Alfalaval LKH-5 User manual

3010-0008
ESE02002-EN4 2017-06
Original manual
Instruction Manual
GM 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 ......................................................................................... 8
3.3. Pre-use check - GM-A ........................................................................... 10
3.4. Recycling information ............................................................................. 10
4. Operation ............................................................................................... 11
4.1. Operation/control ................................................................................. 11
4.2. Trouble shooting .................................................................................. 12
4.3. Recommended cleaning ......................................................................... 13
5. Maintenance ........................................................................................... 14
5.1. General maintenance ............................................................................. 14
5.2. Dismantling of pump/shaft seals ................................................................ 16
5.3. Assembly of pump/shaft seal .................................................................... 17
5.4. Assembly - new shaft ............................................................................ 17
6. Technical data ......................................................................................... 18
6.1. Technical data ..................................................................................... 18
6.2. Torque specifications ............................................................................. 19
6.3. Weight (kg) ........................................................................................ 19
6.4. Noise emission .................................................................................... 20
7. Parts list and service kits ............................................................................ 21
7.1. GM/GM-A ......................................................................................... 21
7.2. GM Centrifugal Pump ............................................................................ 22
7.3. GM-A Centrifugal Pump .......................................................................... 24
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
GM, GM-A
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

2 Safety
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) !
GM-A:
Always remove the impeller before checking the direction of rotation.
Never start the pump if the impeller is fitted and the pump casing is removed.
GM:
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)
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 the 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.
Always use Alfa Laval genuine spare parts.
Always disconnect the power supply when servicing the pump.
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 it’s upright position.
Always ensure that the unit is securely fixed during transportation.
Always use the original packaging or similar during transportation.
6

3 Installation
3.1 Unpacking/delivery
Step 1
CAUTION
Alfa Laval cannot be held responsible for incorrect unpacking.
Check the delivery for:
1. Complete pump.
2. Delivery note.
3. Motor instructions.
4. Test certificate, IF ORDERED!
Step 2
Remove any packing materials from the inlet and the outlet.
Avoid damaging the inlet and the outlet.
Avoid damaging the connections for flushing liquid, if supplied.
Step 3
Inspect the pump for visible transport damages.
Step 4
Always remove the shroud, if fitted, before lifting the pump.
7

3 Installation
Study 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 - GM-A.
3.2 Installation
Step 1
!
Always read the technical data thoroughly. (See chaper 6 Technical data)
Always have the pump electrically connected by authorised personnel.
CAUTION
Alfa Laval cannot be held responsible for incorrect installation.
WARNING:
Alfa Laval recommend the installation of a 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 that described above.
Note
In case of shaft seal leakage, the media will drip from the slot in the bottom of the adaptor. In case of shaft seal leakage, Alfa
Laval recommend placing a drip tray underneath the slot for collecting the leakage.
Step 2
Ensure that there is sufficient clearance around the pump.
Step 3
Check that the flow direction is correct.
Step 4
1. Ensure that the pipelines are routed correctly.
2. Ensure that the connections are tight.
Remember seal rings!
TD202-037_1 Few bends
Correct!
8

3 Installation
Study 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 - GM-A.
Step 5
Avoid stressing the pump.
Pay special attention to:
-Vibrations.
- Thermal expansion of the tubes.
- Excessive welding.
- Overloading of the pipelines.
9

3 Installation
Study the instructions carefully and pay special attention to the warnings!
GM: Impeller and collets of glassfibre reinforced plastic. GM-A: Impeller and yoke of stainless steel.
Check the direction of rotation of pump shaft/motor fan before operation. - See the indication label on the pump.
3.3 Pre-use check - GM-A
Step 1
!
Always remove the impeller before checking the direction of rotation.
!
Never start the pump if the impeller is fitted and the pump casing is removed.
Step 2
Dismantle the pump in accordance with the instructions in section 5.2.
Step 3
GM-A
1. Start and stop the motor momentarily.
2. Ensure that the direction of rotation of the motor fan is clockwise as viewed from the back of the motor.
Step 4
Assemble the pump in accordance with the instructions in section 5.3.
Pre-use check GM
See the indication label
1. Start and stop the motor momentarily.
2. Ensure that the direction of rotation of the motor fan is clockwise as viewed from the back of the motor.
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 disposed of in agreement with local regulations.
•Scrapping
- At end of use, the equipment shall 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.
10

4Operation
Study 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!
Step 3
Never run the pump with both the suction side and the pressure
side blocked.
Explosion danger!
=>See the warning label!
Step 4
CAUTION
The shaft seal must not run dry.
CAUTION
Never throttle the inlet side.
Step 5
Control:
Reduce the capacity and the power consumption by means of:
- Throttling the pressure side of the pump.
- Controlling the speed of the motor.
- Reducing the impeller diameter.
11

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 - Smaller impeller
- Pumping of high-density liquids
- Low outlet pressure (counter pressure) - Higher counter pressure (throttling)
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
Leaking shaft seal - Dry run Replace:
All wearing parts
- Incorrect rubber grade If necessary:
- Change rubber grade
-Abra
sive 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
12

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= Nitric acid.
4.3 Recommended cleaning
Step 1
Always handle lye and acid with great care.
Danger, caustic
Always wear rubber
gloves!
Always wear protective
goggles!
Step 2
Never touch the pump or the pipelines when sterilising.
Danger of burns!
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) +100l(26.4gal) =Cleaningagent.
NaOH water
2.2 l (0.6 gal) +100l(26.4gal) =Cleaningagent.
33% NaOH water
2. 0.5% by weight HNO3at 70°C (158°F).
0.7 l (0.2 gal) +100l(26.4gal) =Cleaningagent.
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!
Clean water Cleaning agent
13

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.
Check the pump for smooth operation after service.
5.1 General maintenance
Step 1
!
Always read the technical data thoroughly. (See chapter 6
Technical data)
Always disconnect the power supply when servicing the pump.
NOTE
All scrap must be stored/discharged in accordance with current
rules/directives.
Step 2
Never touch the pump or the pipelines when pumping hot liquids
or when sterilising.
Danger of burns!
Step 3
!
The pump and the pipelines must never be pressurised when the pump is serviced.
Step 4
CAUTION
Fit the electrical connections correctly if they have been removed
fromthemotorduringservice(see3.3Pre-usecheck-GM-A)
CAUTION
Pay special attention to the warnings!
Step 5
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 recommend the casing O-ring is replaced when the pump is maintained.
14

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.
Check the pump for smooth operation after service.
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
Lubrication Before fitting
Lubricate the O-rings with
silicone grease or silicone oil
(not the sealing surfaces)
Before fitting
Silicone grease or silicone oil
None
The bearings are permanently
lubricated
15

5 Maintenance
Study the instructions carefully. The items refer to the parts list and service kits section.
Handle scrap correctly.
: Relates to the shaft seal.
5.2 Dismantling of pump/shaft seals
Step 1
1. Remove cap nuts (13).
2. Remove collets (14a) (GM only) or yoke (14b) (GM-A only).
3. Remove pump casing (11) and O-ring (10) (use a plastic
hammer if necessary).
Step 2
1. Remove impeller (9) by pulling it off the pump shaft (7) (GM
only).
2. Turn impeller (9) anticlockwise and remove it from the pump
shaft (only GM-A). Use a plastic hammer if necessary.
Step 3
1. Remove back plate (8).
2. The shaft seal is now accessible.
Step 4
1. Turn nut (22) clockwise and remove it from stationary seal
ring (23).
2. Remove stationary seal ring (23) and seal (26) from back
plate (8).
3. Remove the rest of the shaft seal from pump shaft (7).
Step 5
If fitted, remove the shroud.
Step 6
1. Remove nuts (2).
2. Remove adaptor (4) from the motor.
3. Remove thrower (5) from pump shaft (7).
4. Knock out pin (6).
5. Pull off pump shaft (7).
16

5 Maintenance
Study the instructions carefully.
The items refer to the parts list and service kits section.
Lubricate the rubber seals before fitting them.
5.3 Assembly of pump/shaft seal
Step 1
1. Fit pump shaft (7) on the motor shaft.
2. Lock the pump shaft with pin (6).
3. Fit adaptor (4) on the motor.
4. Fit and tighten nuts (2).
NOTE! Ensure that the adaptor drain hole is turned downwards.
Step 2
If supplied, fit the shroud.
Step 3
1. Fit thrower (5) on pump shaft (7).
2. Lubricate the external surface of the pump shaft.
3. Fit spring (19), spacer (20) and washer (21) on pump shaft (7).
4. Fit O-ring (24) on pump shaft (7).
NOTE! Ensure correct position of the joint when Teflon O-rings
are used.
Step 4
Push seal ring (25) as far as possible over O-ring (24).
NOTE! Push and pull until the O-ring is correctly positioned.
1. Fit seal (26) and stationary seal ring (23) in back plate (8).
2. Fit nut (22), turn it anticlockwise and tighten.
3. Fit the back plate on adaptor (4).
Step 5
1. Push impeller (9) on pump shaft (7) (GM only).
2. Fit impeller (9) on pump shaft (7), turn it clockwise and tighten
(GM-A only).
Step 6
1. Fit O-ring (10) and pump casing (11) on back plate (8).
2. Fit collets (14a) (GM only) or yoke (14 b) (GM-A only).
3. Fit and tighten cap nuts (13).
5.4 Assembly - new shaft
Step 1
1. Fit the pump shaft to the motor shaft.
(Hit a mark in the motor shaft with a chisel before the pump shaft is mounted.
This way the shaft can be adjusted with a hammer and not move unintentionally)
2. Fit the adaptor part, back plate and impeller.
3. Adjust shaft position so that there is about 1 mm between the impeller and back plate.
4. Remove impeller, back plate and adapter so only the pump shaft is remaining, in the right position.
5. Drill a hole (ø4 +/- 0.2) through both motor shaft and pump shaft with the pump shaft in the right position.
6. TheholemustNOTbedrilledinthekeywayofthemotor.
7. Mount ø4x30 pin using a small hammer.
17

6 Technical data
It is important to observe the technical data during installation, operation and maintenance.
Inform personnel about the technical data.
6.1 Technical data
The GM centrifugal pump is specially designed for food, chemical, pharmaceutical and other industries where acid-resistant steel
is resistant to the product to be pumped. The instruction manual is part of the delivery. Study the instructions carefully. GM:
Impeller and collets of glassfibre reinforced plastic. GM-A: Impeller and yoke of stainless steel. The standard delivery does not
include the test certificate. This can be supplied on request.
Data
Max. inlet pressure 400 kPa (4 bar) (58 PSI )
Temperature range GM -10oCto+80
oC
GM-A -10oC to +140oC(EPDM)
Impeller diameter GM-1/1A 95 mm
GM-2/2A 115 mm
Max. speed: 4000 rpm
Materials
Product wetted steel parts AISI 316L
Other steel parts Stainless steel
Impeller, GM Glassfibre reinforced Nylon (std.) or Polypropylene
Impeller, GM-A AISI 316L
Adapter, GM Plastic (POM)
Adapter, GM-A AISI 304
Collets, GM Glassfibre reinforced Noryl
Product wetted seals Nitrile (standard)
Alternative seals EPDM, Viton (FPM) and Teflon (PTFE)
Finish Semi-bright
Shaft seal
Seal types Mechanical single seal
Material, stationary seal ring AISI 329 with sealing surface of silicon carbide
Material, rotating seal ring Carbon (standard) or silicon carbide
Material, O-rings Nitrile (standard)
Alternative material, O-rings EPDM, Viton (FPM) and Teflon (PTFE)
Motor
Foot-flanged motor acc. to IEC metric standard, 2 poles = 3000/3600 rpm. at 50/60 Hz IP55 (drain hole with labyrinth
plug), insulation class F
Motor sizes (kW), 50 Hz 0.55
Motor sizes (kW), 60 Hz 0.65
For further information, see PD sheet.
18

6 Technical data
It is important to observe the technical data during installation, operation and maintenance.
Inform personnel about the technical data.
6.2 Torque specifications
The table below specifies the tightening torques for the screws, bolts and nuts in this pump.
Always use below torques if no other values are stated. This can be a matter of personal safety.
Size Tightening torque
Nm lbf-ft
M8 20 14.8
M104029.5
M126749.0
M14 110 81.0
6.3 Weight (kg)
Pump Type: GM, GM-A
Motor
70
Size
0.55kW
GM-1 15
GM-1A 17
GM-2 15
GM-2A 17
Weight can vary depending of configuration. Weihgt is only to be seen as a reference value during handling, transporting and packaging.
19

6 Technical data
It is important to observe the technical data during installation, operation and maintenance.
Inform personnel about the technical data.
6.4 Noise emission
Pump Type Sound pressure level (dBA)
LKH-5 60
LKH-10 69
LKH-15 72
LKH-20 70
LKH-25 74
LKH-35 71
LKH-40 75
LKH-45 70
LKH-50 75
LKH-60 77
LKH-70 88
LKH-75 79
LKH-85 86
LKH-90 75
LKH-112 70
LKH-113 69
LKH-114 68
LKH-122 75
LKH-123 77
LKH-124 80
SolidC-1 68
SolidC-2 72
SolidC-3 73
SolidC-4 72
MR-166 76
MR-185 82
MR-200 81
MR-300 82
GM 54
FM-OS 61
The above LKH noise levels are the same for LKHPF, LKHI, LKH UltraPure, LKH Evap and LKHex
The above SolidC noise levels are the same for SolidC UltraPure.
The noise measurements have been carried out with the original motor and shroud, approximately at the Best Efficiency
Point (BEP) with water at ambient temperature and at 50 Hz.
Very often, the noise level generated by the flow through the process system (e.g. valves, pipes, tanks etc.) is much higher than
what is generated by the pump itself. Therefore, it is important to consider the noise level from the total system and take the
necessary precautions with regards to personal safety if required.
20