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Summary of Contents for GEA NEMA/3-A
- Page 1 Hygienic Pumps GEA Hilge TP (NEMA / 3-A) Operating instruction (Translation from the original language) 430BAL012563EN_3...
- Page 2 Nothing contained in this documentation may be reproduced or distributed in any form (print, photocopy, microfilm or another method) without the prior written permission of GEA Hilge Niederlassung der GEA Tuchenhagen GmbH hereinafter referred to as Manufacturer This restriction also applies to the drawings and diagrams included in the documentation. 430BAL012563EN_3...
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Page 3: Table Of Contents
TABLE OF CONTENTS General Information Information on the Document 1.1.1 Binding Character of These Operating Instructions 1.1.2 Notes on the Illustrations 1.1.3 Symbols and Highlighting Manufacturer address Customer service Confirmation of FDA compliance Safety Intended use 2.1.1 Requirements for operation 2.1.2 Improper operating conditions Operator’s Duty of Care... - Page 4 9.1.1 Cleaning Process Examples 9.1.2 Cleaning effect Steam sterilization Manual exterior cleaning Maintenance 10.1 Safety instructions 10.2 Inspections 10.2.1 Replacement of O-rings 10.3 Maintenance intervals 10.4 Prior to disassembly 10.5 Disassembly 10.5.1 Removing the pump cover and impeller 10.5.2 Removing the single-acting mechanical seal EW 10.5.3 Removing the single-acting flushed mechanical seal QU 10.5.4...
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Page 5: General Information
General Information Information on the Document General Information Information on the Document The present Operating Instructions are part of the user information for the product. The Operating Instructions contain all the information you need to transport, install, commission, operate and carry out maintenance for the product. 1.1.1 Binding Character of These Operating Instructions These Operating Instructions contain the manufacturer's instructions to the... -
Page 6: Manufacturer Address
Result of the previous operation. ® The operation is complete, the goal has been achieved. Hint! Further useful information. Manufacturer address GEA Hilge Niederlassung der GEA Tuchenhagen GmbH Hilgestraße 37-47 55294 Bodenheim Germany Phone +49 6135 7016-0 Fax +49 6135 1737 hilge@gea.com gea.com... -
Page 7: Confirmation Of Fda Compliance
General Information Confirmation of FDA compliance Phone +49 6135 7016101 (Service) spareparts.hilge@gea.com Confirmation of FDA compliance Fig.1 430BAL012563EN_3 23.10.2019... -
Page 8: Safety
Intended use Safety Intended use GEA Hilge Centrifugal Pumps TP with NEMA standard motor are suitable for the proper hygienic conveyance of biologically complex and expensive liquids up to a viscosity of 1000 mPas = 1000 cP. Therefore they can be used as product pumps in the food industry, pharmaceutical industry and as cleaning agent pumps in CIP cleaning circuits. -
Page 9: Subsequent Changes
No technical modifications should ever be made to this pump. Otherwise, you will have to re-conduct the conformity assessment/risk assessment in accordance with applicable national directives. Only original spare parts from GEA should be installed. This ensures that the pump is always operating properly and efficiently. General safety instructions and dangers The pump is safe to operate. -
Page 10: Principles For Safe Operation
Safety General safety instructions and dangers • the pump is operated under impermissible conditions. 2.4.1 Principles for safe operation Dangerous situations during operation can be avoided by safety-conscious and proactive behaviour of the personnel. The following principles apply for safe operation of the pump: •... -
Page 11: Supplementary Regulations
Safety Supplementary Regulations Supplementary Regulations In addition to the instructions in this documentation the following also has to be observed: • pertinent accident prevention regulations, • generally accepted safety rules, • national regulations applicable in the country of use, • work and safety instructions applicable in the facility, •... -
Page 12: Safety Equipment
Safety Safety equipment User groups Personnel Qualifications Operating personnel Adequate instruction and sound knowledge in the following areas: • Functionality of the pump • Operating sequences on the pump • What to do in case of an emergency • Lines of authority and responsibilities with respect to the task Maintenance personnel Appropriate training and a sound knowledge of the structure and functionality of the pump. -
Page 13: Residual Dangers
Safety Residual dangers Signs on the pump Sign Meaning General hazard warning Fig.3 Warning Crushing Fig.4 Explosive atmosphere hazard warning Fig.5 Residual dangers Dangerous situations can be avoided by safety-conscious and proactive behaviour of the personnel and by wearing personal protective equipment. Residual hazards on the pump and preventative measures Danger Cause... -
Page 14: Danger Zones
Safety Danger zones Residual hazards on the pump and preventative measures Danger Cause Measure Danger of injury Danger presented by The operator must moving or sharp-edged exercise caution and parts prudence. For all work: • Wear suitable work clothing. • Never operate the machine if the cover panels are not... - Page 15 Safety Fig.6 • In case of malfunction, take the pump out of service (separate from the power supply) and secure against restarting. • Never touch the lantern (5), the fan housing of the motor (60), the suction (S) or the pump discharge nozzle (D) while the pump is running. Fingers can be crushed or cut off.
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Page 16: Description
Description Design Description Design Fig.7: Pump TP - Standard The pump consists of the following parts: • Pump housing (4), pump cover (3), motor stool (5) • Impeller (1), shaft (7), cap nut (9) • A three-phase asynchronous motor (60) •... -
Page 17: Motor Versions
Description Motor versions The centrifugal pump TP has normal suction. It requires the constantly supply of fluid on the suction nozzle. The impeller with its blades curved backward, rotates in the pump at the speed of the motor. The rotation of the impeller transmits energy in the form of centrifugal forces and speed increases to the conveying medium which is then pumped from the discharge nozzle. -
Page 18: Transport And Storage
Transport and storage Storage conditions Transport and storage Storage conditions The storage facility must be covered and well-ventilated. Avoid high humidity. The pump must be drained at temperatures below the freezing point. Transport Fig.8 For transport, the following principles apply: •... -
Page 19: Scope Of Supply
Externally visible transport damage and / or missing packages must be indicated immediately on the freight note with the delivering forwarder. Written recourse must be taken immediately against the freight forwarder by the recipient and GEA must be informed about the process. Claims must be submitted within 6 days to the freight forwarder for transport damage that is not recognized immediately. -
Page 20: Technical Data
Technical data Type plate Technical data Type plate The identification plate is used to distinctly identify the pump. GEA Tuchenhagen GmbH Am Industriepark 2-10, 21514 Büchen, Germany Type Motor Order Year Serial Fig.9: Type plate sample The type plate provides the following key data:... -
Page 21: Materials - Product Contacting
SIC/SIC. Gaskets /seals EPDM / FKM 5.2.3 Motor Motors used must be specially designed for axial loads and axial clearance and must meet the GEA Tuchenhagen requirements profile. Power range Power range Operating voltage [hp] [hp] Size... -
Page 22: Specific Operating Data - Nominal Values
Technical data Technical data Power range Power range Operating voltage [hp] [hp] Size Motor (standard)* (2-pin) (4-pin) TP 8080 15.0 … 50.0 5.0 … 10.0 TP 16040 15.0 … 60.0 3.0 … 10.0 * Observe different operating voltages if the motors deviate from the standard 5.2.4 Specific operating data - nominal values 60 Hz / 3500 rpm... -
Page 23: Resistance Of Sealing Materials
Technical data Resistance of Sealing Materials Maximum allowable working pressure Switching Permissible maximum (MAWP) = feed pressure pressure feed pressure Size + max. output pressure nominal (pump) [bar] [psi] [bar] [psi] [dB(A)] TP 8050 TP 8080 TP 16040 Dynamic viscosity max. -
Page 24: Lubricants
Technical data Lubricants 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 177.2600 or FDA 21 CFR 177.1550. -
Page 25: Weights
Technical data Weights 430BAL012563EN_3 23.10.2019... -
Page 26: Torques
Technical data Torques Torques Torques of the cap nuts and parts Tighten the cap nuts and parts to the torques specified in the table. Torques [Nm] Pump cover (48) Lantern (47) Cap nut (58) Size TP 1020 17.5 TP 2030 TP 1540 TP 2050 TP 3050... - Page 27 Technical data Torques of the pump shaft Torques Cylinder screw (51) [Nm] [ft lb] 430BAL012563EN_3 23.10.2019...
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Page 28: Assembly And Installation
Assembly and installation Safety instructions Assembly and installation Safety instructions Hazardous situations during installation can be avoided by safety-conscious and proactive behaviour of the personnel. For installation, the following principles apply: • Only qualified personnel are allowed to set-up, install and commission the pump. -
Page 29: Installing The Pipelines
Assembly and installation Installing the pipelines Fig.11: 3-A stand Dimension B: min. 4" (102 mm) Screw-in depth of feet Notice Hygiene risk, food safety Feet that are not sealed correctly leave room for invisible impurities. ► Screw the feet in so far that the O-ring is positioned on the smooth counterpart. -
Page 30: Connecting The Motor
Assembly and installation Connecting the motor Zero delivery head of the pump (bar) + feed height / system pressure / steam pressure (bar) + density of the feed medium(t/m Only operate the pump during ongoing flushing. ® Pipeline is installed. Connecting the motor Danger Risk of injury / risk of material damage... -
Page 31: Checking The Direction Of Rotation
Follow the instructions on the type plate or in the terminal box of the respective motor when connecting it. The GEA motor standard includes a thermostat for thermal monitoring. If necessary, these are connected accordingly for frequency converter operation. For this purpose there are 2 connections in the terminal box, which may appear different depending on the motor manufacturer. -
Page 32: Checking The Sealing Liquid
Assembly and installation Checking the sealing liquid ® The direction of rotation is seen from the motor to the pump is clockwise. Check the direction of rotation of the fan wheel after the protective cover is removed. ® Direction of rotation is checked. Hint! Make sure to check the tightening torque of the cap nut on the impeller if the pump has been started in the wrong direction of... -
Page 33: Start-Up
Start-up Safety instructions Start-up Safety instructions Initial commissioning For initial commissioning, the following principles apply: • Take protective measures against dangerous contact voltages in accordance with pertinent regulations. • The pump must be fully assembled and properly adjusted. All screw connections must be securely tightened. -
Page 34: Operation And Control
Operation and control Safety instructions Operation and control Safety instructions Dangerous situations during operation can be avoided by safety-conscious and proactive behaviour of the personnel. For operation, the following principles apply: • Monitor the pump during operation. • Safety devices must not be changed, removed or taken out of service. Check all safety devices at regular intervals. -
Page 35: Cleaning
Cleaning Cleaning Cleaning Cleaning All parts in contact with product must be cleaned at regular intervals. Always observe the safety data sheets issued by the cleaning agent manufacturers. Only cleaning agents may be used which do not damage the seals and the interior parts of the pump. -
Page 36: Steam Sterilization
Cleaning Steam sterilization Steam sterilization A steam sterilization of the pumps GEA Hilge TP and TPS is possible under the following conditions: • Pumps with encapsulated mechanical seal type SHJ (EW, QW, DW) • The pump may not be operated during steam sterilization •... -
Page 37: Maintenance
Maintenance Safety instructions Maintenance 10.1 Safety instructions Maintenance and repair Before carrying out maintenance work and repairs to electrical devices on the pump, the following steps must be carried out according to the "5 safety rules": • Isolate from the power supply •... -
Page 38: Inspections
Inspections The pump is maintenance-free for the most part. In order to prevent possible malfunctions, 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. -
Page 39: Prior To Disassembly
Maintenance Prior to disassembly • type and temperature of the cleaning solution, • ambient conditions. Maintenance Intervals Maintenance intervals Applications (guideline values) Media at temperatures of 60 °C to 130 °C approx. every 3 months (140 °F to 266 °F) Media at temperatures of <... - Page 40 Maintenance Disassembly Fig.13: Pump TP Requirement: • Pump motor is disconnected from the power supply • Pump has been removed from the pipeline, drained and cooled down to room temperature. Carry out the following steps: Check the gaskets (suction and discharge nozzles) and replace them necessary.
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Page 41: Removing The Single-Acting Mechanical Seal Ew
Maintenance Disassembly 10.5.2 Removing the single-acting mechanical seal EW Fig.14: Mechanical seal EW (A) with detail drawing If there are leaks or wear on the mechanical seal, remove and replace it. Notice The pump shaft (7) is a sensitive component. Damage to this part can result in malfunctions. -
Page 42: Removing The Single-Acting Flushed Mechanical Seal Qu
Maintenance Disassembly 10.5.3 Removing the single-acting flushed mechanical seal QU Fig.15: Single-acting flushed mechanical seal QU (A) with detail If there are leaks or wear on the mechanical seal, remove and replace it. Notice The pump shaft (7) is a sensitive component. Damage to this part can result in malfunctions. - Page 43 Maintenance Disassembly Hint! The further disassembly of the pump is only necessary in certain cases, for example in the case of a defective motor. See chapter "Removing the pump from the motor". For installation, see chapter "Installation" ® Single-acting flushed mechanical seal QU (A) is dismantled. 430BAL012563EN_3 23.10.2019...
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Page 44: Removing The Double-Acting Mechanical Seal Dw
Maintenance Disassembly 10.5.4 Removing the double-acting mechanical seal DW Fig.16: Double-acting mechanical seal DW (A) with detail If there are leaks or wear on the mechanical seal, remove and replace it. Notice The pump shaft (7) is a sensitive component. Damage to this part can result in malfunctions. -
Page 45: Removing The Motor
Maintenance Disassembly Check driver ring (120.7) and O-ring (120.14) and replace them if damaged. Hint! The further disassembly of the pump is only necessary in certain cases, for example in the case of a defective motor. See chapter "Removing the pump from the motor". For installation, see chapter "Installation"... -
Page 46: Maintenance
The shaft protection sleeve is shrunk onto the pump shaft in the factory. If the shaft protection sleeve can not be pulled off, it is advisable to contact the GEA service department in this case. Dispose of used mechanical seal parts appropriately or return them to GEA. ® Done 10.6.3... -
Page 47: Prior To Installation
Installing the motor Before installation, it is important to ensure that a motor is used in accordance with the GEA Tuchenhagen specification and that the required axial clearance and the permissible axial forces of the motor are maintained. Also make sure that the motor is equipped with an A-side fixed bearing. -
Page 48: Installing The Mechanical Seal
To reduce friction during installation, lubricate all sliding surfaces for O-rings with silicone grease. • GEA recommends Rivolta F.L.G. MD-2, PARALIQ GTE 703 and grease BARRIERTA L 55/3*. These lubricants are approved for foodstuff and are resistant to beer froth. They have the NSF-H1 (USDA H1) registration. They... -
Page 49: 10.8.2.1 Installing The Single Slide-Ring Packing Ew
PARALIQ GTE 703 can be ordered under the material no. 413-064, Rivolta F.L.G. MD-2 under the material no. 413-071 and grease BARRIERTA L 55/3* under the material no. 413-137 from GEA. • Degrease the sliding surfaces of the mechanical seal before installation. -
Page 50: 10.8.2.2 Installing The Single-Acting Mechanical Seal, Flushed Qu
Maintenance Installation 10.8.2.2 Installing the single-acting mechanical seal, flushed QU Fig.21: Single-acting mechanical seal, flushed QU, with detail drawing Observe the following instructions when installing the mechanical seal: • The 2 flushing holes (S) must be in a vertical alignment so that the air can escape from the flushing chamber. -
Page 51: 10.8.2.3 Installing The Double-Acting Mechanical Seal Dw
Maintenance Installation 10.8.2.3 Installing the double-acting mechanical seal DW Fig.22: Double-acting mechanical seal DW with detail drawing Observe the following instructions when installing the mechanical seal: • The 2 flushing holes (S) must be in a vertical alignment so that the air can escape from the flushing chamber. -
Page 52: Converting The Mechanical Seal
We recommend having this carried out at GEA if these options are not available. • The existing mechanical seal EW can be used completely, if undamaged. -
Page 53: 10.8.3.2 Convert Single-Acting Mechanical Seal Ew To Double-Acting Mechanical Seal Dw
The press-fit is carried out the easiest by heating the driver ring (120.15) and by uniformly raising it with a suitable soft hollow mandrel, for example one made of brass. We recommend having this carried out at GEA if these options are not available. -
Page 54: Adjusting The Axial Gap
Maintenance Installation 10.8.4 Adjusting the axial gap Caution! If the axial gap is not adjusted correctly, the impeller may come in contact with the pump cover (3) and damage both parts. ► The axial gap (S1) between impeller (1) and pump cover (3) must be adjusted according to the table during each installation of the pump. - Page 55 Maintenance Installation Fig.26 Tools required: • Spacer disc for adjusting the axial gap (S1) Carry out the following steps: Insert the hexagon socket screwdriver (B) into the lantern hole (5.2) and turn the impeller (1) until the hexagon socket screwdriver (B) engages the hexagon socket head (51).
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Page 56: Installing The Pump Cover
Maintenance 10.8.5 Installing the pump cover Pump cover TP Fig.27: Pump TP Carry out the following steps: Grease O-ring (35) and install on the pump housing. Install the pump cover (3). Tighten all cap nuts (48) evenly crosswise with the specified torque, see Section 5.6, Page 26 Check the freedom of movement on the impeller (1). -
Page 57: Drainage Valve Vtp
Intended use - drainage valve VTP Drainage valve VTP 11.1 Intended use - drainage valve VTP The drainage valve VTP is used for residual draining (complete draining) of GEA Hilge centrifugal pumps. The drainage valve can be operated manually or pneumatically. 11.2... -
Page 58: Maintenance - Drainage Valve Vtp
Drainage valve VTP Maintenance - drainage valve VTP Malfunction Cause Remedy Drainage valve is not working Fault in the control system Check the system configuration No compressed air Check the compressed air supply Compressed air pressure too low Check air hoses for free passage and air tightness Fault in the electrical system Check the control / external regulator and... - Page 59 Drainage valve VTP Maintenance - drainage valve VTP Remove the spring-lock washer (17). Close the valve. Disconnect the air hose from the pneumatic connector (A). Disconnect the drainage hose - if present - to the drainage connection (B). Hint! The pressure spring (14) is preloaded. It must be carefully relaxed when the drive cover is loosened.
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Page 60: Technical Data - Drainage Valve Vtp
Technical data - drainage valve VTP Grease the parts. GEA recommends Rivolta F.L.G. MD-2, PARALIQ GTE 703 and grease BARRIERTA L 55/3*. These lubricants are approved for foodstuff and are resistant to beer froth. They have the NSF-H1 (USDA H1) registration. They do not affect the taste or the consistency of the products and are compatible with the seals in contact with product. - Page 61 Drainage valve VTP Technical data: Drainage valve VTP Designation Description Product temperature and Depending on the sealing material operating temperature Draining (pressure free) 1.2 l/min (0.32 gpm) Max. 16 bar (232 psi) during sealing Product pressure Max. 6 bar (87 psi) during opening Min.
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Page 62: Alarms
Alarms Malfunctions and remedies Alarms 12.1 Malfunctions and remedies In the event of a malfunction, the pump must be switched off immediately and secured against being switched back on. Malfunctions may only be remedied by qualified personnel, who must observe the safety instructions. Malfunction Cause Remedy... -
Page 63: Decommissioning
Decommissioning Safety instructions Decommissioning 13.1 Safety instructions For shutting down, the following principles apply: • Switch off the pump with the main switch. • Padlock the main switch (if fitted) in the off position to prevent it from being switched back on. The key to the padlock must be deposited with the person responsible until the machine is restarted. -
Page 64: Reworking Of Ew - Qu
Reworking of EW - QU Reworking of EW - QU GEA Hilge TP / TPS centrifugal pump Borehole for installation of the flushing unit for mechanical seal (single action, flushed) Use existing grain size (K) Fig.31: Sketch for setting threads to accommodate... -
Page 65: Appendix
Appendix Lists Appendix 15.1 Lists 15.1.1 Abbreviations and terms Abbreviation Explanation Unit of measurement for the speed 1/min Revolutions per minute Unit of measurement for the pressure All pressure data [bar] are for overpressure [bar ] unless this is specifically described otherwise. - Page 66 Appendix Abbreviation Explanation Unit of measurement for work Newton meter Torque specification 1 Nm = 0.737 lbft Pound-Force (lb) + Feet (ft) Holding pressure height (m) NPSH (Net Positive Suction Head) Single-acting flushed slide-ring packing (quench) Silicon carbide Molybdenum steel Indicates the size of spanners width across flats s.
- Page 67 Appendix 430BAL012563EN_3 23.10.2019...
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