not contact the adjacent components Fig 38 Deflector The ADAPTA bearing housing has been installed Malfunctions repairs Repair BA 10A ADY 001 GB_1 20 07 2018 65 ...

Page 66: ...00 For details see Section 9 4 2 Page 48 Fig 40 Cylindrical roller bearing pump side Grease the outer race of the cylindrical roller bearing 0327 00 from the motor side of the bearing housing 0330 00 Fig 41 Cylindrical roller bearing motor side Push the angular contact ball bearings 0326 00 in X arrangement onto the shaft 0211 00 Install the motor side spacer 0504 00 and retaining ring 0932 02 Gre...

Page 67: ...otor side Lightly grease the bearing cover 0360 01 on the inside Fasten the bearing cover 0360 01 using the spring washers 0394 05 and the hex head screws 0901 04 torque 10 Nm Fig 45 Bearing cover Clean the bearing cover 0360 00 on the pump side Lightly grease the bearing cover 0360 00 on the inside Fasten the bearing cover 0360 00 using the spring washers 0934 25 and hex head screws 0901 03 torqu...

Page 68: ...he key 0940 01 into the shaft 0211 00 Do not use a mallet The bearings could be damaged Fig 48 Key Grease the coupling seat on the shaft 0211 00 with Klüber paste UH1 96 402 Fig 49 Coupling seat Check the coupling inserts 0867 02 for wear and replace if necessary Push the coupling half 0840 00 onto the shaft 0211 00 so that it is flush with it Fig 50 Coupling half Malfunctions repairs Repair BA 10...

Page 69: ... 96 402 Fig 52 Stud bolts Screw the stud bolts 0902 06 into the bearing housing 0330 00 Fig 53 Bearing housing stud bolts Grease the contact surfaces of the bearing housing 0330 00 and motor 0802 00 as well as the stud bolts 0902 06 with Klüber paste UH1 96 402 Fig 54 Bearing housing stud bolts Malfunctions repairs Repair BA 10A ADY 001 GB_1 20 07 2018 69 ...

Page 70: ...half 0840 01 onto the motor shaft and secure it with the set screw 0904 01 Make sure that the coupling half is flush with the motor shaft Loosely tighten the set screw 0904 01 Fig 57 Coupling half motor side Connect the motor 0801 00 and bearing housing 0330 00 Plug the coupling halves 0840 01 and 0840 00 into each other Fig 58 Coupling Malfunctions repairs Repair BA 10A ADY 001 GB_1 70 20 07 2018...

Page 71: ...ex nuts 0920 09 Fig 59 Bearing housing Align the coupling half 0840 01 Permissible axial offset of the coupling halves 4 mm Fig 60 Axial offset Fasten the coupling half 0840 01 with the set screw 0904 00 Torque M8 8 Nm Fig 61 The ADAPTA bearing housing has been installed Malfunctions repairs Repair BA 10A ADY 001 GB_1 20 07 2018 71 ...

Page 72: ... bolts Grease rear of the discharge casing 0107 00 with Klüber paste Fig 63 Discharge casing rear Push the discharge casing 0107 00 over the shaft 0211 00 Fig 64 Assembly screws for CONTRA II Fig 65 Discharge casing and shaft Use assembly screws when installing CONTRA II so that the larger discharge casing 0107 00 of CONTRA II is held in place It will then not fall on the shaft 0211 00 during asse...

Page 73: ...e shaft 0211 00 with clean water Fig 66 Stationary ring of the mechanical seal Push the mounting sleeve onto the shaft shoulder HILGE assembly tools prevent damage to the mechanical seal during further assembly Fig 67 Mounting sleeve Push the stationary ring of the mechanical seal 0433 00 with the installation sleeve into the seat of the discharge casing 0107 00 Fig 68 Fixed ring of the mechanical...

Page 74: ...ation sleeve in the assembled state as far as it will go onto the connection 0211 00 Fig 69 Rotating unit of the mechanical seal Push seal spacer 0577 00 on the shaft 0211 00 Fig 70 Seal spacer The single conical spring mechanical seal has been installed Malfunctions repairs Repair BA 10A ADY 001 GB_1 74 20 07 2018 ...

Page 75: ...ray bottle Plastic mounting sleeve Prior to installation 1 Check the shaft and counter ring holder for impurities and damage sharp edges If necessary clean or replace parts Fig 72 Shaft and counter ring holder A Counter ring holder B Stationary ring of the mechanical seal counter ring Notice Hygiene risk food safety Danger due to contamination Carefully inspect the seat of the mechanical seal Pay ...

Page 76: ...ver the shaft into the seat On a version with anti twist protection the slot and pin positions must match 2 Push the rotating part of the mechanical seal 0433 00 in the assembled state onto the shaft as far as it will go using a slight rotating motion The mechanical seal has been installed Hint For further assembly information refer to Installing impeller and housing section Malfunctions repairs R...

Page 77: ...s from the GEA Hilge assembly tool kit Spray bottle Plastic mounting sleeve Mounting sleeve Loctite Type 243 Klüber paste UH1 96 402 Extractor Socket wrench with plastic insert Arrangements for double mechanical seals Fig 73 Tandem double mechanical seal CONTRA I Fig 74 Double back to back mechanical seal CONTRA I Malfunctions repairs Repair BA 10A ADY 001 GB_1 20 07 2018 77 ...

Page 78: ...tridge 0491 00 into the seat of the discharge casing 0107 00 Fig 77 Discharge casing with seal cartridge Connect the seal cartridge 0491 00 with the discharge casing 0107 00 GEA Hilge CONTRA I Fastening from the front with countersunk screws 1000 03 Torque 1 5 2 Nm GEA Hilge CONTRA II Fastening from the rear with hex socket screws 0914 02 washer 0554 03 torque 8 Nm Fig 78 Malfunctions repairs Repa...

Page 79: ...EA Hilge CONTRA II Fig 79 Connection of seal cartridge top GEA Hilge CONTRA I bottom GEA Hilge CONTRA II Grease the rear of the discharge casing 0107 00 with Klüber paste Fig 80 Contact surface of discharge casing drive end part Push the discharge casing 0107 00 over the shaft 0211 00 Use assembly screws for Contra II Fig 81 Discharge casing shaft Malfunctions repairs Repair BA 10A ADY 001 GB_1 20...

Page 80: ...nary ring of the mechanical seal 0433 01 and the shaft 0211 00 with clean water Fig 83 Stationary ring of the mechanical seal Push the fixed ring stationary ring of the mechanical seal 0433 01 with the mounting sleeve into the seat of the seal cartridge 0491 00 Fig 84 Set ring of the mechanical seal Wet the mounting sleeve with clean water and push it onto the shaft shoulder Fig 85 Mounting sleeve...

Page 81: ... the mechanical seal Remove the mounting sleeve Fig 87 Mounting sleeve The mechanical seal on the atmosphere side has been installed Hint Further installation steps Installing the mechanical seal in tandem arrangement continue with Section 10 4 15 Page 82 Installing the mechanical seal in back to back arrangement continue with Section 10 4 16 Page 84 Malfunctions repairs Repair BA 10A ADY 001 GB_1...

Page 82: ...t screws 0904 02 one or two turns into the adjusting ring 0516 00 and wet with Loctite 243 Fig 88 Adjusting ring Push the adjusting ring 0516 00 to the correct position on the shaft using a suitable measuring tool Lock the adjusting ring 0516 00 with the set screws 0904 02 Fig 89 Position of the adjusting ring Relieve the spring of the mechanical seal 0433 01 against the adjusting ring 0516 00 usi...

Page 83: ...risk food safety Hygiene risk food safety Always tighten sterile screws with socket wrench and insert Fig 93 Seal cover The mechanical seal on the atmosphere side has been installed Hint The next steps for installing the product side mechanical seal are identical to installing the simple mechanical seal For a conical spring mechanical seal follow the steps in Section 10 4 12 Page 73 For an encapsu...

Page 84: ...n water and push it onto the shaft shoulder Fig 94 Mounting sleeve Push the rotating unit rotary ring of the mechanical seal 0433 00 into the shaft 0211 00 as far as it will go in the assembled state with the mounting sleeve Fig 95 Rotary ring of the mechanical seal Insert the stationary ring counter ring of the mechanical seal 0433 00 into the seat of the seal cover 0471 00 Fig 96 Stationary ring...

Page 85: ... Hygiene risk food safety Hygiene risk food safety Always tighten sterile screws with socket wrench and insert Fig 99 Seal cover The mechanical seal on the atmosphere side has been installed Hint The next steps for installing the product side mechanical seal are identical to installing the simple mechanical seal For a conical spring mechanical seal follow the steps in Section 10 4 12 Page 73 For a...

Page 86: ...y device Impeller nut assembly device plastic Socket wrench Socket wrench bit Install impeller Insert the key 0940 00 Fig 100 Key Insert the O ring 0412 05 into the seal spacer 0557 00 or mechanical seal 0433 00 Fig 101 O ring Grease impeller seat and shaft thread with Klüber paste Fig 102 Impeller seat Malfunctions repairs Repair BA 10A ADY 001 GB_1 86 20 07 2018 ...

Page 87: ...l spacer 0557 00 Fig 103 Conical spring of the mechanical seal Insert the O ring 0412 11 into the discharge casing 0107 00 Fig 104 O ring Install impeller 0230 01 Fig 105 Impeller Install the diffusor casing 0112 02 Fig 106 Diffusor casing Malfunctions repairs Repair BA 10A ADY 001 GB_1 20 07 2018 87 ...

Page 88: ...ng Install second impeller 0230 02 Fig 109 Impeller To install the remaining stages repeat steps Figure 106 Page 87 to Figure 109 Page 88 Observe the different part numbers of the impellers diffusor casings and O rings Grease the thread of the impeller nut 0922 00 with Klüber paste Fig 110 Impeller nut Malfunctions repairs Repair BA 10A ADY 001 GB_1 88 20 07 2018 ...

Page 89: ...eller nut A Fine gearing greased B Coarse gearing against each other greased A B A 0922 00 0230 00 0412 04 Fig 112 Grease overview Replace lock washers 0930 00 after 5 time use Fig 113 Lock washer Insert the lock washers 0930 00 into the impeller nut 0922 00 Fig 114 Lock washers in impeller nut Malfunctions repairs Repair BA 10A ADY 001 GB_1 20 07 2018 89 ...

Page 90: ... push it into the gap between the impeller nut 0922 00 and the impeller 0230 00 Fig 116 O ring Push plastic impeller nut assembly aid over impeller nut Then place metal plate on tie bolts 0905 01 Fig 117 Impeller nut assembly device Fasten impeller nut assembly device with the domed nuts 0927 00 Fig 118 Impeller nut assembly device Malfunctions repairs Repair BA 10A ADY 001 GB_1 90 20 07 2018 ...

Page 91: ...II M20 x 1 5 100 120 Nm Fig 119 Hexagon nut with insert Install the suction cover 0162 00 Fig 120 Suction cover Grease the thread of the tie bolts 0905 01 with Klüber paste Fig 121 Tie bolts Fasten the suction cover 0162 00 using the spring washers 0934 03 and domed nuts 0927 00 torque 20 Nm Fig 122 Suction cover domed nuts Malfunctions repairs Repair BA 10A ADY 001 GB_1 20 07 2018 91 ...

Page 92: ...ily Fig 123 Check rotation Retighten domed nuts 0927 00 approx 30 minutes after initially tightening them Due to the O rings the screw connection needs to set first The impellers and housings are now mounted Malfunctions repairs BA 10A ADY 001 GB_1 92 20 07 2018 ...

Page 93: ...se shut off devices gates valves slowly A pressure shock is a sudden increase in pressure in the system This pressure increase may be triggered by quickly shutting off the flow in the pressure pipe in addition to other causes If a pressure shock occurs the max permissible pump pressure is briefly exceeded by a multitude Perform the following steps 1 Close the pressure side shut off valve 2 Switch ...

Page 94: ...nn bekannt bitte letztes Fördermedium angeben Die Pumpe ist vor Versand Bereitstellung sorgfältig entleert sowie außen und innen gereinigt worden bitte ankreuzen ___ Besondere Sicherheitsvorkehrungen sind bei der weiteren Handhabung nicht erforderlich ___ Folgende Sicherheitsvorkehrun gen hinsichtlich Spülmedien Restflüssigkeiten und Entsorgung sind erforderlich Wir versichern dass die vorstehende...

Page 95: ...Appendix BA 10A ADY 001 GB_1 20 07 2018 95 ...

Page 96: ...e 600 Index In addition the company is included in selected MSCI Global Sustainability Indexes We live our values Excellence Passion Integrity Responsibility GEA versity GEA Hilge Niederlassung der GEA Tuchenhagen GmbH All rights reserved Subject to modi ications Printed in Germany GEA Germany GEA Hilge Niederlassung der GEA Tuchenhagen GmbH Hilgestraße 37 47 55294 Bodenheim Germany Tel 49 6135 70...

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