GEA Hilge HYGIA K Operating Instruction Download Page 1

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Hygienic Pumps

GEA Hilge HYGIA K

Operating instruction (Translation from the original language)
BA.H2A.KYY.001.GB_2

Summary of Contents for Hilge HYGIA K

Page 1: ...Hygienic Pumps GEA Hilge HYGIA K Operating instruction Translation from the original language BA H2A KYY 001 GB_2...

Page 2: ...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 protecti...

Page 3: ...nstallation 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 part...

Page 4: ...t 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...

Page 5: ...16 4 Transport and Storage 17 4 1 Special personnel qualification for transport and storage 17 4 2 Safety precautions for transport and storage 17 4 3 Dimensions weights 18 4 4 Unpacking the pump 18...

Page 6: ...1 Special personnel qualification 43 10 2 Safety instructions 43 10 3 Malfunctions and remedies 44 10 4 Repair 45 10 4 1 Repair order 45 10 4 2 GEA Hilge assembly tool kit 47 Contents and use 47 10 4...

Page 7: ...nd 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 11 Tec...

Page 8: ...irective 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 acc...

Page 9: ...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...

Page 10: ...nt 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...

Page 11: ...nt 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 instruc...

Page 12: ...ims 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 mainte...

Page 13: ...nd 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 r...

Page 14: ...ntrol 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 H2A KYY 001...

Page 15: ...required certified in writing 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 pro...

Page 16: ...Design type Nominal width Output kW Number of poles 3 4 Type plate GEA Hilge Niederlassung der GEA Tuchenhagen GmbH Hilgestrasse D 55294 Bodenheim Pump Type Ser No Q H n P TAG No YOM Made in Germany...

Page 17: ...pe 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...

Page 18: ...kW pole Motor IEC Motor foot Cast iron foot Stainless steel foot Dome stand SUPER dome stand SUPER cast iron foot SUPER stainless steel foot SUPER tronic dome stand SUPER tronic cast foot SUPER tronic...

Page 19: ...d 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 wel...

Page 20: ...ated 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...

Page 21: ...al 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 sea...

Page 22: ...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 cont...

Page 23: ...lms 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 directl...

Page 24: ...gulations 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 Disconn...

Page 25: ...The personnel used for setup installation and connection must be adequately qualified for this work See also Section 2 6 Page 13 6 3 Setup installation and connection 6 3 1 Checking smooth running of...

Page 26: ...unit tighten the fastening screws evenly in a crosswise sequence where applicable The pump unit has been set up and aligned 6 3 3 Installation in the piping system P M P M Fig 5 Installation in the p...

Page 27: ...stem 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 d...

Page 28: ...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 F...

Page 29: ...ly 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...

Page 30: ...he 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 materi...

Page 31: ...sary When using a closed flushing circuit with a supply reservoir regularly monitor the fill level visually or by means of level probes Also make sure that no pressure build up can occur in the flushi...

Page 32: ...the wiring diagram of the delta connection U1 V1 W1 W2 U2 V2 L1 L2 L3 Fig 11 Delta connection 6 3 6 3 Frequency converter operation All three phase motors can be connected to a frequency converter Fre...

Page 33: ...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...

Page 34: ...earthing cable on the side of the motor shroud using the provided hole A and connect it with the earthing conductor A Fig 12 Earthing connection of the motor shroud Earthing the machine pad support E...

Page 35: ...ion Type plate Operating instructions Test bench acceptance Make sure that the pump is operated only under the specified conditions of use These conditions apply to pressure temperature fluid etc 7 3...

Page 36: ...any leakage If pumped fluid or flushing fluid exits 1 Switch off the pump 2 Replace the mechanical seal Follow the installation instructions Section 10 2 Page 43 7 3 4 Function test of the shaft seal...

Page 37: ...orking temperatures and steps 8 1 Special personnel qualification The cleaning personnel must be suitably qualified for this work See also Section 2 6 Page 13 8 2 Safety instructions Warning Damage ca...

Page 38: ...ature 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 C2H4...

Page 39: ...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...

Page 40: ...functions GEA recommends 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 operat...

Page 41: ...t longer intervals The actual maintenance intervals can only be determined by the user since they depend on the operating conditions for instance daily period of use switching frequency type and tempe...

Page 42: ...otors 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 14 Lubri...

Page 43: ...l 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 depressuris...

Page 44: ...r 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...

Page 45: ...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 th...

Page 46: ...If despite careful emptying and cleaning of the pump safety precautions are required the necessary information must be given Malfunctions repairs Repair BA H2A KYY 001 GB_2 46 27 02 2018...

Page 47: ...Mounting sleeve 28 2 Spray bottle 5 Extractor for mechanical seal counter ring 6 Kl ber 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...

Page 48: ...encapsulated mechanical seal Parts list HYGIA I II Pcs Part no Designation Pcs Part no Designation 1 0103 00 Annular casing 1 0554 00 Washer 1 0161 00 Back plate 1 0557 00 Seal spacer 1 0230 00 Impel...

Page 49: ...Fig 17 Parts overview 1 quench version only Parts list of K motor stool Pcs Part no Designation Pcs Part no Designation 1 0340 00 Motor stool 1 0736 04 Pipe 1 0346 00 Intermediate motor stool 1 0736...

Page 50: ...Washer 4 0920 12 Hex nut 4 0554 50 Washer 4 0920 81 Hex nut 4 0554 75 Washer 4 0927 08 Cap nut 2 0592 12 Base 6 0930 02 Circlip 4 0592 13 Base 1 0940 00 Feather key 4 0595 00 Pad 1 0940 03 Feather ke...

Page 51: ...ssembly Always replace mechanical seals completely Remember the properties when replacing the O rings See Section 9 3 1 1 Page 40 Use a screwdriver or an impeller nut mounting device to tighten the im...

Page 52: ...o or three intact areas of the shaft near the wear location If the average diameter matches the diameter of the shaft protection sleeve the sleeve can be tightly installed 3 Mark the position of the s...

Page 53: ...e D Shaft Removing the shaft protection sleeve If necessary the shaft protection sleeve can be removed from the shaft in various ways In most cases it can be pulled easily pulled from the shaft by hea...

Page 54: ...nless stated otherwise the parts listed in these instructions are shown in Section 10 4 3 Page 48 Section 10 4 4 Page 49 and Section 10 4 5 Page 50 Installing the motor motor stool and pump shaft Prea...

Page 55: ...th water and push it into the seal cartridge 0491 00 Use mounting sleeve Fig 23 Radial packing ring Insert the retaining ring 0932 09 into the seal cartridge 0491 00 Fig 24 Circlip Wet hex socket scre...

Page 56: ...d screw them into the back plate 0161 00 up to the stop Fig 28 Set screws Connect the back plate 0160 00 with the motor stool 0340 00 using the spring washers 0554 73 and the hexagon nuts 0920 04 Torq...

Page 57: ...ush the motor stool 0340 00 onto the shaft 0211 00 and fasten it with the hex head bolts 0901 50 washers 0554 74 and 0554 75 and hexagon nuts 0920 09 to the motor flange Torques M10 35 Nm M12 65 Nm M1...

Page 58: ...on Check the rotation of the pump shaft 0211 00 Max permissible runout 0 05 mm In case of larger runout dismount clamp connection and reinstall For replacement motor stool Clean the surface of the mot...

Page 59: ...ed 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...

Page 60: ...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...

Page 61: ...seal 0433 00 and the shaft 0211 00 with clean water Fig 38 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 39 Set ri...

Page 62: ...state onto the shaft 0211 00 as far as it will go Fig 41 Mechanical seal Push the seal spacer 0557 00 onto the shaft Fig 42 Seal spacer The single conical spring mechanical seal has been installed Hi...

Page 63: ...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 44 Shaft and counter...

Page 64: ...e 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...

Page 65: ...ttle Socket wrench Socket wrench bit Install impeller Insert the feather key 0940 00 Fig 45 Feather key Insert the O ring 0412 05 into the seal spacer 0557 00 or mechanical seal 0433 00 Fig 46 O ring...

Page 66: ...paste Hint Only use original part lock washers from GEA Hilge for securing the impeller mounting Fig 50 Lock washers Grease lock washers as shown 0230 00 Impeller 0412 04 O ring 0922 00 Impeller nut A...

Page 67: ...washers in impeller nut Unscrew impeller nut 0922 00 by hand Leave a gap of about 3 mm for the O ring 0412 04 Fig 54 Impeller nut Wet the O ring 0412 04 with water and use the impeller nut 0922 00 to...

Page 68: ...nd insert Fig 56 Socket wrench with insert Tighten the impeller nut 0922 00 To do so lock the impeller 0230 00 with the centring key Torque M10 20 Nm M20 x 1 5 100 120 Nm Fig 57 Impeller nut With open...

Page 69: ...nnular casing Grease the thread of the connecting screw 0905 00 with Kl ber paste Install the upper and lower clamp rings 0501 00 and 0501 01 following the direction indicated on the clamp ring To do...

Page 70: ...ig 63 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...

Page 71: ...65 Safety guards The safety guards are installed 10 4 15 Installing SUPER cover hood RSWLRQDO RSWLRQDO Fig 66 SUPER cover hood Parts list for cover hood Pcs Part no Designation Pcs Part no Designatio...

Page 72: ...d Pcs Part no Designation Pcs Part no Designation 2 0592 12 Base 4 0920 12 Hex nut 4 0592 13 Base 4 0920 81 Hex nut 4 0595 00 Pad 4 0927 08 Cap nut 1 0680 00 Cover hood Malfunctions repairs BA H2A KYY...

Page 73: ...briefly exceeded by a multitude Caution Sticking of the pump Clean the pump suitably after decommissioning See Chapter 8 Page 37 11 3 Temporary decommissioning Perform the following steps 1 Close the...

Page 74: ...12 Appendix Appendix BA H2A KYY 001 GB_2 74 27 02 2018...

Page 75: ...12 1 Certificate of non objection Appendix Certificate of non objection BA H2A KYY 001 GB_2 27 02 2018 75...

Page 76: ...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 avail...

Page 77: ...Appendix BA H2A KYY 001 GB_2 27 02 2018 77...

Page 78: ...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...

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