GEA NOVALOBE 10 Operating Instruction
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GEA NOVALOBE 10 Operating Instruction

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Hygienic Pumps
GEA Hilge NOVALOBE 10 - 50
Operating instruction (Translation from the original language)
BA.280.YYY.001.GB_4

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Summary of Contents for GEA NOVALOBE 10

  • Page 1 Hygienic Pumps GEA Hilge NOVALOBE 10 - 50 Operating instruction (Translation from the original language) BA.280.YYY.001.GB_4...
  • Page 2 (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. LEGAL NOTICE These instructions are part of the technical documentation, which is part of the scope of delivery.
  • Page 3 – unintended operation and usage conditions, – insufficient maintenance, – improper operation, – incorrect 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.
  • Page 4 SYMBOLS USED Danger Stands for an immediate danger which leads to heavy physical injuries or to the death. Warning! Stands for a possibly dangerous situation which leads to heavy physical injuries or to the death. Caution! Stands for a possibly dangerous situation which could lead to light physical injuries or to damages to property.
  • Page 5 LAYOUT INFORMATION Bullet points and numbered list characters Bullet points are used to separate logical contents within a section: • Bullet point 1 Types of bullet point 1. • Bullet point 2 Types of bullet point 2. Numbered list characters are used to separate enumerations within a descriptive text: Descriptive text with consecutive numbering: –...
  • Page 6 BA.280.YYY.001.GB_4 21.02.2022...

  • Page 7: Table Of Contents

    TABLE OF CONTENTS General Information about this document Manufacturer address Customer service EU Declaration of Conformity for Machines Safety Intended use 2.1.1 Pumped fluids Abrasive media Maximum particle size in the pumping medium 2.1.2 Connections and piping 2.1.3 Switching frequency 2.1.4 Types Safety precautions in these operating instructions...
  • Page 8 Special personnel qualification 10.2 Safety instructions 10.3 Malfunctions and remedies 10.4 Repair 10.4.1 Repair order 10.4.2 NOVALOBE 10-50 parts overview 10.4.3 Gear unit parts overview 10.4.4 Installation instructions 10.4.5 Installation instructions Cleaning the components before assembly 10.4.6 Seal variants 10.4.7 Disassemble rotors and mechanical seals 10.4.8...

  • Page 9: General

    Types, technical data and spare part numbers are subject to technical change. We reserve the right to implement changes due to technical progress. 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...

  • Page 10: Eu Declaration Of Conformity For Machines

    EU Declaration of Conformity for Machines in accordance with the EC Machinery Directive 2006/42/EC, Annex II 1. A Manufacturer: GEA HILGE Office of GEA Tuchenhagen GmbH Hilgestrasse 37-47 D 55294 Bodenheim Germany We declare under our sole responsibility that the machine...

  • Page 11: Safety

    Safety Intended use Safety Intended use Warning! Non-intended use! ► Pump only media that are specified in the order. The pump has been specially designed for them. ► Operate the pump only on the electrical grid that was specified in the purchase order.

  • Page 12: Switching Frequency

    Safety Safety precautions in these operating instructions 2.1.3 Switching frequency Do not exceed a switching frequency of 15 switching operations per hour. 2.1.4 Types All information and descriptions in these operating instructions on the use and handling of the pumps refer exclusively to the standard versions. Special designs and customised deviations as well as random external influences in the use and operation are not included in this provision.

  • Page 13: Explanation Of The Safety Symbols Used

    Safety Explanation of the safety symbols used Explanation of the safety symbols used Danger Stands for an immediate danger which leads to heavy physical injuries or to the death. ► Description to avert the danger Warning! Stands for a possibly dangerous situation which leads to heavy physical injuries or to the death.

  • Page 14: Dangers Of Non-Compliance With Safety Information

    Safety Unauthorised modification and ordering of spare parts Warning! Hazardous materials Contact with dangerous substances, e.g. by inhalation. ► Discharge the leakage of dangerous goods such that no danger to persons and the environment arises! ► Comply with legal provisions! ►...

  • Page 15: Staff Qualifications And Training

    Safety Staff qualifications and training Staff qualifications and training The staff for working on and with the pump must have the appropriate qualifications. Responsibilities, competencies and supervision of staff must be clearly defined by the operating company. If personnel do not have the necessary knowledge, they are to be trained and instructed.

  • Page 16: Description

    Description Pump overview Description Pump overview Fig.1: Schematic representation of NOVALOBE Fig.2: Schematic representation of NOVALOBE on trolley Pump overview of NOVALOBE 10-50 Item Description Item Description Suction/discharge port Suction/discharge port Flush port Oil gauge glass Gear Oil inlet/outlet vent valve...

  • Page 17: Pump Name

    Operating poles MW: Multi-wing [kW] point Nameplate GEA Hilge Niederlassung der GEA Tuchenhagen GmbH Hilgestrasse - D - 55294 Bodenheim Pump-Type: Ser.-No.: TAG No.: YOM: Made in Germany Fig.3: Nameplate Pump type: Pump name TAG No.:customer name Serial No.: Serial number...
  • Page 18 Description Note: The nameplate may differ from the presented layout. BA.280.YYY.001.GB_4 21.02.2022...

  • Page 19: Transport And Storage

    Transport and Storage Special personnel qualification for transport and storage Transport and Storage Special personnel qualification for transport and storage Transports may only be carried out by qualified staff, who must observe the safety instructions. Safety precautions for transport and storage Warning! Danger from packaging material with sharp edges! ►...

  • Page 20: Dimensions / Weights

    These net weights are based on pumps: – without gear motor – without coupling – without base frame – with DIN 11851 threaded connection NOVALOBE 10-50 Size Weight [kg] NOVAlobe 10 10.9 NOVAlobe 20 21.9 NOVAlobe 30 48.7 NOVAlobe 40...

  • Page 21: Disposal Of Packaging Material

    Transport and Storage Disposal of packaging material • If the pump is not used immediately, proper storage conditions are as important for later operation as careful installation and proper maintenance. • During storage, the pump should be turned by hand at least once a month. Parts such as shaft and bearings should change their position.

  • Page 22: Technical Data

    Technical data Serial number Technical data The operating safety of the delivered machine is only guaranteed if the machine is used as intended according to the sections of the operating instructions and the purchase order. Warning! Overload of the pump! ►...

  • Page 23: Pressures And Temperatures For Heatable Components

    Pressures and temperatures for heatable components – Type of mechanical seal. – Application (speed, viscosity, etc.) Size max. operating pressure NOVALOBE 10-50 16 bar Size max. differential pressure NOVALOBE 10-50 16 bar Pressures and temperatures for heatable components The table shows the permissible pressures and temperatures for NOVALOBE heatable components.

  • Page 24: Gap Dimensions

    Technical data Gap dimensions Gap dimensions Fig.4: Measuring points of the gap dimensions for single and multi-leaf designs Gap dimensions of NOVALOBE [mm] Measuring points Rotor/pump housing Rotor/pump housing Pump size Rotor/back plate inside outside 10 / 0.06 0.10 - 0.12 0.07 - 0.12 0.12 - 0.15 20 / 0.12...

  • Page 25: Position Of Oil Sight Glass, Locking Screws And Bleed Valve

    Item 6 and 7 Item 5 Nozzle position horizontal vertical high speed [rpm] speed [rpm] speed [rpm] NOVAlobe 10 10 - 650 651 - 800 10 - 800 NOVAlobe 20 10 - 500 501 - 800 10 - 800 NOVAlobe 30...

  • Page 26: Assembly And Installation

    Assembly and installation Safety precautions for setup, installation, and connection Assembly and installation Safety precautions for setup, installation, and connection Warning! Mechanical overload! ► Do not use the pump and its connection port as support for the pipeline. (EN 809 5.2.1.2.3 and EN ISO 14847). ►...
  • Page 27 Assembly and installation Safety precautions for setup, installation, and connection Caution! Vibration! ► Ensure stable construction for mounting of the pump and piping. Insufficiently stiffened substructures may cause an overall structure capable of oscillating, which is excited to oscillate by hydraulic and/or motor forces during changing operating conditions in the system.

  • Page 28: Special Personnel Qualification

    The shaft must be rotatable without the rotors rubbing. If a rotor rubs against something, it has some damage that may have happened during transport of the pump. If the rotors rub: Contact the GEA Hilge service. If the rotors rotate freely: Reattach the coupling guard.

  • Page 29: Aligning The Coupling

    Assembly and installation Setup, installation, and connection Align the unit horizontally over the machined flat surfaces of the connecting pieces with a machine spirit level parallel to the motor axis. After aligning the unit, tighten the fastening screws evenly in a crosswise sequence (where applicable).

  • Page 30: Adjusting The Coupling Via The Set-Up

    Assembly and installation Setup, installation, and connection 6.3.3.1 Adjusting the coupling via the set-up Fig.8: Alignment of the pump shaft to the drive shaft The correct adjustment of the coupling is done by aligning the pump shaft to the drive shaft. Alignment is possible in the range from -0.5 mm to +1 mm. For this, perform the following steps: Loosen the connection of the feet to the base or to the trolley.

  • Page 31: Permissible Displacement Values For Flender Couplings

    Assembly and installation Setup, installation, and connection 6.3.3.2 Permissible displacement values for Flender couplings Permissible displacement values for Flender B / BDS coupling Axial offset type B Outer diameter of the coupling (da) Size of type B max. axial displacement [mm] (clearance) Axial offset type BDS Outer diameter of the coupling...

  • Page 32: Installation In The Piping System

    Assembly and installation Setup, installation, and connection Torques and clearances for types B / BDS 0904.01 0904.00 Fig.9: Coupling N-EUPEX, clearance S Torques and clearances for types B / BDS Size of type B Size of type BDS Clearance S [mm] Threaded pin DIN EN ISO 4029 (serrated cup point)

  • Page 33: Using The Mechanical Seal

    Assembly and installation Setup, installation, and connection 6.3.4.1 Using the mechanical seal For perfect operation, mechanical seals require a lubrication film in the sealing 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.

  • Page 34: Flush Ports

    Assembly and installation Setup, installation, and connection The effect on the environment is subjective and depends largely on the correct installation and the nature of the rest of the remaining system. Foundation Vibration damping is best achieved if the pump is set up on a flat, solid concrete foundation.

  • Page 35: Connecting The Flushing

    Assembly and installation Setup, installation, and connection The simple flushed mechanical seal is suitable for applications where media tend to crystallise or harden on contact with the atmosphere. Double mechanical seal The double mechanical seal can be operated with flushed pressure below the pump pressure.

  • Page 36: Delta Connection

    Assembly and installation Setup, installation, and connection Connect the pump according to the ordering information. The following figure shows the wiring diagram of the star connection. Fig.14: Star connection 6.3.6.2 Delta connection Delta connection for low voltage. Connect the pump according to the ordering information. The following figure shows the wiring diagram of the delta connection.

  • Page 37: Checking The Direction Of Rotation After Connecting

    Assembly and installation Setup, installation, and connection Notice Incorrect operation of the frequency converter! ► Follow the manufacturer's instructions to install and operate a frequency converter. 6.3.6.4 Checking the direction of rotation after connecting Perform the following steps: Re-install all safety devices. Connect flushed mechanical seal for flushing or blocking medium (See Section 6.3.5.3, Page 35) Check that hydraulic connections are firmly secured.
  • Page 38 Assembly and installation Because the rotary pistons rotate in different directions, the increased volume between the rotary pistons creates a vacuum that draws the pumping medium into the pump. Fig.16: Procedure step 1 The pumping medium is enclosed between the rotary piston and pump housing and is conveyed to the outlet.

  • Page 39: Commissioning

    Commissioning Special personnel qualification Commissioning Special personnel qualification The commissioning personnel must be suitably qualified for this work. See also Section 2.6, Page 15. Safety instructions for commissioning Warning! Danger by conveying against a closed shut-off valve. Rapid heating and sudden pressure increase. ►...

  • Page 40: Functional Testing Of The Mechanical Seal

    Commissioning Operation with control unit for pumps on trolley If there is no increase of delivery head after commissioning: Switch off the pump. Again vent the pump (system). Repeat steps 7 to 10 and note section on Disruptions and Assistance for Disposal .

  • Page 41: Cleaning

    Cleaning Special personnel qualification Cleaning To ensure the quality of sensitive fluids, pumps must be cleaned immediately after each use. Only in this way will adhesions and deposits be removed completely and contamination of the products be prevented. To achieve the best possible results, Hilge pumps are optimised with regard to gap and dead spaces, designed according to DIN EN 13951, and resistant to the cleaning agents referred to in the following chapter.

  • Page 42: Cip

    Cleaning Warning! Pressure shock by evaporating liquid! ► Completely empty the system before steam sterilisation. Notice Disposal of cleaning agents ► Dispose of cleaning agents properly and in an environmentally friendly way. CIP stands for Cleaning in Place, the pump is completely rinsed with cleaning agents.

  • Page 43: Sip

    Cleaning SIP stands for sterilisation in place, in which the pump is sterilised with superheated steam. For steam sterilization or sanitization, minimum temperatures of 121 ° C (250 ° F) must be applied to all wetted surfaces. The maximum permissible temperatures can be obtained from the section technical data.

  • Page 44: Maintenance / Servicing

    Maintenance / servicing Safety instructions for maintenance and servicing Maintenance / servicing Safety instructions for maintenance and servicing Warning! Improper execution of work! ► Maintenance and inspection should be carried out by authorised and qualified personnel. Warning! Danger from tilting / toppling over of the pump! ►...

  • Page 45: Gear Lubrication

    Maintenance / servicing Pump maintenance – The O-ring is deformed at one or more locations. – The O-ring has cracks. – The surface of the O-ring is porous and brittle. – The O-ring has lost its elasticity. 9.3.2 Gear lubrication 9.3.2.1 Relubrication interval Relubrication interval Oil temperature...

  • Page 46: Information On The Gear Unit Nameplate

    Maintenance / servicing Maintenance of the motor 9.3.2.4 Information on the gear unit nameplate Fig.19: Nameplate (example) Gear motor nameplate Designation Manufacturer Gear unit type Operating mode Year of manufacture Serial number Rated torque of the gear output shaft Drive power Weight according to order execution Total gear ratio Installation position...
  • Page 47 Maintenance / servicing Fig.20: Motor nameplate Nameplate designations 1 - QR code 13 - Permissible voltage range 3 - Number of phases 15 - Power factor 4 - Type designation 16 - Speed 5 - Order number/motor number 17 - Explosion protection code 6 - Year of manufacture 18 - Locked rotor current/rated current 7 - Thermal class insulation system...

  • Page 48: Malfunctions / Repairs

    Malfunctions / repairs Special personnel qualification Malfunctions / repairs 10.1 Special personnel qualification The troubleshooting / repair personnel must be suitably qualified for this work. See also Section 2.6, Page 15. 10.2 Safety instructions Warning! Improper execution of work! ► Repair work should be carried out by authorised and qualified personnel. Danger Electric shock by touching live parts! ►...

  • Page 49: Malfunctions And Remedies

    Malfunctions / repairs Malfunctions and remedies Caution! Unsuitable tools! ► Make sure that all the parts can be mounted without damage. ► Use GEA Hilge assembly tools. 10.3 Malfunctions and remedies Actions for troubleshooting Malfunction Cause Remedy Pump does not Incorrect electrical connection (2 phases).

  • Page 50: Repair

    Malfunctions / repairs Repair Actions for troubleshooting Malfunction Cause Remedy Leakage in the Pump is strained (causing leaks at the pump body Install pump without strain, support piping by fixed pump body, the or at the connections). points. connections, the mechanical seal.

  • Page 51: Novalobe 10-50 Parts Overview

    Malfunctions / repairs Repair 10.4.2 NOVALOBE 10-50 parts overview NOVAlobe 30 0101.01 0904.09 0504.10 0412.58/59 0433.02 0906.01/02 0560.13 0412.60 0818.00 0329.00 0906.01 0412.58 0412.54 0161.01 0433.03 0927.06 0902.21 0560.14 0818.01 0329.01 0906.02 0412.59 Fig.21: NOVALOBE 10-50 parts overview Fig.22: Mechanical seal torsion protection...

  • Page 52: Gear Unit Parts Overview

    Malfunctions / repairs Repair 10.4.3 Gear unit parts overview 0914.00 0913.00 0411.04 0904.00 0871.02 0411.05 0903.09 0504.06 0504.05 0940.02 0328.00 0328.01 0421.07 0213.00 0504.02 0504.01 0642.00 0411.05 0411.01 0871.01 0504.08 0903.08 0504.07 0328.02 0421.09 0328.03 0210.00 0560.00 0504.04 0504.03 0412.53 0421.08 0560.01 Fig.23:...

  • Page 53: Installation Instructions

    ► Always replace mechanical seals completely. ► To tighten the rotor bolts 0906.01 / 02, use the original GEA-Hilge wrench and lock screw ► Check removed parts for damage and wear, and replace if necessary.

  • Page 54: Cleaning The Components Before Assembly

    Malfunctions / repairs Repair 10.4.5.1 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-rings or the mechanical seal. Use a brush and / or other tools in order not to damage the surface.
  • Page 55 Malfunctions / repairs Repair A: Single mechanical seal, B: Single mechanical seal, flushed, C: Double mechanical seal D: Single O-ring seal, E: Double O-ring seal Fig.25: NOVALOBE mechanical seal variants 1 - slide ring (rotating) 8 -- O-ring 15 -- O-ring 2 - set ring 9 -- O-ring 20 - seal carrier for O-ring...

  • Page 56: Disassemble Rotors And Mechanical Seals

    Malfunctions / repairs Repair 10.4.7 Disassemble rotors and mechanical seals Tools and equipment: • Klüber paste UH1 96-402 • Puller for mechanical seals • Lock screw (included with delivery) • Socket wrench for rotor bolts Contact for tool order: Section 1.3, Page 9. Fig.26: Puller for mechanical Fig.27:...
  • Page 57 Malfunctions / repairs Repair Disassemble rotors and mechanical seals Fix the rotors with the lock screw and remove the rotor bolts (0906.01/02) with the socket wrench. Fig.31: Use of lock screw and socket wrench Remove the rotor bolts (0906.01/02) and the O- rings (0412.58/59).
  • Page 58 Malfunctions / repairs Repair Disassemble rotors and mechanical seals Remove the o-ring (item 8, Figure 25, Page 55, B). Fig.35: O-ring Press the dowel pins (0329.00/01) out of the rotor units (0818.00/01). Fig.36: Dowel pins Remove the o-ring (item 9, Figure 25, Page 55, B). Fig.37: O-ring Remove the mechanical seals (0433.02/03) with...
  • Page 59 Malfunctions / repairs Repair Disassemble rotors and mechanical seals Remove the set ring (item 2, Figure 25, Page 55, Fig.39: Set ring Remove the O-ring (item 7, Figure 25, Page 55, B) from the set ring. Fig.40: O-ring Remove the seal carrier (item 3, Figure 25, Page 55, B).
  • Page 60 Malfunctions / repairs Repair Disassemble rotors and mechanical seals Remove the O-ring (item 15, Figure 25, Page 55, B) from the radial packing ring Fig.43: O-ring, radial packing ring Remove the O-ring (item 6, Figure 25, Page 55, B) from the shaft. Fig.44: O-ring →...

  • Page 61: Install Mechanical Seals And Rotors

    Malfunctions / repairs Repair 10.4.8 Install mechanical seals and rotors Tools and equipment: • Klüber paste UH1 96-402 • Klüber paste NH1 87-703 HYG • Loctite 248 threadlocker • Mounting sleeve for seal carrier • Lock screw, see Figure 27, Page 56 •...
  • Page 62 Malfunctions / repairs Repair Install mechanical seals and rotors Grease the O-ring (item 15, Figure 25, Page 55, B) with Klüber paste NH1 87-703 HYG. Fig.48: O-ring, seal carrier Grease the seal carrier of the flushed mechanical seal (item 3, Figure 25, Page 55, B) with Klüber paste NH1 87-703 HYG.
  • Page 63 Malfunctions / repairs Repair Install mechanical seals and rotors Press the mechanical seals into the correct positions on the output shaft (0210.00) and drive shaft (0213.00). Fig.52: Mechanical seal, drive shaft Hint! The grooves in the seal carrier must stand together at a 90 °...
  • Page 64 Malfunctions / repairs Repair Install mechanical seals and rotors Press the o-ring (item 9), Figure 25, Page 55, B of the seal carrier into position. Fig.56: O-ring, seal carrier Grease the inner surfaces of the rotors (0818.00 / 01) with Klüber paste UH1 96-402. Insert the dowel pins (0329.00) into the rotors.
  • Page 65 Malfunctions / repairs Repair Install mechanical seals and rotors Grease the contact surfaces between the rotors and the output shafts (0210.00 / 0213.00) with Klüber paste UH1 96-402. Fig.60: Output shafts Slide the rotors onto the output shafts (0210.00) and (0213.00). Fig.61: Rotor, output shaft Grease the contact surfaces between the rotors...
  • Page 66 Malfunctions / repairs Repair Install mechanical seals and rotors Grease the threads of the rotors (0906.01 / 02) with Klüber paste UH1 96-402. Screw the rotor bolts into the output shafts (0210.00) and (0213.00). For NL40 or NL50, the M20/M24, threads in the shafts must be cleaned from the old threadlocker.

  • Page 67: Torques For Installation

    If the rotors or the pump housing are replaced, note the permissible gap dimensions in Section 5.8, Page 24. If the distances do not match the given values, contact GEA Hilge Service (Section 1.3, Page 9). Fig.67: Back plate Use the cap nuts (0161.01) to attach the pump housing (0927.06) to the back plate (0101.01).

  • Page 68: Decommissioning

    → 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. BA.280.YYY.001.GB_4 21.02.2022...

  • Page 69: Appendix

    Appendix Assembly instructions for pumps with free shaft end Appendix 12.1 Assembly instructions for pumps with free shaft end These assembly instructions refer to pumps without motor and without base. 12.1.1 Special personnel qualification The assembly personnel must be suitably qualified for this work. See also Section 2.6, Page 15.
  • Page 70 Appendix Assembly instructions for pumps with free shaft end Alignment of the pump shaft to the gear motor shaft Carry out the alignment of the coupling according to the assembly instructions of the selected coupling manufacturer. The correct adjustment of the coupling is done by aligning the pump shaft to the drive shaft.

  • Page 71: Certificate Of Non-Objection

    Appendix Certificate of non-objection 12.2 Certificate of non-objection BA.280.YYY.001.GB_4 21.02.2022...
  • Page 72 Appendix Certificate of non-objection This section contains a certificate of non-objection. In the event of inspection or repair send the pump including this certificate to HILGE. Certificate of non-objection The following pump and its accessories, together with this certificate of non-objection, are herewith contracted out by the undersigned for inspection/repair: Pump data •...
  • Page 73 Appendix BA.280.YYY.001.GB_4 21.02.2022...
  • Page 74 • GEA is a global technology company with multi-billion euro sales operations in more than 50 countries. Founded in 1881 the company is one of the largest providers of innovative equipment and process technology. GEA is listed in the STOXX ®...

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