GEA CONTRA CN User manual

GEA Hilge
GEA Hilge
CONTRA CN
Installation and operating instructions English
Translation of the original operating manual
BA.10A.CNY.001.03.17.GB
engineering fora better world

1/1
EC - Declaration of conformity for machines
in accordance with EC Machinery Directive 2006/42 /EC, Annex II 1. A
Manufacturer: HILGE GmbH & Co. KG
Hilgestraße 37-47
55294 Bodenheim, Germany
We, as manufacturer, declare in sole responsibility that the machinery
Product:
Model:
Type
complies to all relevant provisions of this and the following directives:
Relevant EC
Regulations: 2006/42/EC EC Machinery Directive
Applied harmonized
standards, in particular: EN 809:1998/A1+AC(D)
EN ISO 12100:2010
Remarks: We also declare that the special technical documentation for this incomplete machine
has been created in accordance with Annex VII, Part B and we obligate to provide these
upon reasoned request from the individual national authorities by data transfer.
Authorized person for compiling and handing over
technical documentation:
HILGE GmbH & Co.KG
Hilgestraße 37-47
55294 Bodenheim, Germany
Bodenheim, 2016-03-29
Franz Bürmann
Managing Director GEA Hilge
Centrifugal pump
GEA Hilge CONTRA
CN

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
2.7 Safety instructions for the operator / user __________________________________________8
2.8 Unauthorized modifications and production of spare parts _____________________________9
2.9 Improper operation____________________________________________________________9
2.10 Transport __________________________________________________________________9
2.11 Cleaning__________________________________________________________________10
2.12 Repair contract_____________________________________________________________10
3. Product description__________________________________________ 11
3.1 Pump Overview _____________________________________________________________11
3.2 Description _________________________________________________________________11
3.2.1 Areas of application______________________________________________________12
3.3 Proper usage _______________________________________________________________12
3.3.1 Pumped liquids _________________________________________________________12
3.3.2 Minimum flow rate _______________________________________________________12
3.3.3 Connections and pipelines ________________________________________________12
3.3.4 Motor activation _________________________________________________________12
3.4 Design ____________________________________________________________________13
3.5 Technical data ______________________________________________________________13
3.5.1 Pump denomination _____________________________________________________13
3.5.2 Pump serial number _____________________________________________________13
3.5.3 Nameplate _____________________________________________________________14
3.5.4 Performance data _______________________________________________________14
3.6 Weights ___________________________________________________________________15
3.6.1 Noise emissions ________________________________________________________16
3.6.2 Maximum operating temperature ___________________________________________16
3.6.3 Maximum operating pressure ______________________________________________17
4. Mounting, installation and connection __________________________ 18
4.1 Inspection before pump installation ______________________________________________18
4.1.1 Check failure-free running of the impeller _____________________________________18
4.2 Set-up and alignment of the pump assembly_______________________________________18
4.3 Aligning the coupling _________________________________________________________20
4.4 Permissible shift values Flender H / HDS coupling __________________________________21
4.4.1 Coupling size___________________________________________________________21
4.4.2 Axial shift rS2 __________________________________________________________21
4.4.3 Angular shift rKw ________________________________________________________21
4.4.4 Radial shift rKr__________________________________________________________21
4.5 Installation in the pipeline______________________________________________________22
4.5.1 Space requirements _____________________________________________________24
4.5.2 Reduction of noise and vibration ____________________________________________25
4.6 Connections for flushing system ________________________________________________26
4.6.1 Double mechanical seal __________________________________________________26
4.6.2 Double mechanical seal - back-to-back-arrangement____________________________27

4.6.3 Double mechanical seal - tandem arrangement ________________________________ 28
4.7 Electrical connections ________________________________________________________ 28
4.7.1 Star connection_________________________________________________________ 29
4.7.2 Delta connection________________________________________________________ 29
4.7.3 Checking the direction of rotation after connection______________________________ 29
5. Start-up / shut-down__________________________________________30
5.1 Start-up ___________________________________________________________________ 30
5.1.1 Check application conditions ______________________________________________ 30
5.1.2 Starting up the pump ____________________________________________________ 30
5.1.3 Functional check of mechanical seal ________________________________________ 31
5.2 Shut-down _________________________________________________________________ 31
5.2.1 Shutting down the pump __________________________________________________ 31
5.2.2 Cleaning pump after shut-down ____________________________________________ 31
6. Maintenance / servicing_______________________________________32
6.1 Safety instructions for maintenance, inspection and installation work____________________ 32
6.2 Maintenance of the pump _____________________________________________________ 33
6.3 Maintenance of the motor _____________________________________________________ 33
6.4 Maintenance of CN bearing____________________________________________________ 33
6.4.1 Bearing lubrication ______________________________________________________ 33
6.4.1.1 Cylinder bearing greases _____________________________________________ 33
6.4.1.2 Grease quantities for roller bearings during assembly_______________________ 34
6.4.2 Bearing replacement_____________________________________________________ 34
6.4.2.1 Premature bearing replacement________________________________________ 34
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
6.6.5 Assembly of the double mechanical seal _____________________________________ 44
6.6.6 Assembly of the double mechanical seal, back to back __________________________ 48
6.6.7 Assembly of impellers and casings__________________________________________ 50
6.7 Troubleshooting_____________________________________________________________ 54
6.8 Disposal___________________________________________________________________ 55
6.9 HILGE assembly tool kit ______________________________________________________ 56
6.9.1 Content and use ________________________________________________________ 56
7. Certificate of non-objection____________________________________57
7.1 Certificate of non-objection ____________________________________________________ 57

Introduction
5
BA.10A.CNY.001.01.10.GB
1. Introduction
1.1 Target group This operating manual is intended for:
• the operators of the pump and
• maintenance and repair personnel.
It is assumed that all such personnel will have the basic tech-
nical background required for the start-up, maintenance and
repair of pump systems.
Sections aimed only for specially authorised personnel are in-
dicated by a preceding notation to this effect.
1.2 Symbols and formatting The following symbols and formats are intended to make it
easier to read this document:
• Listed items
Instructions Instructions that must be carried out in a specific sequence
are numbered in the corresponding order.
*
Important information and helpful tips are identified with the
index finger symbol.
Safety instructions The system used to identify safety instructions is described in
section 2.3.
1.3 References to the document
Copyright This document may not be copied, translated into other lan-
guages, or made available to third parties without our explicit
written approval.
Technical changes Design variants, technical data, and spare part numbers are
subject to technical change.
The right to make changes for the sake of further technical de-
velopment is reserved.
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.

Safety
6BA.10A.CNY.001.01.10.GB
2. Safety
2.1 Instructions for the operator
2.1.1 General information All our pumps are professionally packed before they leave our
warehouse to avoid damage during transport.
Unpacking If, after carefully unpacking and inspecting the shipment, you
however find damage, you must promptly inform the shipping
agent (railway, post office, lorry driver, shipping line, etc.).
Your claim should be filed with the shipping agent. The ship-
ping risk passes to the customer as soon as the shipment
leaves our warehouse.
Storage If the pump is not put into service immediately, it is important
that it is stored properly to ensure that it will function correctly
later. This is just as important as proper installation and main-
tenance.
The pump must be protected from cold, moisture, and dust as
well as from mechanical influences.
Specially trained personnel is required to install and maintain
the pump properly.
2.2 Safety instructions in the
operating manual
Read safety instructions! The operating manual contains all basic information required
for the set-up, operation, and maintenance of the pump. The
installer as well as the technical personnel or operator re-
sponsible for the pump must therefore read this manual be-
fore installing and starting the pump. The operating manual
must always be available at the site where the machine/sys-
tem is being used. Not only the general safety instructions
presented in this section but also the specific safety instruc-
tions in later sections must be followed.
2.3 Identification of instructions in
the operating manual
Symbol The safety instructions presented in this operating manual are
identified as shown below.
Fig. 1 Symbol for safety instructions
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!
!

Safety
7
BA.10A.CNY.001.01.10.GB
Signal words In order to classify the safety labels they are distinguished by
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.
•CAUTION
Characterises a hazard with minor risk which can causes
minor or medium bodily harm if it is not avoided.
Don’t remove instructions from machine Instructions attached directly to the machine, such as Rota-
tional direction arrow must be noted and kept in completely
legible condition.
Damaged or illegible instructions must be replaced.
2.4 Qualifications and training of
personnel The employees operating, maintaining, inspecting, and in-
stalling the pump must have the appropriate qualifications for
this work. The operator must define in detail the tasks for
which the employees are responsible, the tasks of which they
are in charge, and the manner in which they are supervised.
If the employees do not have the necessary knowledge, they
must be instructed and trained accordingly. This can be done,
if necessary, by the manufacturer/supplier under contract to
the operator. The operator must also guarantee that the em-
ployees fully understand the contents of the operating manu-
al.
2.5 Hazards upon failure to follow
the safety instructions If these safety instructions are not followed employees, the
machine itself and the environment will be in danger.
Failure to follow the safety instructions can lead to the loss of
the right to file claims for damages.
Failure to follow instructions can, for example, lead in partic-
ular to the following hazards:
• Breakdown of important functions of the machine/system
• Failure of recommended methods of maintenance and
repair
• Endangerment of personnel by electrical, mechanical,
and chemical hazards
• Endangerment of the environment by leakage of hazard-
ous materials.
2.6 Safety-conscious work The safety instructions given in this operating manual, the ex-
isting national regulations for accident prevention, and any
applicable internal working, operating, and safety instructions
of the operator must be followed.

Safety
8BA.10A.CNY.001.01.10.GB
2.7 Safety instructions for the
operator / user
WARNING
!
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!
WARNING
!
Trapping hazard!
Danger from rotating components. Rotating parts can cause
death, serious injury or damage to the equipment.
• Do not remove protection against contact with moving
parts (e.g. coupling guard) while the machine is operat-
ing.
• Replace defect safety equipment immediately!
DANGER
!
Danger generated by contact with or by inhaling hazard liq-
uids, exhalations or steams.
Inhaling hazardous liquids, condensates or sprays can cause
death, serious injury or damage to the equipment.
• Drain away leakage of hazardous pumping media in such
a way that there is no danger to personnel or to the envi-
ronment!
• Follow legal regulations!
• If shaft seal fail switch off the pump. Replace seal before
next start-up!
WARNING
!
Tripping hazard from electric power cable.
• Route the electric power cable in such a way that no one
can trip over it. (In case of portable pumps).
DANGER
!
Electrical hazard! Danger of electrical shock from contact of
energised components
An electric shock can cause death or bodily harm.
• Only use acceptable electric cables and plugs!

Safety
9
BA.10A.CNY.001.01.10.GB
2.8 Unauthorized modifications
and production of spare parts No modifications or changes to the machine may be made
without written approval of the manufacturer. In the interest of
safety, only original spare parts and accessories authorized
by the manufacturer may be used. The use of other parts can
exempt the manufacturer from liability for damage which may
thus be caused.
2.9 Improper operation The operational reliability of the delivered machine can be
guaranteed only when it is used properly as indicated in the
following sections.
*
The given limit values may not be exceed under any circum-
stances.
2.10 Transport
WARNING
!
Falling loads are dangerous!
Falling loads may cause death, severe bodily injuries or prop-
erty damage.
• Transport work must only be performed by persons quali-
fied to do so, and all safety instructions must be
observed.
• Use suitable load carrying equipment with sufficient
capacity to transport the pump.
• Make certain there are no persons under the suspended
load.
• Make certain the pump is aligned horizontally when it is
lifted!
CAUTION
!
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
K.0369V1

Safety
10 BA.10A.CNY.001.01.10.GB
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.
WARNING
!
Danger from pressure surge! Liquids under high pressure can
be forcibly ejected from the pump.
Pressure surge can cause bodily injury or damage to the plant
and pump.
• Before sterilisation always evacuate the system com-
pletely!
2.12 Repair contract The duty to follow the legal regulations on work safety and the
regulations on environmental protection means that all com-
mercial enterprises must protect their employees, the public
at large, and the environment from the harmful effects of haz-
ardous materials.
Examples of legal regulations on work safety:
• the Workplace Act (ArbStättV)
• the Hazardous Materials Act (GefStoffV)
• the accident prevention regulations(BGV A1)
• and all applicable laws, rules, guidelines, regulations etc.
in the country of operation.
Examples of regulations on environmental protection:
• the Recycling and Waste Law (KrW/AbfG)
• the Water Economy Law (WHG)
• and all applicable laws, rules, guidelines, regulations etc.
in the country of operation.
Certificate of non-objection The certificate of non-objection attached to the shipment is a
component of the inspection/repair contract. This does not af-
fect our right to refuse acceptance of this contract for other
reasons.
The certificate of non-objection can be found on 57.
HILGE products and their parts will only be inspected/re-
paired if the certificate of non-objection is present and has
been correctly completed by authorized and qualified techni-
cal personnel.
Pumps which have been operated in media exposed to radi-
ation will not be accepted.
If any additional safety measures are required even after the
careful draining and cleaning of the pump, the necessary in-
formation must be provided.