Alfa level LKH UltraPure-60 User manual

3007-0089
ESE01703-EN11 2018-02
Original manual
Instruction Manual
LKH UltraPure Centrifugal Pump

Table of contents
The information herein is correct at the time of issue but may be subject to change without prior notice
1. EC Declaration of Conformity ....................................................................... 4
2. Safety .................................................................................................... 5
2.1. Important information ............................................................................. 5
2.2. Warning signs ..................................................................................... 5
2.3. Safety precautions ................................................................................ 6
3. Installation .............................................................................................. 7
3.1. Unpacking/delivery ............................................................................... 7
3.2. Installation ......................................................................................... 10
3.3. Pre-use check ..................................................................................... 12
3.4. Recycling information ............................................................................. 13
4. Operation ............................................................................................... 14
4.1. Operation/control ................................................................................. 14
4.2. Trouble shooting .................................................................................. 16
4.3. Recommended cleaning ......................................................................... 17
5. Maintenance ........................................................................................... 18
5.1. General maintenance ............................................................................. 18
5.2. Cleaning procedure ............................................................................... 20
5.3. Dismantling of pump/shaft seals ................................................................ 21
5.4. Assembly of pump/single shaft seal ............................................................ 24
5.5. Assembly of pump/double mechanical shaft seal ............................................. 26
5.6. Assembly of flushing set - if not supplied with pump ......................................... 29
5.7. Adjustment of shaft ............................................................................... 31
6. Technical data ......................................................................................... 33
6.1. Technical data ..................................................................................... 33
6.2. Relubrication intervals ............................................................................ 34
6.3. Torque specifications ............................................................................. 37
6.4. Weight (kg) ........................................................................................ 37
6.5. Noise emission .................................................................................... 38
7. Parts list and service kits ............................................................................ 39
7.1. LKH UltraPure -10, -20, -25, -35, -40, -45, -60, -70. ........................................ 39
7.2. LKH UltraPure - Product wetted parts .......................................................... 40
7.3. LKH UltraPure - Motor dependent parts ....................................................... 42
7.4. LKH UltraPure - Shaft seal ....................................................................... 44
3

1 EC Declaration of Conformity
Revision of Declaration of Conformity 2009-12-29
The Designated Company
Alfa Laval Kolding A/S
Company Name
Albuen 31, DK-6000 Kolding, Denmark
Address
[phone]
Phone No.
hereby declare that
Pump
Designation
LKH UP-10, LKH UP-20, LKH UP-25, LKH UP-35, LKH UP-40, LKH UP-45, LKH UP-60, LKH UP-70
Type
From serial number 10.000 to 1.000.000
is in conformity with the following directive with amendments:
- Machinery Directive 2006/42/EC
The person authorised to compile the technical file is the signer of this document
Global Product Quality Manager
Pump, Valves, Fittings and Tank Equipment Lars Kruse Andersen
Title Name
Kolding 2013-12-03
Place Date Signature
4

2 Safety
Unsafe practices and other important information are emphasised in this manual.
Warnings are emphasised by means of special signs.
Always read the manual before using the pump!
2.1 Important information
WARNING
Indicates that special procedures must be followed to avoid serious personal injury.
CAUTION
Indicates that special procedures must be followed to avoid damage to the pump.
NOTE
Indicates important information to simplify or clarify procedures.
2.2 Warning signs
General warning:
Dangerous electrical voltage:
Caustic agents:
5

2Safety
All warnings in the manual are summarised on this page.
Pay special attention to the instructions below so that severe personal injury and/or damage to the pump are avoided.
2.3 Safety precautions
Installation:
Always read the technical data thoroughly. (See chapter 6 Technical data) !
Always use a lifting crane when handling the pump.
Never start in the wrong direction of rotation with liquid in the pump.
Always have the pump electrically connected by authorised personnel. (See the motor instruction)
Never start the pump if the impeller is fitted and the pump casing is removed.
Operation:
Always read the technical data thoroughly. (See chapter 6 Technical data) !
Never touch the pump or the pipelines when pumping hot liquids or when sterilising.
Never run the pump with both the suction side and the pressure side blocked.
Never run the pump when partially installed or not completely assembled.
Necessary precautions must be taken if leakage occurs as this can lead to hazardous situations.
Always handle lye and acid with great care.
Never use the pump for products not mentioned in Alfa Laval pump selection program.
The Alfa Laval pump selection program can be acquired from your local Alfa Laval sales company.
Maintenance:
Always read the technical data thoroughly. (See chapter 6 Technical data). !
Never service the pump when it is hot.
Never service the pump if pressurised.
Motors with grease nipples:
Remember lubrication according to information plate/label on the motor.
Always disconnect the power supply when servicing the pump.
Always use Alfa Laval genuine spare parts.
Transportation:
Transportation of the pump or the pump unit:
Never lift or elevate in any way other than described in this manual
Always drain the pump head and accessories of any liquid
Always ensure that no leakage of lubricants can occur
Always transport the pump in its upright position
Always ensure that the unit is securely fixed during transportation
Always use original packaging or similar during transportation
6

3 Installation
3.1 Unpacking/delivery
Step 1
Always use a lifting crane when handling the pump (see 6
Technical data).
CAUTION
Alfa Laval cannot be held responsible for incorrect unpacking.
WARNING
Be aware that certain pump configurations can tilt, and therefore
cause injuries to feet or fingers. The pump should be supported
underneath the adaptor, when not installed in the process line.
Check the delivery for:
1. Complete pump.
2. Delivery note.
3. Motor instructions.
4. Instructions for flushing set, IF ORDERED!
Step 2
Remove any packing materials from the inlet and the outlet.
Avoid damaging the inlet and the outlet.
3007-0090
Remove
packing
materials!
Step 3
Inspect the pump for visible transport damage. Inspection!
3007-0090
7

3 Installation
Step 4
Avoid damaging the flushing liquid connections, if supplied. Caution!
3007-0092
Step 5
Always remove the shroud, if fitted, before lifting the pump. Remove the shroud before ifting!
3007-0093
8

3 Installation
Step 6
ONLY LKH UltraPure-60 and LKH UltraPure-70 Do NOT use eyebolt in casing to lift the pump. The
eyebolt is for casing removal only.
3007-0093
9

3 Installation
Read the instructions carefully and pay special attention to the warnings! Always check the pump before operation.
- See pre-use check in section 3.3 Pre-use check. The large pump sizes are very heavy. Alfa Laval therefore recommends the
use of a lifting crane when handling the pump.
3.2 Installation
Step 1
Always read the technical data thoroughly. (See chaper 6 Technical data)
Always use a lifting crane when handling the pump.
Always have the pump electrically connected by authorised personnel. (see the motor instructions).
CAUTION
Alfa Laval cannot be held responsible for incorrect installation.
WARNING
Alfa Laval recommends the installation of lockable repair breaker. If the repair breaker is to be used as an emergency stop,
the colours of the repair breaker must be red and yellow.
CAUTION
The pump does not prevent back flow when intentionally or unintentionally stopped. If back flow can cause any hazardous
situations precautions must be taken e.g. check valve to be installed in the system to prevent the problem described above.
Note
The 3A standard requires minimum clearance between the lowest part of the base, pump, motor or drive and for the floor to
be no less than 4 inch. (100mm)
Step 2
Ensure at least 0.5m (1.6 ft) clearance around the pump.
3007-0094
10

3 Installation
Read the instructions carefully and pay special attention to the warnings! Always check the pump before operation.
- See pre-use check in section 3.3 Pre-use check. The large pump sizes are very heavy. Alfa Laval therefore recommends the
use of a lifting crane when handling the pump.
Step 3
Check that the flow direction is correct.
O: Outlet
I: Inlet
3007-0007
O
I

Step 4
1. Ensure that the pipelines are routed correctly.
2. Ensure that the connections are tight.
Remember seal rings!
3007-0008

Few bends
Correct
Step 5
Avoid stress on the pump.
Pay special attention to:
-Vibrations.
- Thermal expansion of the tubes.
- Excessive welding.
- Overloading of the pipelines.
- Piping system must be self-supported.
3007-0009
!
Note
In the event of leakage at the shaft seal, the medium will drip from the slot into the bottom of the adapter. In the instance, Alfa
Laval recommends placing a drip tray underneath the slot to collect the liquid.
11

3 Installation
Read the instructions carefully and pay special attention to the warnings!
LKH UltraPure is not supplied with an impeller screw as standard but can be supplied with one.
Check the direction of rotation of the impeller before operation.
- See the indication label on the pump.
3.3 Pre-use check
Step 1
Never start in the wrong direction of rotation with liquid in the
pump.
1. Start and stop the motor momentarily.
2. Ensure that the direction of rotation of the motor fan is
clockwise as viewed from the rear end of the motor.
See the indication
label!
3007-0014

View from rear end
of motor
12

3 Installation
3.4 Recycling information
• Unpacking
- Packing material consists of wood, plastics, cardboard boxes and in some cases metal straps.
- Wood and cardboard boxes can be reused, recycled or used for energy recovery.
- Plastics should be recycled or burnt at a licensed waste incineration plant.
- Metal straps should be sent for material recycling.
• Maintenance
- During maintenance, oil and wear parts in the machine are replaced.
- All metal parts should be sent for material recycling.
- Worn out or defective electronic parts should be sent to a licensed handler for material recycling.
- Oil and all non-metal wear parts must be taken care of in accordance with local regulations.
• Scrapping
- At end of use, the equipment must be recycled according to relevant, local regulations. Beside the equipment itself, any
hazardous residues from the process liquid must be considered and dealt with in a proper manner. When in doubt, or in the
absence of local regulations, please contact your local Alfa Laval sales company.
13

4Operation
Read the instructions carefully and pay special attention to the warnings!
4.1 Operation/control
Step 1
Always read the technical data thoroughly. See chapter 6 Technical data
CAUTION
Alfa Laval cannot be held responsible for incorrect operation/control.
Step 2
Never touch the pump or the pipelines when pumping hot liquids
or when sterilising.
Danger of burns!
3007-0015
Step 3
Never run the pump with both the suction side and the pressure
side blocked.
Danger of explosion!
!
3007-0016
!
!
See the warning
label!
Step 4
CAUTION
The shaft seal must not run dry.
CAUTION
Never throttle the inlet side.
Do not allow to
run dry
3007-0017


14

4Operation
Read the instructions carefully and pay special attention to the warnings!
Step 5
Double mechanical shaft seal:
1. Connect the inlet of the flushing liquid correctly.
2. Regulate the water supply correctly.
O: Outlet
I: Inlet
Tmax =70°C
(158°F)
Pmax
LKHUP10-60
=5bar
(72.5 psi)
Pmax
LKHUP70
=3bar
(43.5 psi)
3007-0095
O
I

Step 6
Control:
Reduce the capacity and the power consumption by means of:
- Throttling the pressure side of the pump.
- Reducing the impeller diameter.
- Reducing the speed of the motor.
3007-0018
Throttling!
15

4Operation
Pay attention to possible faults.
Study the instructions carefully.
4.2 Trouble shooting
NOTE!
Study the maintenance instructions carefully before replacing worn parts.
Problem Cause/result Remedy
Overloaded motor - Pumping of viscous liquids - Larger motor or smaller impeller
- Pumping of high density liquids
- Low outlet pressure (counter pressure) - Higher counter pressure (throttling)
- Lamination of precipitates from the
liquid - Frequent cleaning
Cavitation:
- Damage - Low inlet pressure - Increase the inlet pressure
- Pressure reduction (sometimes to
zero) - High liquid temperature - Reduce the liquid temperature
- Increasing of the noise level - Reduce the pressure drop before the
pump
- Reduce speed
Leaking shaft seal - Dry run Replace:
All wearing parts
-Incor
rect rubber grade If necessary:
-Chang
e rubber grade
- Abrasive particles in the liquid - Select stationary and rotating seal ring
in silicon carbide/silicon carbide
Leaking O-ring seals Incorrect rubber grade Change rubber grade
16

4Operation
The pump is designed for cleaning in place (CIP). CIP = Cleaning In Place.
Study the instructions carefully and pay special attention to the warnings!
NaOH = Caustic soda.
HNO3=Nitricacid.
4.3 Recommended cleaning
Step 1
Always handle lye and acid with great care.
Caustic danger!
Always use rubber gloves! Always use protective
goggles!
Step 2
Never touch the pump or the pipelines when sterilising.
Danger of burns!
3007-0015
Step 3
Examples of cleaning agents: Use clean water, free from chlorides.
1. 1% by weight NaOH at 70°C (158°F).
1kg(2.2lb) +100 l (26.4 gal) = Cleaning agent.
NaOH water
2.2 l (0.6 gal) +100 l (26.4 gal) = Cleaning agent.
33% NaOH water
2. 0.5% by weight HNO3at 70°C (158°F).
0.7 l (0.2 gal) +100 l (26.4 gal) = Cleaning agent.
53% HNO3water
1. Avoid excessive concentration
of the cleaning agent
⇒Dose gradually!
2. Adjust the cleaning flow to the
process.
Sterilisation of milk/viscous
liquids
⇒Increase the cleaning flow!
Step 4
Always rinse well with clean water after using a cleaning agent.
NOTE
The cleaning agents must be stored/disposed of in accordance
with current regulations/directives.
Always rinse!
Water Cleaning agent
NOTE
If pumps are sterilised using steam, standard 3A requeres the process system to be disigned to automatically shut down if the
product pressure in the system becomes less than of the atmosphere and it cannot be started until the system is re-sterilised.
17

5 Maintenance
Maintain the pump carefully. Study the instructions carefully and pay special attention to the warnings!
Always keep spare shaft seals and rubber seals in stock.
See separate motor instructions.
5.1 General maintenance
Step 1
Always read the technical data thoroughly. (See chaper 6 Technical data)
Always disconnect the power supply when servicing the pump.
NOTE
All scrap must be stored/disposed of in accordance with current rules/directives.
Step 2
Never service the pump when it is hot.
Danger of burns!
3007-0015
Step 3
Never service the pump with pump and pipelines under pressure.
CAUTION
Fit the electrical connections correctly if they have been removed
from the motor during service.
Pay special attention to the warnings!
Atmospheric
pressure required!
3007-0019
Step 4
Recommended spare parts:
Order service kits from the service kits list
(see chapter 7 Parts list and service kits).
Ordering spare parts
Contact your local Alfa Laval sales company.
Note:
If the pump is supplied with FEP O-rings. Alfa Laval recommends that the casing O-ring is replaced during pump maintenance.
18

5 Maintenance
Maintain the pump carefully. Study the instructions carefully and pay special attention to the warnings!
Always keep spare shaft seals and rubber seals in stock.
See separate motor instructions.
Shaft seal Rubber seals Motor bearings
Preventive maintenance Replace after 12 months:
(one-shift) Complete shaft seal
Replace when replacing the
shaft seal
Maintenance after leakage
(leakage normally starts slowly)
Replace at the end of the
day: Complete shaft seal
Replace when replacing the
shaft seal
Planned maintenance - Regular inspection for
leakage and smooth
operation
- Keep a record of the pump
- Use the statistics for
planning of inspections
Replace after leakage:
Complete shaft seal
Replace when replacing the
shaft seal
Yearly inspection is
recommended
- Replace complete bearing
if worn
- Ensure that the bearing is
axially locked (See motor
instructions)
Lubrication Before fitting
Lubricate the Quad-/O-rings
with silicone grease or silicone
oil
Before fitting
Silicone grease or silicone oil
See section 6.2 Relubrication
intervals
Pre-use check
CAUTION!
Fit the electrical connections correctly if they have been removed from the motor during service. (See 3.3 Pre-use check).
Pay special attention to warnings!
1. Start and stop the motor momentarily.
2. Ensure that the pump operates smoothly.
19

5 Maintenance
5.2 Cleaning procedure
Cleaning procedure for soiled impeller screw tapped hole:
1. Remove stub shaft (7) per section 4 of Service manual.
2. Submerge and soak the stub shaft for 5 minutes in a COP tank with 2% caustic wash
3. Scrub the blind tapped impeller screw hole vigorously by plunging a clean 1/2” diameter sanitary bristle pipe brush in and out
of the hole for two minutes while submerged.
4. Soak stub shaft (7) in acid sanitiser for 5 minutes, then scrub blind tapped hole as described in step 3 above.
5. Rinse well with clean water and blow-dry the blind tapped hole with clean air.
6. Swab test the inside of the tapped hole to determine cleanliness.
7. Should the swab test fail, repeat steps 2 to 6 above until swab test is passed.
Should swab testing continue to fail, or time is of the essence, install a new (spare) stub shaft (7).
20