Alfalaval LKH UltraPure User manual

ESE01703-EN162022-10
Originalmanual
InstructionManual
LKHUltraPureCentrifugalPump

Tableofcontents
Theinformationhereiniscorrectatthetimeofissuebutmaybesubjecttochangewithoutpriornotice
1.DeclarationsofConformity.................................................................4
2.Safety..........................................................................................6
2.1.Importantinformation.............................................................................6
2.2.Warningsigns.....................................................................................7
2.3.Safetyprecautions................................................................................
3.Installation....................................................................................10
3.1.Unpacking/delivery...............................................................................10
3.2.Installation.........................................................................................12
3.3.Pre-usecheck.....................................................................................17
3.4.Recyclinginformation.............................................................................1
4.Operation.....................................................................................19
4.1.Operation/control.................................................................................19
4.2.Troubleshooting..................................................................................21
4.3.Recommendedcleaning.........................................................................22
5.Maintenance..................................................................................24
5.1.Generalmaintenance.............................................................................24
5.2.Cleaningprocedure...............................................................................26
5.3.Dismantlingofpump/shaftseals................................................................27
5.4.Assemblyofpump/singleshaftseal............................................................30
5.5.Assemblyofpump/doublemechanicalshaftseal.............................................33
5.6.Assemblyofflushingset-ifnotsuppliedwithpump.........................................37
5.7.Adjustmentofshaft...............................................................................39
6.Technicaldata................................................................................41
6.1.Technicaldata.....................................................................................41
6.2.Relubricationintervals............................................................................42
6.3.Torquespecifications.............................................................................42
6.4.Weight(kg)........................................................................................42
6.5.Noiseemission....................................................................................43
7.Partslistandservicekits...................................................................44
7.1.LKHUltraPure-10,-20,-25,-35,-40,-45,-60,-70.........................................44
7.2.LKHUltraPure-Productwettedparts..........................................................46
7.3.LKHUltraPure-Motordependentparts.......................................................4
7.4.LKHUltraPure-Shaftseal.......................................................................50
3

1DeclarationsofConformity
EU EU
EUDeclaration Declaration Declarationof of ofConformity Conformity Conformity
TheDesignatedCompany
AlfaLavalKoldingA/S,Albuen31,DK-6000Kolding,Denmark,[phone]
Companyname,addressandphonenumber
Herebydeclarethat
Pump
Designation
LKHUP-10,LKHUP-20,LKHUP-25,LKHUP-35,LKHUP-40,LKHUP-45,LKHUP-60,LKHUP-70
Type
Serialnumberfrom10.000to1.000.000
isinconformitywiththefollowingdirectiveswithamendments:
-MachineryDirective2006/42/EC
-RoHSEUDirective2011/65/EUandamendments
Thepersonauthorisedtocompilethetechnicalfileisthesignerofthisdocument.
GlobalProductQualityManagerLarsKruseAndersen
TitleName
Kolding,Denmark2022–10–01
PlaceDate(YYYY-MM-DD)Signature
ThisDeclarationofConformityreplacesDeclarationofConformitydated2013-12-03
4

1DeclarationsofConformity
UK UK
UKDeclaration Declaration Declarationof of ofConformity Conformity Conformity
TheDesignatedCompany
AlfaLavalKoldingA/S,Albuen31,DK-6000Kolding,Denmark,[phone]
Companyname,addressandphonenumber
Herebydeclarethat
Pump
Designation
LKHUP-10,LKHUP-20,LKHUP-25,LKHUP-35,LKHUP-40,LKHUP-45,LKHUP-60,LKHUP-70
Type
Serialnumberfrom10.000to1.000.000
isinconformitywiththefollowingdirectiveswithamendments:
-TheSupplyofMachinery(Safety)Regulations200
-TheRestrictionoftheUseofCertainHazardousSubstancesinElectricalandElectronicEquipmentRegulations2012
Signedonbehalfof:AlfaLavalKoldingA/S
GlobalProductQualityManagerLarsKruseAndersen
TitleName
Kolding,Denmark2022–10–01
PlaceDate(YYYY-MM-DD)Signature
DoCRevison_01_102022
5

2Safety
Unsafepracticesandotherimportantinformationareemphasisedinthismanual.
Warningsareemphasisedbymeansofspecialsigns.
Always Always
Alwaysread read readthe the themanual manual manualbefore before beforeusing using usingthe the thepump! pump! pump!
2.1Importantinformation
W W
WARNING ARNING ARNING
Indicatesthatspecialproceduresmustbefollowedtoavoidseriouspersonalinjury.
CAUTION CAUTION
CAUTION
Indicatesthatspecialproceduresmustbefollowedtoavoiddamagetothepump.
NOTE NOTE
NOTE
Indicatesimportantinformationtosimplifyorclarifyprocedures.
This This
ThisInstruction Instruction Instructionmanual manual manualis is isdesigned designed designedto to topr pr provide ovide ovidethe the theuser user userwith with withthe the theinformation information informationto to toperform perform performtasks tasks taskssafely safely safelyfor for forall all allphases phases phasesin in inthe the the
life life
lifetime time timeof of ofthe the thepr pr product oduct oductsupplied. supplied. supplied.
The The
TheUser User Usershall shall shallalways always alwaysr r read ead eadthe the thesafety safety safetysection section sectionfirst. first. first.Her Her Hereafter eafter eafterthe the theUser User Usercan can canskip skip skipto to tothe the ther r relevant elevant elevantsection section sectionfor for forthe the thetask task taskto to tobe be be
carried carried
carriedout out outor or orfor for forthe the theinformation information informationneeded. needed. needed.
This This
Thisis is isthe the thecomplete complete completemanual manual manualfor for forthe the thesupplied supplied suppliedpr pr product. oduct. oduct.
Skills Skills
Skillsfor for forpersonal: personal: personal:
Operators: Operators:
Operators:
The The
Theoperators operators operatorsshall shall shallr r read ead eadand and andunderstad understad understadthe the theinstruction instruction instructionmanual manual manualfor for forthe the thesupplied supplied suppliedpr pr product oduct oduct
Maintenance Maintenance
Maintenancepersonnel: personnel: personnel:
The The
Themaintenance maintenance maintenancepersonnel personnel personnelshall shall shallr r read ead eadand and andunderstad understad understadthe the theinstruction instruction instructionmanual. manual. manual.
The The
Themaintenance maintenance maintenancepersonnel personnel personnelor or ortechnicians technicians techniciansshall shall shallbe be beskilled skilled skilledwithin within withinthe the thefield field fieldr r requir equir equired ed edto to tocarry carry carryout out outthe the themaintenance maintenance maintenancework work work
safely safely
safely. . .
T T
Trainees: rainees: rainees:
T T
Trainees rainees raineescan can canperform perform performtasks tasks tasksunder under underthe the thesupervision supervision supervisionof of ofan an anexperienced experienced experiencedemployee. employee. employee.
People People
Peoplein in ingeneral: general: general:
The The
Thepublic public publicshall shall shallnot not nothave have haveaccess access accessto to tothe the thesupplied supplied suppliedpr pr product. oduct. oduct.
How How
Howto to tocontact contact contactAlfa Alfa AlfaLaval Laval Laval
Contactdetailsforallcountriesare
continuallyupdatedonourwebsite.
Pleasevisitwww.alfalaval.comtoaccesstheinformationdirectly.
6

2Safety
Unsafepracticesandotherimportantinformationareemphasisedinthismanual.
Warningsareemphasisedbymeansofspecialsigns.
Always Always
Alwaysread read readthe the themanual manual manualbefore before beforeusing using usingthe the thepump! pump! pump!
2.2Warningsigns
General General
Generalwar war warning: ning: ning:
Danger Danger
Dangerous ous ouselectrical electrical electricalvoltage: voltage: voltage:
Caustic Caustic
Causticagents: agents: agents:
7

2Safety
Allwarningsinthemanualaresummarisedonthispage.
Payspecialattentiontotheinstructionsbelowsothatseverepersonalinjuryand/ordamagetothepumpareavoided.
2.3Safetyprecautions
General General
General
Always Always
Alwaysensurethatpersonnelmusthaveexperiencewithliftingoperations.
Always Always
Alwaysensuretheliftingpointtobeinlinewithcenterofgravity.Adjustliftingpointifnecessary.
Always Always
Alwayskeepaneyeontheloadandstayclearduringtheliftingoperation.
Always Always
Alwaysensurethattheliftingequipmentissuitableforthespecificpump.
Always Always
Alwaysuseappropriateliftingequipmentforheavypartswhenrelevant.Useliftinglogswhenapplied.
Topreventunexpectedstartandcontactwithelectricalliveandmovingparts.
Always Always
Alwaysdisconnectthepowersupplysafely:
-Thepowersupplydisconnectingdevicemustbedisconnected(inoffposition)andlocked.
-Incasethepumpiscapableofbeingpluggedintoanelectricalsupply,removaloftheplugissufficient,provided
thattheoperatorcancheckfromanyofthepointstowhichhehasaccessthattheplugremainsremoved.
Always Always
Alwaysrefertothemotorinstructionmanualforinstallationandmaintenanceofthemotor.
Never Never
Nevertouchtheimpellerthroughtheinlet/outletduringstart/stopasthiscancauseseriousinjury.
Installation: Installation:
Installation:
Always Always
Alwaysreadthetechnicaldatathoroughly.(Seechapter6Technicaldata)
Pump Pump
Pumpwith with withImpeller Impeller Impellerscr scr screw: ew: ew:
Never Never
Neverstartinthewrongdirectionofrotationwithliquidinthepump.
Always Always
Alwayshavethepumpelectricallyconnectedbyauthorisedpersonnel.(Seethemotorinstruction)
Operation: Operation:
Operation:
Always Always
Alwaysreadthetechnicaldatathoroughly.(Seechapter6Technicaldata)
Never Never
Nevertouchthepumporthepipelineswhenpumpinghotliquidsorwhensterilising.
Never Never
Neverrunthepumpwithboththesuctionsideandthepressuresideblocked.
Never Never
Neverrunthepumpwhenpartiallyinstalledornotcompletelyassembled.
Necessary Necessary
Necessaryprecautionsmustbetakenifleakageoccursasthiscanleadtohazardoussituations.
Always Always
Alwayshandlelyeandacidwithgreatcare.
Never Never
NeverusethepumpforproductsnotmentionedintheAlfaLavalpumpselectionprogram.
TheAlfaLavalpumpselectionprogramcanbeacquiredfromyourlocalAlfaLavalsalescompany.
Maintenance: Maintenance:
Maintenance:
Always Always
Alwaysreadthetechnicaldatathoroughly.(Seechapter6Technicaldata)
Never Never
Neverservicethepumpwhenitishot.
Never Never
Neverservicethepumpifpressurised.
Always Always
AlwaysuseAlfaLavalgenuinespareparts.
Motors Motors
Motorswith with withgr gr grease ease easenipples: nipples: nipples:
Always Always
Alwayslubricateacordingtomotormanufacturesrecommendedprocedures.
Always Always
Alwayslocateandremovegreaseventplugs,ifprovided,priortoaddinggrease.
Always Always
Alwayscheckmotornameplateforgreasetypeandlubricationintervals.
8

2Safety
Allwarningsinthemanualaresummarisedonthispage.
Payspecialattentiontotheinstructionsbelowsothatseverepersonalinjuryand/ordamagetothepumpareavoided.
T T
Transportation: ransportation: ransportation:
T T
Transportation ransportation ransportationof of ofthe the thepump pump pumpor or orthe the thepump pump pumpunit: unit: unit:
Never Never
Neverliftorelevateinanywayotherthandescribedinthismanual
Always Always
Alwaysdrainthepumpheadandaccessoriesofanyliquid
Always Always
Alwaysensurethatnoleakageoflubricantscanoccur
Always Always
Alwaystransportthepumpinitsuprightposition
Always Always
Alwaysensurethattheunitissecurelyfixedduringtransportation
Always Always
Alwaysusetheoriginalpackagingorsimilarduringtransportation
Always Always
Alwaysusesuitabletransportdeviceie.forkliftorpalletlifter
Storage: Storage:
Storage:
IdeallyasaguideAlfaLavalwouldrecommend:
-Storesuppliedproductassuppliedinoriginalpackaging
-Portopeningshouldbeprotectedagainstanyingress
-Baresteel(notstainless)shouldbelightlyoiled/greased
-Storeinaclean,dryplacewithoutdirectsunlightorUVlight
-Temperaturerange-5to40°C
-Relativehumiditylessthan60%
-Noexposuretocorrosivesubstances(alsoaircontained)
9

3Installation
3.1Unpacking/delivery
Step Step
Step1 1 1
Alwaysusealiftingcranewhenhandlingthepump(see6
Technicaldata).
CAUTION CAUTION
CAUTION
AlfaLavalcannotbeheldresponsibleforincorrectunpacking.
W W
WARNING ARNING ARNING
Beawarethatcertainpumpconfigurationscantilt,andtherefore
causeinjuriestofeetorfingers.Thepumpshouldbesupported
underneaththeadaptor,whennotinstalledintheprocessline.
Check Check
Checkthe the thedelivery delivery deliveryfor: for: for:
1.Completepump.
2.Deliverynote.
3.Motorinstructions.
4.Instructionsforflushingset,IFORDERED!
Step Step
Step2 2 2
Removeanypackingmaterialsfromtheinletandtheoutlet.
Avoiddamagingtheinletandtheoutlet.
Avoiddamagingtheconnectionsforflushingliquid,ifsupplied.
*Removepackingmaterials!
Step Step
Step3 3 3
Inspectthepumpforvisibletransportdamage.
10

3Installation
Step Step
Step4 4 4
Alwaysremovetheshroud,iffitted,beforeliftingthepump.Caution!
Step Step
Step5 5 5
ONLYLKHUltraPure-60andLKHUltraPure-70DoNOT NOT
NOTuseeyeboltincasingtoliftthepump.The
eyeboltisforcasingremovalonly.
11

3Installation
Readtheinstructionscarefullyandpayspecialattentiontothewarnings!Alwayschecthepumpbeforeoperation.
-Seepre-usechecinsection3.3Pre-usechec.Thelargepumpsizesareveryheavy.AlfaLavalthereforerecommendsthe
useofaliftingcranewhenhandlingthepump.
3.2Installation
Step Step
Step1 1 1
Always Always
Alwaysreadthetechnicaldatathoroughly.
(Seechaper6Technicaldata)
Always Always
Alwaysusealiftingcranewhenhandlingthepump.
Always Always
Alwayshavethepumpelectricallyconnectedbyauthorisedpersonnel.(Seethemotorinstructions).
CAUTION CAUTION
CAUTION
AlfaLavalcannotbeheldresponsibleforincorrectinstallation.
CAUTION CAUTION
CAUTION
Thepumpdoesnotpreventbackflowwhenintenrionallyorunintentionallystopped.Ifbackflowcancauseanyhazardous
situations,precautionsmustbetakene.g.checkthevalvetobeinstalledinthesystempreventinghazardoussituations
fromarising.
CAUTION CAUTION
CAUTION
Ifthepumphasbeenstoredforlongerperiodoftimethereisariskthatthesealfacesmaysticktogetherandconsequently
causedamagetothesealatstart-up.Pleaseensurethatthepumpshaftcanberotatedbyhandbeforestart-up.
W W
WARNING: ARNING: ARNING:
AlfaLavalrecommendsthesupplydisconnectingdeviceshallbeinaccordancewithEN60204-1.Alwaysdisconnectthe
supplydisconnectingdevicesafelyafterinstallationbeforecontinuingtheinstallation.
Step Step
Step2 2 2
Ensureatleast0.5m(1.6ft)clearancearoundthepump.
Ensurethefloor/frameisabletosupporttheweightofthepump.
SeeTechnicaldataandotherenvironmentrequirementsinsection
6.
Ensurethepumpissupportedbyallfourfeetequally.
12

3Installation
Readtheinstructionscarefullyandpayspecialattentiontothewarnings!Alwayschecthepumpbeforeoperation.
-Seepre-usechecinsection3.3Pre-usechec.Thelargepumpsizesareveryheavy.AlfaLavalthereforerecommendsthe
useofaliftingcranewhenhandlingthepump.
Step Step
Step3 3 3
Checkthattheflowdirectioniscorrect.
O:Outlet
I:Inlet
Step Step
Step4 4 4
1.Ensurethatthepipelinesareroutedcorrectly.
2.Ensurethattheconnectionsaretight.
3.Remembersealrings!
Step Step
Step5 5 5
Avoidstressonthepump.
Payspecialattentionto:
-Vibrations.
-Thermalexpansionofthetubes.
-Excessivewelding.
-Overloadingofthepipelines.
-Pipingsystemmustbeself-supported.
13

3Installation
Readtheinstructionscarefullyandpayspecialattentiontothewarnings!Alwayschecthepumpbeforeoperation.
-Seepre-usechecinsection3.3Pre-usechec.Thelargepumpsizesareveryheavy.AlfaLavalthereforerecommendsthe
useofaliftingcranewhenhandlingthepump.
Note Note
Note
Intheeventofleakageattheshaftseal,themediumwilldripfromtheslotintothebottomoftheadapter.Intheinstance,Alfa
Lavalrecommendsplacingadriptrayunderneaththeslottocollecttheliquid.
Step Step
Step6 6 6
Ensurecorrectalignmentofpumpinletandoutletwithpiping
system.
Alignmentcanbedonebyadjustingthepumplegs.
Centreofinletandoutlettobealignedwithcentreofpipingsystem.
Nogapsbetweenconnectionsonpumpinletandinletpipe,andpumpoutletandoutletpipe.
14

3Installation
Readtheinstructionscarefullyandpayspecialattentiontothewarnings!Alwayschecthepumpbeforeoperation.
-Seepre-usechecinsection3.3Pre-usechec.Thelargepumpsizesareveryheavy.AlfaLavalthereforerecommendsthe
useofaliftingcranewhenhandlingthepump.
Angelbetweenconnectionsonpumpinlerandinletpipe,pumpoutletandoutletpipenotallowed.
Ensurecorrectaligmentofpumpcasingandpumpbackplate.Anglenotallowed.Alignmentcanbedonebyadjustingthe
pmplegs.
Ensurestudboltsincasingarealignedwithholesinbackplate.
15

3Installation
Readtheinstructionscarefullyandpayspecialattentiontothewarnings!Alwayschecthepumpbeforeoperation.
-Seepre-usechecinsection3.3Pre-usechec.Thelargepumpsizesareveryheavy.AlfaLavalthereforerecommendsthe
useofaliftingcranewhenhandlingthepump.
Note Note
Note
Incaseofshaftsealleakage,themediawilldripfromtheslotinthebottomoftheadaptor.Incaseofshaftsealleakage,Alfa
Lavalrecommendsputtingadriptrayunderneaththeslottocollecttheleakage.
Alwaysensuretheadaptorshieldandmotorfanguardarepresentandmountedcorrectlyandallownoaccesstorotating
partsbeforeinstallingandstartingthepump.
16

3Installation
Readtheinstructionscarefullyandpayspecialattentiontothewarnings!
LKHUltraPureisnotsuppliedwithanimpellerscrewasstandardbutcanbesuppliedwithone.
Checthedirectionofrotationoftheimpellerbeforeoperation.
-Seetheindicationlabelonthepump.
3.3Pre-usecheck
Seetheindication
label!
Never Never
Neverstartinthewrongdirectionofrotationwithliquid
inthepump.
1.Connectpowersupply
2.Startandstopthemotormomentarily.
3.Ensurethatthedirectionofrotationofthemotorfan
isclockwise clockwise
clockwiseasviewedfromtherearendofthe
motor.
4.Disconnectpowersupplysafely.
Viewfromrearendof
motor
17

3Installation
3.4Recyclinginformation
• •
•Unpacking Unpacking Unpacking
-Packingmaterialconsistsofwood,plastics,cardboardboxesandinsomecasesmetalstraps.
-Woodandcardboardboxescanbereused,recycledorusedforenergyrecovery.
-Plasticsshouldberecycledorburntatalicensedwasteincinerationplant.
-Metalstrapsshouldbesentformaterialrecycling.
• •
•Maintenance Maintenance Maintenance
-Duringmaintenance,oilandwearpartsinthemachinearereplaced.
-Allmetalpartsshouldbesentformaterialrecycling.
-Wornoutordefectiveelectronicpartsshouldbesenttoalicensedhandlerformaterialrecycling.
-Oilandallnon-metalwearpartsmustbetakencareofinaccordancewithlocalregulations.
• •
•Scrapping Scrapping Scrapping
-Atendofuse,theequipmentmustberecycledaccordingtorelevant,localregulations.Besidetheequipmentitself,any
hazardousresiduesfromtheprocessliquidmustbeconsideredanddealtwithinapropermanner.Whenindoubt,orinthe
absenceoflocalregulations,pleasecontactyourlocalAlfaLavalsalescompany.
18

4Operation
Readtheinstructionscarefullyandpayspecialattentiontothewarnings!
4.1Operation/control
Step Step
Step1 1 1
Always Always
Alwaysreadthetechnicaldatathoroughly.Seechapter6Technicaldata
CAUTION CAUTION
CAUTION
AlfaLavalcannotbeheldresponsibleforincorrectoperation/control.
Step Step
Step2 2 2
Never Never
Nevertouchthepumporthepipelineswhenpumpinghotliquids
orwhensterilising.
Danger Danger
Dangerof of ofbur bur burns! ns! ns!
Step Step
Step3 3 3
Never Never
Neverrunthepumpwithboththesuctionsideandthepressure
sideblocked.
Danger Danger
Dangerof of ofexplosion! explosion! explosion!
Seethewarninglabel!
19

4Operation
Readtheinstructionscarefullyandpayspecialattentiontothewarnings!
Step Step
Step4 4 4
CAUTION CAUTION
CAUTION
Theshaftsealmustnotrundry.
CAUTION CAUTION
CAUTION
Never Never
Neverthrottletheinletside.
* *
*Do Do Donot not notallow allow allowto to torun run rundry dry dry
Step Step
Step5 5 5
Double Double
Doublemechanical mechanical mechanicalshaft shaft shaftseal: seal: seal:
1.Connecttheinletoftheflushingliquidcorrectly.
2.Regulatethewatersupplycorrectly.
O:Outlet
I:Inlet
Tmax=70°C
(15°F)
Pmax
LKHUP10-60
=5bar
(72.5psi)
Pmax
LKHUP70
=3bar
(43.5psi)
Step Step
Step6 6 6
Contr Contr
Control: ol: ol:
Reducethecapacityandthepowerconsumptionbymeansof:
-Throttlingthepressuresideofthepump.
-Reducingtheimpellerdiameter.
-Reducingthespeedofthemotor.
*Throttling!
20