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GEA Hilge HYGIA ADAPTA, Operating Instruction

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GEA Hilge HYGIA ADAPTA Operating Instruction Download Page 25

6

Assembly and installation

6.1

Safety precautions for setup, installation, and connection

Warning!

 

Tipping (tilting) of the pump!
► The surface for setting up the pump should be clean, level and have
sufficient load-bearing capacity.
► Bolt the provided fastening points to the foundation for proper setup of
the pump according to the usual rules of mechanical engineering.

Warning!

 

Mechanical overload!
► Do not use the pump and its connection port as support of the piping.
(EN 809 5.2.1.2.3 and EN ISO 14847).
► Follow the general rules of mechanical engineering and plant
construction and the regulations of the manufacturers of connecting
elements (e.g. flanges). These regulations may include information on
tightening torques, max. permissible angular misalignment, tools/equipment
to use.
► Be sure to avoid any strain on the pump.
► After piping, check the alignment of the coupling (where applicable).

Caution!

 

Overload by foreign bodies!
► Before installing the pump in the system, remove all plastic films 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 nominal diameters of the system should be equal to or greater
than the DNE or DNA connections of the pump.
► For suction operation, install a foot valve.
► Route the suction line in ascending direction and the supply line at a
slight slope towards the pump.
► If the local conditions do not permit a continuous ascent of the suction
line: Provide a vent at its highest point.
► Install a shut-off valve in the supply line close to the pump.
► Open the suction side shut-off valve completely during operation.
► Do not use the suction side shut-off valve for controlling.
► Install a shut-off valve in the pressure line close to the pump. This can be
used to control the flow rate.

Assembly and installation

Safety precautions for setup, installation, and connection

BA.H2A.ADY.002.GB_1

 

18.12.2017

25

Summary of Contents for Hilge HYGIA ADAPTA

Page 1: ...Hygienic Pumps GEA Hilge HYGIA ADAPTA US Version C Version D Operating instruction Translation from the original language BA H2A ADY 002 GB_1 ...

Page 2: ...g out activities in the phases of the life of the pump The operator is required to complement these instructions with information based on existing national regulations for occupational safety health protection and environmental protection In addition to these instructions and the mandatory regulations for accident prevention applicable in the country and place of use the recognised technical rule...

Page 3: ...installation incorrect or improper connection of electrical components resulting or arising from unauthorised modifications or failure to follow the instructions caused by use of accessories spare parts that have not been supplied or recommended by the manufacturer BA H2A ADY 002 GB_1 18 12 2017 3 ...

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: ... 1 Special personnel qualification for transport and storage 18 4 2 Safety precautions for transport and storage 18 4 3 Dimensions weights 19 4 4 Unpacking the pump 20 4 5 Disposal of packaging material 21 5 Technical data 22 5 1 Serial number 22 5 2 Performance data 22 5 3 Noise emissions 22 5 4 Maximum operating temperatures 23 5 5 Maximum operating pressure 23 5 6 Resistance of Sealing Material...

Page 6: ...ler bearing greases 46 9 5 Maintenance of the motor 47 10 Malfunctions repairs 48 10 1 Special personnel qualification 48 10 2 Safety instructions 48 10 3 Malfunctions and remedies 49 10 4 Repair 50 10 4 1 Repair order 50 10 4 2 GEA Hilge assembly tool kit 52 Contents and use 52 10 4 3 Parts overview 53 10 4 4 Parts overview of ADAPTA bearing support sizes 1 and 2 54 10 4 5 Parts overview ADAPTA b...

Page 7: ...11 3 Temporary decommissioning 92 11 4 Disposal 92 12 Appendix 93 12 1 Certificate of non objection 94 BA H2A ADY 002 GB_1 18 12 2017 7 ...

Page 8: ...BA H2A ADY 002 GB_1 8 18 12 2017 ...

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 12 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: ...l 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 settling section w...

Page 11: ...erefore be read by the installer and relevant 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 H2A ADY 00...

Page 12: ...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 13: ...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 14: ...be done by the product manufacturer vendor on behalf of the operating company The operating company must also ensure that the contents of the operating instructions are fully understood by the staff 2 7 Safety equipment Do not remove instructions from the pump Signs attached directly on the machine such as an arrow to indicate the direction of rotation must absolutely be observed and kept in fully...

Page 15: ...d 02 11 The material quality 1 4404 or 1 4435 AISI 316 316L Fe 1 and the respective version standard is implemented in accordance with the order and if desired fully certified 3 2 1 Standard version applications The standard version of the pumps is used in the following areas Breweries beer wort mash yeast etc Dairies milk milk mixes cheese production etc Soft drinks fruit juice lemonade mineral w...

Page 16: ...ntal assembly on 3 A dome base see catalogue No 3 4 Type plate GEA Hilge Niederlassung der Tuchenhagen GmbH Hilgestrasse D 55294 Bodenheim Pump Type Ser No 990012340001 P N 99001234 Q 50 USgpm H 60 ft n 3450 rpm P 5 hp TAG No YOM 12 2017 Made in Germany GEAHilge HYGIAI 1 D AHUO0 IA0160 OFAF22 211 EEMSE D Fig 2 Type plate Pump type Pump name P Motor rating Serial No Pump number n Speed P N Pump num...

Page 17: ... General purpose motors These motor variants are used in all applications that are not subject to strict hygiene regulations Description BA H2A ADY 002 GB_1 18 12 2017 17 ...

Page 18: ...ope to suitable anchor points Never fasten a rope to the pump housing or the suction pressure port For version with casing Remove the stainless steel casing before transport Fig 3 Anchor points example Storage of the pump Caution Frost Risk due to external conditions In case of frost risk drain the pump completely If the pump is not used immediately proper storage conditions are as important for l...

Page 19: ...HP NEMA frame size Total Weight kg Total Weight lb BG1 2 1 143T 41 2 90 8 BG1 1 5 145T 42 2 93 0 BG1 2 145T 44 2 97 4 BG1 3 182T 77 8 171 5 BG2 5 184T 73 8 162 7 BG2 7 5 213T 95 8 211 2 BG2 10 215T 100 5 221 6 BG2 Weights HYGIA ADAPTA on spherical stand 2 pole P2 HP NEMA frame size Total Weight kg Total Weight lb BG1 2 1 5 143T 43 4 95 6 BG1 2 145T 47 1 103 8 BG1 3 182T 59 5 131 1 BG1 5 184T 68 3 ...

Page 20: ...4 2 BG2 25 284TS 274 0 604 0 BG2 AD3 30 286TS 288 0 634 9 BG2 AD3 Weights HYGIA ADAPTA on 3A assembly 4 pole P2 HP NEMA frame size Total Weight kg Total Weight lb BG1 2 1 143T 46 0 101 4 BG1 1 5 145T 47 0 103 6 BG1 2 145T 49 0 108 0 BG1 3 182T 86 3 190 3 BG2 5 184T 82 2 181 3 BG2 7 5 213T 107 0 236 0 BG2 10 215T 111 8 246 4 BG2 4 4 Unpacking the pump All of our pumps leave our warehouse properly p...

Page 21: ...ed waste disposal company Packaging materials not suitable for recycling must always be disposed of in accordance with the requirements of environmental protection and waste disposal legislation as well as the requirements of the local authorities Packaging materials suitable for recycling should be reused or reprocessed Transport and Storage Disposal of packaging material BA H2A ADY 002 GB_1 18 1...

Page 22: ...he serial number is indicated on the type plate 5 2 Performance data The performance data delivery head and 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 Noise emissions GEA Hilge HYGA I II 60 Hz Output kW HP Number of pole...

Page 23: ...pressures The pump s maximum operating pressure pump depends on various factors Pump type Type of connections Type of mechanical seal 5 6 Resistance of Sealing Materials The resistance of sealing materials depends on the type and temperature of the medium conveyed The exposure time can adversely affect the service life of the seals The sealing materials comply with the regulations of FDA 21 CFR 17...

Page 24: ...nic 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 approx 30 min up to 150 C 302 F o Fuels hydrocarbons Product with a fat content of max 35 Product with a fat content of more than 35 Oils Depending on the installation conditions Technical data BA H2A ADY 002 GB_1 24 18 12 20...

Page 25: ...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 26: ...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 27: ... 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 28: ...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 29: ... operation P Pump M Motor 6 3 3 1 Space requirements Maintain the following minimum distances Pay attention to motor performance Horizontal assembly 40 in 12 in 12 in 0 75 5 hp 7 5 hp Fig 6 Minimum distances in horizontal assembly Assembly and installation Setup installation and connection BA H2A ADY 002 GB_1 18 12 2017 29 ...

Page 30: ...GIA on 3 A stand Dimension B at least 4 102 mm Screw in depth of the feet Notice Hygiene risk food safety Feet which are improperly sealed provide space for hidden contaminants Screw in the feet so that the O ring rests on the smooth counterpart 6 3 3 2 Noise and vibration damping To achieve optimum performance and to minimize noise and vibration it is recommended to provide the pump with vibratio...

Page 31: ...allation An incorrectly designed damper may even increase the vibration Vibration dampers should therefore be designed by the vendor of the vibration damper Compensators If the pump is mounted on a foundation along with vibration dampers be sure to install compensators at the pipe connections This prevents the pump from hanging in the connections Compensators are installed to absorb expansion shri...

Page 32: ...g gap which prevents contact between the two sliding surfaces Usually this lubrication film is formed by the pumped product or by an externally supplied flushing sealing fluid Due to the friction heat between the sliding faces the lubrication film evaporates towards the atmosphere This means there is a leak that is invisible in water water like or volatile liquids e g alcohol The amount of leakage...

Page 33: ...l the product side mechanical seal and the radial packing ring on the atmospheric side The flushing fluid must meet the following criteria good flowability no impurities no solids no dissolved components adequate thermal conductivity no chemical or mechanical attacking of the pump materials sealing materials and elastomers No contaminating of the pumped fluid Viscosity 5 mPas Water hardness 5 dH o...

Page 34: ...ction mechanical seals need a sealing fluid which has the following tasks including others Pressure build up in the sealing space Preventing penetration of fluid into the sealing gap Protection against dry running Lubrication and cooling of the mechanical seals A clean liquid compatible with the pumped fluid is used as the sealing fluid Ensuring the flushing operation 1 Open the inlet of sealing f...

Page 35: ...ion and cooling of the mechanical seals A clean liquid compatible with the pumped fluid is used as the flushing medium Ensuring the flushing operation 1 Open the inlet of flushing fluid 2 Vent the seal cartridge 3 Ensure pressureless circulation Done For abrasive media use lost flushing in which the flushing fluid is discharged directly Permissible supply pressures and temperatures The supply of t...

Page 36: ... converter Operation with frequency converter Operating conditions Measures Noise sensitive applications Install a dU dt filter between the motor and frequency converter reduces voltage spikes and thus noise Particularly noise sensitive applications Install sinusoidal filter Cable length Use a cable which satisfies the conditions prescribed by the manufacturer of the frequency converter Supply vol...

Page 37: ...ion if necessary The direction of rotation has been checked and corrected if necessary 6 4 4 Earthing Warning Electrical voltage by different potentials The occurrence of potential differences can cause damage to persons and property Properly earth the pump and motor to achieve potential equalisation 6 4 4 1 Earthing the motor Equipotential bonding for the motor is performed via the protective con...

Page 38: ...cceptance Make sure that the pump is operated only under the specified conditions of use These conditions apply to pressure temperature fluid etc 7 3 2 Commissioning of the pump Perform the following steps 1 Check that all connections are firmly secured 2 Make sure that all safety devices are installed 3 Make sure that the electrical connections are correct 4 Ensure that the pipe system provided b...

Page 39: ... pump system 3 Repeat steps 7 to 10 and follow Section 10 3 Page 49 7 3 3 Functional testing of the mechanical seal Perform the following steps 1 Inspect the pump and check whether liquid exits at the mechanical seal An intact mechanical seal operates virtually without any leakage If pumped fluid or flushing fluid exits 1 Switch off the pump 2 Replace the mechanical seal Follow the installation in...

Page 40: ...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 14 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 41: ...emperature 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 1 13 14 150 3 Acid H2SO4 H3PO4 HNO3 2 2 3 60 140 1504 5 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...

Page 42: ...sing 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 warm wate...

Page 43: ...ommends 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 slide ring packing 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 ...

Page 44: ...ideline 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 carrier structure sizes 1 and 2 The bearing structure consists of two angular contact ball bearings They are paired and are installed as fixed bearings in an O arrangement to accommodate axial and r...

Page 45: ...ity cm3 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 1000 11 0327 00 approx 3000 10 9 4 3 Bearing rep...

Page 46: ...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 47: ...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 13 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 48: ...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 49: ...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 50: ...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 51: ...If despite careful emptying and cleaning of the pump safety precautions are required the necessary information must be given Malfunctions repairs Repair BA H2A ADY 002 GB_1 18 12 2017 51 ...

Page 52: ...ting sleeve Ø 28 2 Spray bottle 5 Extractor for mechanical seal counter ring 6 Klüber paste UH1 96 402 7 Socket wrench a f 32 7 Socket wrench bit a f 27 8 Optimol paste TA 9 Socket wrench a f 24 9 Socket wrench bit a f 17 10 Screw locking compound Loctite Type 243 12c Mechanical seal mounting sleeve Ø 28 and Ø 30 12c Plastic adapter Ø 28 12d Mechanical seal mounting sleeve Ø 19 and Ø 22 12d Plasti...

Page 53: ... KLM housing Parts list of HYGIA I II Pcs Part no Designation Pcs Part no Designation 1 0103 00 Ring housing 1 0557 00 Sealing washer 1 0161 00 Housing cover 12 0901 07 Hex screw 1 0230 00 Impeller 4 0902 02 Stud bolts 1 0412 00 O ring seal 1 0905 00 Connecting screw 1 0412 04 O ring seal 1 0920 00 Hex nut 1 0412 05 O ring seal 1 0922 00 Impeller nut 1 0433 00 Mechanical seal 12 0927 00 Cap nut 1 ...

Page 54: ... 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 support 1 0926 00 Locknut 1 0360 01 Bearing cover 4 0934 05 Spring washer 1 0507 00 Splash ring 1 0940 00 Feather key 1 0507 02 Splash ring V ring 1 0940 01 Feather key 1 0507 05 Splash ring V ring 1 0970 00 Type plate 4 0560 00 Round head grooved...

Page 55: ...ty 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 support 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 Support disc 4 0934 05 Spring washer 1 0504 01 Support disc 4 0934 25 Spring washer 1 0507 00 Splash ring 1 0940 01 Feather key 1 0507 02...

Page 56: ...on 1 0211 00 Shaft 6 0867 02 Coupling insert 1 0346 00 Intermediate lantern 4 0901 02 Hex screw 4 0554 02 Washer 4 0902 06 Stud screw 4 0554 50 Washer 1 0904 00 Set screw 2 0592 12 Base 1 0904 01 Set screw 4 0592 13 Base 4 0904 20 Set screw 4 0595 00 Pad 4 0920 09 Hex nut 1 0680 00 Cover hood 4 0920 12 Hex nut 1 0801 00 Motor 4 0920 81 Hex nut 1 0840 00 Coupling 4 0927 08 Cap nut 1 0840 01 Couplin...

Page 57: ... no mineral oil greases for the wet section assembly Always replace mechanical seals completely Remember the properties when replacing the O rings See Section 9 3 1 1 Page 43 Use a screwdriver or an impeller nut mounting device to tighten the impeller nut 0922 00 10 4 7 1 Cleaning the components before assembly Notice Hygiene risk food safety Contaminated components contaminate the pump and instal...

Page 58: ... when replacing the bearings Do not use a mallet Fig 19 Shaft with roller bearing Fill the gaps of roller bearings 0326 00 100 with grease For details see Section 9 4 1 Page 44 Fig 20 Roller bearings Push the shaft 0211 00 into the bearing support 0330 00 Fig 21 ADAPTA bearing support Lightly grease the bearing cover 0360 01 on the inside Push the bearing cap over the shaft 0211 00 Fig 22 Bearing ...

Page 59: ...nto the shaft 0211 00 so that the sealing lip contacts the bearing cover 0360 01 Fig 24 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 support 0330 00 Fig 25 Position V ring Insert the feather key 0940 01 into the shaft 0211 00 Do not use a mallet The bearings could be damaged Fig 26 Feather key Malfunctions repairs Repai...

Page 60: ...the coupling half 0840 00 with the set screw 0904 00 torque 3 ft lb 4 Nm Fig 28 Set screw Connect the bearing support 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 29 Stainless steel foot Insert the feather key 0940 01 into the motor shaft Fig 30 Feather key Malfunctions repairs Repair BA H2A ADY 002 G...

Page 61: ...shaft Loosely tighten the set screw 0904 01 Fig 32 Coupling half motor side Connect the motor to the bearing support 0330 00 by plugging the coupling halves 0840 00 and 0840 01 into each other Fig 33 Connect coupling halves Connect the bearing carrier 0330 00 and motor using the hex head screws 0902 06 spring washers 0934 06 and hex nuts 0920 09 torque M10 26 ft lb 35 Nm torque M12 48 ft lb 65 Nm ...

Page 62: ... 01 with the set screw 0904 00 torque 3 ft lb 4 Nm Fig 35 Feeler gauge Push the splash ring 0507 00 onto the shaft 0211 00 During the further installation make sure that the splash ring does not contact the adjacent components Fig 36 Splash ring The ADAPTA bearing support has been installed Malfunctions repairs Repair BA H2A ADY 002 GB_1 62 18 12 2017 ...

Page 63: ...00 For details see Section 9 4 2 Page 45 Fig 38 Cylindrical roller bearing pump side Grease the outer race of the cylindrical roller bearing 0327 00 from the motor side of the bearing support 0330 00 Fig 39 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 64: ...e 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 7 ft lb 10 Nm Fig 43 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 65: ...er key 0940 01 into the shaft 0211 00 Do not use a mallet The bearings could be damaged Fig 46 Feather key Grease the coupling seat on the shaft 0211 00 with Klüber paste UH1 96 402 Fig 47 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 48 Coupling half Malfunctions repairs Repa...

Page 66: ...UH1 96 402 Fig 50 Stud bolts Screw the stud bolts 0902 06 into the bearing support 0330 00 Fig 51 Bearing carriers stud bolts Grease the contact surfaces of the bearing carrier 0330 00 and motor 0802 00 as well as the stud bolts 0902 06 with Klüber paste UH1 96 402 Fig 52 Bearing carriers stud bolts Malfunctions repairs Repair BA H2A ADY 002 GB_1 66 18 12 2017 ...

Page 67: ...oupling 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 55 Coupling half motor side Connect the motor 0801 00 and bearing support 0330 00 Plug the coupling halves 0840 01 and 0840 00 into each other Fig 56 Coupling Malfunctions repairs Repair BA H2A ADY 002 GB_1 18 12...

Page 68: ...s 0920 09 Fig 57 Bearing support Align the coupling half 0840 01 Permissible axial offset of the coupling halves 4 mm 0 16 Fig 58 Axial offset Fasten the coupling half 0840 01 with the set screw 0904 00 Torque M8 6 ft lb 8 Nm Fig 59 The ADAPTA bearing support has been installed Malfunctions repairs Repair BA H2A ADY 002 GB_1 68 18 12 2017 ...

Page 69: ...g 60 Back plate with stud bolts Grease the seat of the component that borders on the back plate 0161 00 with Klüber paste UH1 96 402 Fig 61 Contact surface of back plate structural part Connect the back plate 0161 00 to the structural part using the stud bolts 0902 02 the spring washers 0934 00 and the hex head screws 0920 04 torque M10 26 ft lb 35 Nm Fig 62 Back plate on the structural part The b...

Page 70: ...ted exactly Two versions are described below Version 1 Conical spring mechanical seal with seal spacer Variant 2 encapsulated hygienic mechanical seal Preparation 1 Remove the feather key 0940 00 from the shaft 0211 00 2 Remove the mechanical seal 0433 00 and the O rings 0412 00 and 0412 05 Done Determining the air gap a or a Version 1 Conical spring mechanical seal with seal spacer 1 Push the sea...

Page 71: ...1 Push the impeller 0230 00 onto the shaft 0211 00 making sure it does not contact the shaft shoulder It should be flush with the shaft thread at the front 2 Carefully place the annular casing 0103 00 against the back plate 0161 00 Thus the impeller 0230 00 is pushed by the annular casing 0103 00 into the zero gap position The air gap then forms behind the impeller 3 Remove annular casing 0103 00 ...

Page 72: ...l seal 0433 00 and the shaft 0211 00 with clean water Fig 64 Fixed ring of the mechanical seal Push the counter ring of the mechanical seal 0433 00 into the seat of the back plate 0161 00 Fig 65 Set ring Push the mounting sleeve onto the shaft shoulder Moisten the mounting sleeve with clean water HILGE assembly tools prevent damage to the mechanical seal during further assembly Fig 66 Mounting sle...

Page 73: ...d state onto the shaft 0211 00 as far as it will go Fig 67 Mechanical seal Push the seal spacer 0557 00 onto the shaft Fig 68 Seal spacer The single conical spring mechanical seal has been installed Hint For further installation read Section 10 4 17 Page 85 Malfunctions repairs Repair BA H2A ADY 002 GB_1 18 12 2017 73 ...

Page 74: ... Spray 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 70 Shaft and counter ring holder A Counter ring holder B Fixed 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 at...

Page 75: ...he O ring over 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 installation read Section 10 4 17 Page 85 Malfunctions repairs Repair BA H2A ADY ...

Page 76: ...g sleeve Mounting sleeve Loctite Type 243 Klüber paste UH1 96 402 Extractor Socket wrench with plastic insert Arrangements for double mechanical seals 0491 00 0433 01 0904 02 0433 00 0471 00 0516 00 0918 00 0412 03 0914 02 0554 03 0412 02 0412 01 0107 00 0161 00 Fig 71 Double tandem mechanical seal with encapsulated spring HYGIA I Fig 72 Double back to back mechanical seal HYGIA I Malfunctions rep...

Page 77: ...ring Press the seal cartridge 0491 00 into the seat of back plate 0161 00 Fig 75 Back plate with seal cartridge Connect the seal cartridge 0491 00 with the back plate 0161 00 GEA Hilge HYGIA I Fastening from the front with Phillips screws 1000 03 Torque M4 1 1 1 5 ft lb 1 5 2 Nm GEA Hilge HYGIA II Fastening from the rear with hex socket screws 0914 02 washer 0554 03 torque M6 6 ft lb 8 Nm Fig 76 B...

Page 78: ...EA Hilge HYGIA I bottom GEA Hilge HYGIA II Grease the seat of the component that borders on the back plate 0161 00 with Klüber paste UH1 96 402 Fig 78 Contact surface of back plate structural part Connect the back plate 0161 00 to the structural part using the stud bolts 0902 02 the spring washers 0934 00 and the hex head screws 0920 04 torque M10 26 ft lb 35 Nm Fig 79 Back plate on the structural...

Page 79: ...Fixed ring of the mechanical seal Push the fixed ring counter ring of the mechanical seal 0433 01 with the mounting sleeve into the seat of the seal cartridge 0491 00 Fig 81 Set ring Wet the mounting sleeve with clean water and push it onto the shaft shoulder Fig 82 Mounting sleeve Malfunctions repairs Repair BA H2A ADY 002 GB_1 18 12 2017 79 ...

Page 80: ...the mechanical seal Remove the mounting sleeve Fig 84 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 81 Installing the mechanical seal in back to back arrangement continue with Section 10 4 16 Page 83 Malfunctions repairs Repair BA H2A ADY 002 GB_1 ...

Page 81: ...t screws 0904 02 one or two turns into the adjusting ring 0516 00 and wet with Loctite 243 Fig 85 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 86 Position of the adjusting ring Relieve the spring of the mechanical seal 0433 01 against the adjusting ring 0516 00 usi...

Page 82: ...lbf ft 8 Nm Use the socket wrench with plastic insert to tighten the sterile screws Fig 90 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 72 For an encapsulated sterile mech...

Page 83: ...sh it onto the shaft shoulder Fig 91 Mounting sleeve Push the rotating unit slide 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 92 Slide ring of the mechanical seal Insert the fixed ring counter ring of the mechanical seal 0433 00 into the seat of the seal cover 0471 00 Insert the O ring 0412 01 into the seal cov...

Page 84: ...wrench with plastic insert to tighten the sterile screws Fig 95 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 72 For an encapsulated sterile mechanical seal follow the step...

Page 85: ...ottle Socket wrench Socket wrench bit Install impeller Insert the feather key 0940 00 Fig 96 Feather key Insert the O ring 0412 05 into the seal spacer 0557 00 or mechanical seal 0433 00 Fig 97 O ring Grease impeller seat and shaft thread with Klüber paste Fig 98 Impeller seat Malfunctions repairs Repair BA H2A ADY 002 GB_1 18 12 2017 85 ...

Page 86: ...paste Hint Only use original spare part lock washers from Hilge for securing the impeller mounting Fig 101 Lock washers Grease lock washers as shown 0230 00 Impeller 0412 04 O ring 0922 00 Impeller nut A Fine gearing greased B Coarse gearing against each other greased A B A 0922 00 0230 00 0412 04 Fig 102 Grease overview Malfunctions repairs Repair BA H2A ADY 002 GB_1 86 18 12 2017 ...

Page 87: ...rs in impeller nut Unscrew impeller nut 0922 00 by hand Leave a gap of approximately 0 12 3 mm for the O ring 0412 04 Fig 105 Impeller nut Wet the O ring 0412 04 with water and use the impeller nut 0922 00 to push it into the gap between the impeller nut 0922 00 and the impeller 0230 00 Fig 106 O ring Malfunctions repairs Repair BA H2A ADY 002 GB_1 18 12 2017 87 ...

Page 88: ...and insert Fig 107 Tighten the impeller nut 0922 00 To do so lock the impeller 0230 00 with the centring key Torque M10 15 lbf ft 20 Nm M20 x 1 5 74 89 lbf ft 100 120 Nm Fig 108 Impeller nut With open conical spring Relax the spring of the mechanical seal 0433 00 against the seal spacer 0557 00 using the extractor Fig 109 Axial face seal The impeller has been installed Malfunctions repairs Repair ...

Page 89: ... Annular casing Grease the thread of the connecting screw 0905 00 with Klüber paste Install the upper and lower clamp rings 0501 00 and 0501 01 following the direction indicated on the clamp ring To do so tighten the connection screw 0905 00 the washer 0554 00 and the hex nut 0920 00 by hand Fig 112 Clamp ring Malfunctions repairs Repair BA H2A ADY 002 GB_1 18 12 2017 89 ...

Page 90: ...4 Clamp ring The KLM housing has been installed Installing the HPM housing Wet the O ring 0412 00 with water and insert it into the back plate 0161 00 Install the annular casing 0103 00 Fasten the housing 0103 00 using the hex head screws 0901 07 spring washers 0934 03 and cap nuts 0927 00 Torques HYGIA I M8 14 lbf ft 19 Nm HYGIA II M10 26 lbf ft 35 Nm Fig 115 HPM housing The HPM housing has been ...

Page 91: ...r inserts Attaching the wear inserts Install the wear inserts 0686 01 and 0686 02 with the screws 1000 11 Fig 116 Wear inserts on the lantern The wear inserts are installed Malfunctions repairs BA H2A ADY 002 GB_1 18 12 2017 91 ...

Page 92: ...d by a multitude Caution Sticking of the pump Clean the pump suitably after decommissioning See Chapter 8 Page 40 11 3 Temporary decommissioning 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 tem...

Page 93: ...12 Appendix Appendix BA H2A ADY 002 GB_1 18 12 2017 93 ...

Page 94: ...12 1 Certificate of non objection Appendix Certificate of non objection BA H2A ADY 002 GB_1 94 18 12 2017 ...

Page 95: ...n liquids hazardous to health ___ was used for the following Please state the last liquid pumped if known The pump was carefully drained and also cleaned inside and out before it was shipped made available please mark with a cross ___ No special safety measures are required in the course of further handling ___ The following safety measures pertaining to flushing liquids residual liquids and dispo...

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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