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Summary of Contents for GEA CONTRA CN
- Page 1 GEA Hilge CONTRA CN Installation and operating instructions English Translation of the original operating manual BA.10A.CNY.001.03.17.GB engineering for a better world GEA Hilge...
- Page 2 Annex VII, Part B and we obligate to provide these upon reasoned request from the individual national authorities by data transfer. HILGE GmbH & Co.KG Authorized person for compiling and handing over Hilgestraße 37-47 technical documentation: 55294 Bodenheim, Germany Bodenheim, 2016-03-29 Franz Bürmann Managing Director GEA Hilge...
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Page 3: Table Of Contents
1. Introduction _________________________________________________ 5 1.1 Target group_________________________________________________________________5 1.2 Symbols and formatting ________________________________________________________5 1.3 References to the document ____________________________________________________5 2. Safety ______________________________________________________ 6 2.1 Instructions for the operator _____________________________________________________6 2.1.1 General information_______________________________________________________6 2.2 Safety instructions in the operating manual _________________________________________6 2.3 Identification of instructions in the operating manual __________________________________6 2.4 Qualifications and training of personnel ___________________________________________7 2.5 Hazards upon failure to follow the safety instructions _________________________________7 2.6 Safety-conscious work ________________________________________________________7... - Page 4 6.5 Assembly __________________________________________________________________ 35 6.5.1 Parts overview _________________________________________________________ 35 6.5.2 Instructions for assembly _________________________________________________ 37 6.6 Assembly of Contra CN _______________________________________________________ 38 6.6.1 Assembly of coupling and motor____________________________________________ 39 6.6.2 Mechanical seal arrangements_____________________________________________ 40 6.6.3 Different fixing of seal cartridge ____________________________________________ 41 6.6.4 Assembly of the single mechanical seal ______________________________________ 42...
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Page 5: Introduction
Introduction 1. Introduction Overview This section describes the requirements which are important for reading and understanding this manual. You will learn the symbols and formats that make the reading easier. 1.1 Target group This operating manual is intended for: • the operators of the pump and •... -
Page 6: Safety
Safety 2. Safety Overview This section describes what you have to consider for your own safety. You will learn the structure and identifica- tion of safety instructions. Read this important section attentively! 2.1 Instructions for the operator All our pumps are professionally packed before they leave our 2.1.1 General information warehouse to avoid damage during transport. -
Page 7: Qualifications And Training Of Personnel
Safety In order to classify the safety labels they are distinguished by Signal words the following signal words: • DANGER Characterises an imminent hazard with a high risk which can cause death or grievous bodily harm. • WARNING Characterises a possible hazard with medium risk which can cause death or bodily harm if it is not avoided. -
Page 8: Safety Instructions For The Operator / User
Safety 2.7 Safety instructions for the operator / user WARN ING Burn hazard from hot or cold mechanical components. Cold or hot mechanical components can cause severe injury. • Take structural measures to prevent contact with them! WARN ING Trapping hazard! Danger from rotating components. -
Page 9: Unauthorized Modifications And Production Of Spare Parts
Using incorrect lifting points is dangerous! Unsuitable lifting points may cause damage to the pump. • Fasten the rope to suitable lifting points. • Never fasten a rope to the pump casing or intake/dis- charge branch! Fig. 2 Attachment points for Contra CN BA.10A.CNY.001.01.10.GB... -
Page 10: Cleaning
Safety 2.11 Cleaning CIP and SIP methods must be in accordance with the latest current guidelines of the EC. When special cleaning agents and methods are used, the supplier must confirm that they are safe for the materials in- volved. WARN ING Danger from pressure surge! Liquids under high pressure can be forcibly ejected from the pump. -
Page 11: Product Description
Product description 3. Product description Overview This section describes the pump as well as it’s design and application. Section „Technical Data“ describes limits for application. You must know and keep these limits. 3.1 Pump Overview Fig. 3 Overview Contra • 0107 - discharge casing •... -
Page 12: Areas Of Application
Product description 3.2.1 Areas of application Pumps of the standard design are used for: Standard design • industrial application • CIP processes • all systems and processes involved in the food product, dairy, and beverage industries Because of the consistent hygienic design and the use of ma- Hygienic Design terials which are free of both pores and inclusions, the pump is highly suitable for use in:... -
Page 13: Design
Product description 3.4 Design All information and descriptions in this Operating Manual con- cerning the use and operation of the pumps are based exclu- sively on the standard designs. These rules do not apply to special designs, to customer spe- cific modifications, or to random external influences which may occur during use and operation. -
Page 14: Nameplate
Product description The nameplate is shown in fig. 4 and contains the following 3.5.3 Nameplate data: HILGE GmbH & Co. KG Hilgestraße - D - 55294 Bodenheim Pump-Type m3/h min-1 Doc.-No. MADE BY HILGE Fig. 4 HILGE nameplate, example • 1 - pump type •... -
Page 15: Weights
Product description 3.6 Weights Design features of the described standard pumps: Caution: The weights can - depending on design and accessories - dif- fer from those presented. The manufacturer gives you when given the pump / order number precise information. •... -
Page 16: Noise Emissions
Product description Measured values according to DIN EN ISO 3746 for pump 3.6.1 Noise emissions units; uncertainty of measurement 3dB (A). Motor power [dB (A) 1. Stage 2. Stage 3. Stage 4. Stage 5. Stage 6. Stage 0,75 18,5 Tab. 4 Noise emissions Contra I/II 2-pole Motor power [dB (A) -
Page 17: Maximum Operating Pressure
Product description 3.6.3 Maximum operating pressure WARNING Pressure overload is dangerous! Exceeding the maximum operating pressure may cause the pump to be destroyed. • The pump must be operated according to the order data. • Never exceed the specified maximum operating pres- sures! The maximum permitted operating pressure depends on var- Pump operating pressure... -
Page 18: Mounting, Installation And Connection
Mounting, installation and connection 4. Mounting, installation and connection Overview This chapter is intended for the maintenance and repair personnel. This section describes how to mount, adjust and install the pump.You get to know what to consider when you connect the pump to the electric mains supply and how to improve the flow in order to avoid dry running of the shaft seals. - Page 19 Mounting, installation and connection WARNING Electrical danger due to short circuit! Short circuits can cause death, bodily injury or damage to the plant. • In case of a vertical installation: Under no circumstances the motor should be positioned underneath the pump. If there is leakage the motor could be damaged.
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Page 20: Aligning The Coupling
Mounting, installation and connection 4.3 Aligning the coupling Careful alignment significantly increases the service life of the Why is alignment important? coupling as well as the shaft bearing and sealings. Fig. 5 shows the possible types of deviation in coupling align- ment. -
Page 21: Permissible Shift Values Flender H / Hds Coupling
Mounting, installation and connection 4.4 Permissible shift values Never under any circumstances exceed the following shift values of the coupling during operation. Flender H / HDS coupling 4.4.1 Coupling size The following table contains a list of coupling designations Design H and HDS and drill hole diameters. -
Page 22: Installation In The Pipeline
Mounting, installation and connection 4.5 Installation in the pipeline WARN ING Danger of mechanical overload! A mechanical overload can cause death, bodily harm or dam- age to the plant. Pumped liquid can leak under high pressure. • Do not use the pump or its connecting sleeves to support the pipeline. - Page 23 Mounting, installation and connection What is dry running? Details about dry running To seal the pump shaft against the pump casing the mechan- ical seal needs lubrication between its rotating faces. This lubrication is provided by the pumped liquid. If the pump is fitted with a quench the lubrication for the quench must be provided from an external source.
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Page 24: Space Requirements
Mounting, installation and connection Fig. 7 Installation in the pipeline • above: gravity feed mode • below: suction mode • P - pump • M - motor 4.5.1 Space requirements ATTENTION Overheating! Damage to property. Ensure sufficient ventilation. Make sure not to re absorb warm cooling air. Consider other heat sources in the area. -
Page 25: Reduction Of Noise And Vibration
Mounting, installation and connection Noise and vibration are generated by the pulsating flow of the 4.5.2 Reduction of noise and vibration rotors and by the flow in pipes and fittings. The effect on the environment is subjective and depends on correct installation and the state of the remaining system. -
Page 26: Connections For Flushing System
Mounting, installation and connection 4.6 Connections for flushing system HILGE pumps with double mechanical seal are equipped with 4.6.1 Double mechanical seal a seal cartridge. Depending on the seal design the barrier or flushing fluid flows inside this seal cartridge. The connection must be carry out as shown in Fig. -
Page 27: Double Mechanical Seal - Back-To-Back-Arrangement
Mounting, installation and connection 4.6.2 Double mechanical seal - back-to- back-arrangement In order to continue functioning, the mechanical seals require Barrier liquid a barrier liquid, some of its purposes being: • Pressurisation in the sealing space • Prevent the feed liquid from penetrating into the sealing •... -
Page 28: Double Mechanical Seal - Tandem Arrangement
Mounting, installation and connection 4.6.3 Double mechanical seal - tandem arrangement In order to continue functioning, the mechanical seals require Flushing liquid a flushing liquid, some of its purposes being: • Preventing leaks • Dry-run protection • Lubrication and cooling of the mechanical seals •... -
Page 29: Star Connection
Mounting, installation and connection Star-connection 3-phase system for high voltage. 4.7.1 Star connection Connect the pump as specified in the order documents. The figure below shows the schema for star connection. Fig. 11 Star connection Delta-connection for low voltage. 4.7.2 Delta connection Connect the pump as specified in the order documents. -
Page 30: Start-Up / Shut-Down
Start-up / shut-down 5. Start-up / shut-down Overview This section describes how to start up and shut down the pump. You get to know which inspections contribute to failure-free operation and increased life of the pump. 5.1 Start-up 5.1.1 Check application conditions Check the application conditions of the pump in this way: 1. -
Page 31: Functional Check Of Mechanical Seal
Start-up / shut-down 5.1.3 Functional check of mechanical seal Check the function of the mechanical seal in this way: 1. Watch the pump and check the mechanical seal for flaw- less functioning (leak test). An intact mechanical seal works virtually without leakage. If liquid pumped or flushing liquid leak: 1. -
Page 32: Maintenance / Servicing
Maintenance / servicing 6. Maintenance / servicing Overview This chapter is intended for the maintenance and repair personnel. In this section you will get important information concerning maintenance and servicing the pump. Read this sec- tion before you carry out maintenance work or troubleshooting measures!. 6.1 Safety instructions for maintenance, inspection and installation work... -
Page 33: Maintenance Of The Pump
Maintenance / servicing CA UTION Danger of frost! Frost causes damage to the plant and pump. • When there is danger of frost drain the pump completely. CA UTION Danger of improper tools! Improper tools can cause damage to the pump and plant. •... -
Page 34: Grease Quantities For Roller Bearings During Assembly
Maintenance / servicing 6.4.1.2 Grease quantities for roller bearings The hollow areas between the cylinder bodies are filled in the during assembly factory 30% - 50% with grease. This grease filling is sufficient for operation of the bearing under conditions normally en- countered. -
Page 35: Assembly
Maintenance / servicing 6.5 Assembly 6.5.1 Parts overview Fig. 13 Parts overview Contra CN with bearing housing Qty. Part No. Description Qty. Part No. Description 0107,00 discharge casing 0327.00 cylindrical roller bearing 0112,02 0331.00 bearing bracket diffusor casing 0112,03 diffusor casing 0360.00... - Page 36 1000,01 counter sunk screw 0970.00 plate 0211.00 pump shaft 0970.01 plate 0326.00 angular contact ball bearing 1002.01 pan head slotted screw Tab. 11 Parts list Contra CN Parts which are depending on number of stages are partially without figure. BA.10A.CNY.001.01.10.GB...
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Page 37: Instructions For Assembly
Maintenance / servicing 6.5.2 Instructions for assembly DA NGER Maintenance or assembly work can be dangerous if important instructions are disregarded. • Before you maintenance or assemble the pump note sec- tion 6.1 on 32. CA UTION For pump assembly important aspects have to be taken into account: A wrong assembly of the pump can cause damages to the pump. -
Page 38: Assembly Of Contra Cn
Maintenance / servicing 6.6 Assembly of Contra CN Assemble the CN bearing housing in this way: Unless specially noted in individual cases, the part numbers Please note given in the following instructions may be found in tab. Tabelle 11. Compare the description with fig. 13. -
Page 39: Assembly Of Coupling And Motor
Maintenance / servicing 6.6.1 Assembly of coupling and motor Assemble the coupling and the motor in this way: 1. Slide coupling half 0840.00 onto the shaft 2. Slide coupling half 0840.01 onto the motor shaft. 0211.00. Screw grub screw 0904.00 one or two turns into Screw grub screw 0904.00 one or two turns into the coupling half 0840.01. -
Page 40: Mechanical Seal Arrangements
Maintenance / servicing Following mechanical seal arrangements are available 6.6.2 Mechanical seal arrangements Fig. 22 Single mechanical seal (spiral spring) Fig. 23 Single mechanical seal (enclosed spring) Fig. 25 Double mechanical seal, back to back Fig. 24 Double mechanical seal, tandem •... -
Page 41: Different Fixing Of Seal Cartridge
Maintenance / servicing The assembly of the seal cartridge 0491.00 used for the dou- 6.6.3 Different fixing of seal cartridge ble mechanical seal is very similar between Contra I and Con- tra II. Fig. 27 Fixing of seal cartridge • above: Contra I •... -
Page 42: Assembly Of The Single Mechanical Seal
Maintenance / servicing 6.6.4 Assembly of the single mechanical Assemble the single mechanical seal in this way: seal The part numbers given in the following instructions may be Please note found in tab. Tabelle 11. 1. Coat the thread of the tie bolts 0905.01with 3. - Page 43 Maintenance / servicing 6. Slide the assembly sleeve from HILGE assem- 7. Push the stationary ring of the mechanical seal bly tool kit (pos. 3, fig. 81) onto the shaft exten- 0433.00 into the seat of the discharge casing sion. 0107.00.
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Page 44: Assembly Of The Double Mechanical Seal
Maintenance / servicing 6.6.5 Assembly of the double mechanical Assemble the double mechanical seal in this way: seal The part numbers given in the following instructions may be Please note found in tab. Tabelle 11. The assembly aids listed here may be found on page 56. 1. - Page 45 Maintenance / servicing 5. Grease the back side of the discharge casing 6. Assemble the discharge casing 0107.00 onto 0107.00. the shaft 0211.00. Use Klüberpaste UH1 96-402 from HILGE as- sembly tool kit for this (pos. 6, fig. 81. Fig. 41 Discharge casing / bearing housing Fig.
- Page 46 Maintenance / servicing 9. Slide the assembly sleeve from HILGE assem- 11. Slide the rotating part of the mechanical seal bly tool kit (pos. 3, fig. 81) onto the shaft exten- 0433.01 in complete assembly onto the shaft sion. 0211.00 up to the stop. Use installation sleeve from HILGE assembly kit (pos.
- Page 47 Maintenance / servicing 19. Insert the O-ring 0412.01 into the seal cover 20. Fix the seal cover 0471.00 to the discharge cas- 0471.00. ing 0107.00 by means of the hexagon head ster- ile screws 0918.00. For tightening the hexagon head sterile screws 0918.00: Use socket wrench with insert (HILGE assembly tool kit, fig.
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Page 48: Assembly Of The Double Mechanical Seal, Back To Back
Maintenance / servicing 6.6.6 Assembly of the double mechanical Assemble the double mechanical seal back to back in seal, back to back this way: The part numbers given in the following instructions may be Please note found in tab. Tabelle 11. The assembly aids listed here may be found on 56. - Page 49 Maintenance / servicing 7. Insert the O-rings 0412.03 into the hexagon 8. Fix the seal cover 0471.00 to the discharge cas- head sterile screws 0918.00. ing 0107.00 by means of the hexagon head ster- ile screw 0918.00. 9. For tightening the hexagon head sterile screw 0918.00: Use socket wrench with insert (HILGE assembly tool kit, fig.
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Page 50: Assembly Of Impellers And Casings
Maintenance / servicing 6.6.7 Assembly of impellers and casings CAUTION Danger that the pump shaft will be bent because of a non con- centrically torque! A bending of the pump shaft will destroy the pump! • To tighten impeller nut 0922.00, use either a screw device or the impeller-fastening-aid which is mentioned below. - Page 51 Maintenance / servicing 8. Insert the O-ring 0412.12 into the diffusor casing 9. Insert the O-ring 0412.22 into the impeller 0112.02. 0230.02. Fig. 67 Second O-ring Fig. 68 Impeller O-ring 10. Fit the second Impeller 0230.02 To mount the following pump stages follow steps 6 to 9.
- Page 52 Maintenance / servicing 13. Insert the Nord-Lock washer 0930.00 into the 14. Tighten the impeller nut 0922.00 by hand. Let impeller nut 0922.00. about 5 mm space for the O-ring 0412.04. Fig. 72 Nord-Lock washer in impeller nut Fig. 73 Impeller nut 15.
- Page 53 Maintenance / servicing 20. Fit the suction cover 0162.00. 21. Fit the washers 0934.03 and the hexagon nuts Grease threads of the tie bolts 0905.01 using 0927.00. Tighten the nuts 0927.00. Klüberpaste UH1 96-402 from HILGE assembly To tighten the nuts properly use a torque adjust- tool kit, pos.
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Page 54: Troubleshooting
Maintenance / servicing 6.7 Troubleshooting Problem Cause Remedy 1. Incorrect electrical hook-up (2 phases). 1. Check the electrical connections and cor- Pump does not 2. Wrong rotational direction. rect them if necessary. deliver or deliv- 2. Reverse the phases of the power supply ers at a reduced 3. -
Page 55: Disposal
This product or parts of it must be disposed of in an environ- mentally sound way: 1. Use the public or private waste collection service. 2. If this is not possible, contact the nearest GEA Hilge company or service workshop. BA.10A.CNY.001.01.10.GB... -
Page 56: Hilge Assembly Tool Kit
Maintenance / servicing 6.9 HILGE assembly tool kit Remove and install the mechanical seals safely and reliably by using tools of the HILGE assembly tool kit. Fig. 81 HILGE assembly tool kit The list below specifies the tools of the kit: 6.9.1 Content and use description description... -
Page 57: Certificate Of Non-Objection
Certificate of non-objection 7. Certificate of non-objection Overview This section contains a certificate of non-objection. In case of inspection or repairing send the pump including these certificate to HILGE. 7.1 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: •... - Page 60 Responsibility GEA-versity GEA Group is a global engineering company with multi-billion euro sales and operations in more than 50 countries. Founded in 1881, the company is one of the largest providers of innovative equipment and process technology. GEA Group is listed in the STOXX Europe 600 Index.
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