GEA Hilge MAXA BLOC Operational manual

GEA Hilge
GEA Hilge
MAXA BLOC
Installation and operating instructions English
Translation of the original operating manual
98412735-0417 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: Centrifugal pump
Model: GEA Hilge MAXA
Type BLOC
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, 2016-04-05
Franz Bürmann
Managing Director GEA Hilge

3
English (GB) Installation and operating instructions
1. Introduction
Overview
This section describes the requirements that are important for
reading and understanding this operating manual. The symbols
and formats that make the reading easier are also described.
1.1 Target group
This operating manual is intended for:
• the operators of the pump
• maintenance and repair personnel.
It is assumed that all such personnel will have the basic technical
background required for the start-up, maintenance, and repair of
pump systems.
Sections intended only for specially authorised personnel are
indicated 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:
• enumerations and listed items.
Instructions
Instructions that must be carried out in a specific sequence are
numbered in the corresponding order.
Safety instructions
The system used to identify safety instructions is described in
section 2.3 on page 3.
1.3 References to the document
Copyright
This document may not be copied, translated into other
languages, or made available to third parties without our explicit
written consent.
Technical changes
Design variants, technical data, and spare part numbers are
subject to technical changes.
We reserve the right to make changes for the sake of further
technical development.
2. Safety
Overview
This section describes what you have to consider for your own
safety. Read this important section attentively and follow the
instructions!
2.1 Operator notes
2.1.1 Unpacking the pump
In order to avoid transport damage, all of our pumps are
professionally packed when they leave our warehouse.
If, after carefully unpacking and closely reviewing the shipment,
you nevertheless detect damage, please immediately inform the
transporter (railway, post office, freight forwarder, shipping
company). Please file your damage claim with them. The
transport risk is assumed by the customer as soon as the
shipment leaves our warehouse.
2.1.2 Storing the pump
If you do not use the pump straight away, correct storage
conditions are just as important as careful installation and
appropriate maintenance in order to ensure smooth subsequent
operation. The pump should be protected against cold, moisture
and dust, and should also be shielded against mechanical
impacts.
Trained personnel are required for proper installation and
maintenance.
2.2 Safety instructions in the operating manual
Read all safety instructions!
The operating manual contains all the basic information required
for the set-up, operation, and maintenance of the pump. The
installer as well as the technical personnel or operator
responsible for the pump must therefore read this operating
manual before installing and starting the pump. The operating
manual must always be available at the site where the pump/
system is used.
The general safety instructions presented in this section as well
as the specific safety instructions in later sections must be
followed.
2.3 Identification of instructions in the operating
manual
Symbols
The safety instructions presented in this operating manual are
identified as shown below.
Fig. 1 Symbols for safety instructions
1. Introduction 3
1.1 Target group 3
1.2 Symbols and formatting 3
1.3 References to the document 3
2. Safety 3
2.1 Operator notes 3
2.2 Safety instructions in the operating manual 3
2.3 Identification of instructions in the operating manual 3
2.4 Qualification and training of personnel 4
2.5 Dangers caused by failure to follow the safety
instructions 4
2.6 Safety-conscious work 4
2.7 Safety instructions for the operator/user 4
2.8 Unauthorised modifications and spare parts 4
2.9 Improper operation 5
2.10 Transport 5
2.11 Cleaning 5
2.12 Repair contract 5
3. Product description 6
3.1 Pump overview 6
3.2 Description 6
3.3 Proper usage 6
3.4 Technical data 6
4. Mounting, installation and connection 8
4.1 Inspection before pump installation 8
4.2 Set-up and alignment of the pump 8
4.3 Installation in the pipeline 8
4.4 Connection of flushing system 10
4.5 Electrical connections 10
5. Start-up / shut-down 11
5.1 Start-up 11
5.2 Shutting down the pump 12
6. Maintenance/servicing 12
6.1 Safety instructions for installation, inspection and
maintenance work 12
6.2 Maintenance of the pump 12
6.3 Maintenance of the motor 13
6.4 Assembly 14
6.5 Troubleshooting 22
6.6 Disposal 23
6.7 HILGE assembly tool kit 23
7. Certificate of non-objection 24
K.0319V1 | K.0320V1
CAUTION
ABC
!

4
• A: Failure to follow these safety instructions can endanger
personnel.
• B: Safety instructions warning against electric voltage.
• C: Failure to follow these safety instructions can endanger the
pump and its operation.
Signal words
The following signal words are used to classify the safety
instructions:
DANGER
Characterises an imminent hazard with a high risk which can
cause death or serious bodily injury.
WARNING
Characterises a possible hazard with a medium risk which can
cause death or bodily injury if it is not avoided.
CAUTION
Characterises a hazard with a minor risk which can cause
minor or medium-level bodily injury if it is not avoided.
Do not remove instructions from pump
Instructions attached directly to the pump, such as a direction-of-
rotation arrow, must be noted and kept in completely legible
condition.
Damaged or illegible instructions must be replaced.
2.3.1 Structure of safety instructions
The safety instructions are structured as follows and use the
symbols and signal words shown here:
Example:
2.4 Qualification and training of personnel
The employees operating, maintaining, inspecting, and installing
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 ensure that the employees fully
understand the contents of the operating manual.
2.5 Dangers caused by failure to follow the safety
instructions
If these safety instructions are not followed, employees, the pump
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 to the
following hazards:
• breakdown of important functions of the pump/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 hazardous
materials.
2.6 Safety-conscious work
The safety instructions given in this operating manual, the
existing national regulations for accident prevention, and any
applicable internal working, operating, and safety instructions of
the operator must be followed.
2.7 Safety instructions for the operator/user
2.8 Unauthorised modifications and spare parts
No modifications or changes to the pump may be made without
the written approval of the manufacturer. In the interest of safety,
only original spare parts and accessories authorised by the
manufacturer may be used. The use of other parts can exempt
the manufacturer from liability for damage.
SIGNAL WORD
Description of danger!
▲Possible consequence.
►Action to eliminate the danger.
DANGER
Electric shock if electrical parts are touched!
▲Death, serious bodily injury, damage to property.
►Before attempting to diagnose any fault, make
sure that the main switch has been switched off.
It must be ensured that the power supply cannot
be accidentally switched on.
WARNING
Hot or cold mechanical components!
▲Serious bodily injury.
►Take structural measures to prevent contact with
them!
WARNING
Trapping hazard!
▲Death, serious bodily injury, damage to property.
►Do not remove protection against contact with
moving parts (e.g. coupling guard) while the
pump is in operation.
►Replace defective safety equipment immediately.
WARNING
Contact with hazardous substances (e.g.
inhalation)!
▲Death, serious bodily injury, damage to property.
►Drain away leakage of hazardous pumped liquids
in such a way that there is no danger to
personnel or to the environment.
►Follow legal regulations.
►If shaft seal fails, switch off the pump. Replace
seal before next start-up.
WARNING
Tripping hazard from electric power cable!
▲Death, serious bodily injury.
►Route the electric power cable in such a way that
no one can trip over it (in case of portable
pumps).
WARNING
Electrical hazard!
▲Death, serious bodily injury.
►Use only approved electric cables and plugs.

5
2.9 Improper operation
The operational reliability of the pump can be guaranteed only
when it is used properly, as indicated in the relevant sections of
the pump operating manual and the order papers.
The given limit values may not be exceeded under any
circumstances.
2.10 Transport
Fig. 2 Attachment points (example)
2.11 Cleaning
CIP and SIP methods must use the best technology and comply
with the current EC guidelines.
When special cleaning agents and methods are used, the
supplier must confirm that they are safe for the materials
involved.
2.12 Repair contract
The duty to follow the legal regulations on work safety and the
regulations on environmental protection means that all
commercial enterprises must protect their employees, the public
at large, and the environment from the harmful effects of
hazardous materials.
Examples of legal regulations on work safety:
• the Workplace Act (ArbStättV)
• the Hazardous Materials Act (GefStoffV)
• the accident prevention regulations (BGV A1)
• regulations for environment protection e.g. the Recycling and
Waste Law (KrW/AbfG), the Water Economy Law (WHG)
• 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 affect
our right to refuse acceptance of this contract for other reasons.
The certificate of non-objection can be found on page 24.
HILGE products and their parts will only be inspected and/or
repaired if the certificate of non-objection is present and has been
correctly completed by authorised and qualified technical
personnel.
Pumps which have been operated in liquids exposed to radiation
will not be accepted.
If any additional safety measures are required even after the
careful draining and cleaning of the pump, the necessary
information must be provided.
WARNING
Falling loads!
▲Death, serious bodily injury, damage to property.
►Transport work must only be performed by
appropriately qualified persons, 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
CAUTION
Incorrect lifting points!
▲Damage to property.
►Fasten the rope to suitable lifting points.
►Never fasten a rope to the pump housing or
suction/discharge port.
►If pump is equipped with shroud, remove shroud
before transporting.
TM05 6441 4712
WARNING
Pressure surge!
▲Death, serious bodily injury, damage to property.
►Before sterilisation, always evacuate the system
completely!

6
3. Product description
Overview
In this section you will get to know the pump as well as its design
and application. The limits for application are described in the
section "Technical data". You must know and observe these
limits.
3.1 Pump overview
Fig. 3 MAXA Bloc up to motor size 112
0102 - volute casing
0153 - suction port
0156 - discharge port
0182 - foot
0183 - support foot
0346 - intermediate ring
0802 - motor.
Fig. 4 MAXA Bloc from motor size 132
0102 - volute casing
0153 - suction port
0156 - discharge port
0346 - intermediate ring
0802 - motor.
3.2 Description
The pump is a single-stage, end-suction, centrifugal pump
designed in accordance with DIN EN 733 specifications. The
hygiene requirements of modern process technology have been
considered in the manufacture of the pump.
3.2.1 Areas of application
Standard design
Pumps of the standard design are used for:
• industrial applications
• textile technology
• surface treatment for environmental technologies
• all systems and processes employed in the production of
foodstuffs, including dairy products and beverages.
3.3 Proper usage
3.3.1 Pumped liquids
Only pure or slightly contaminated liquids may be pumped. These
liquids may not chemically or physically attack the pump
materials or reduce their strength. If liquids with a viscosity
greater than that of water are to be pumped, make sure that the
motor will not be overloaded. The pump may not be operated
beyond the maximum permissible values. Even short periods of
pressure overload (e.g. as a result of a pressure surge) should be
avoided.
3.3.2 Minimum flow rate, Qmin
Do not operate pumps size 65 to 150 below the minimum flow
rate of Qmin = 10-15 % Qopt.
Do not operate pump size 200-400 below the minimum flow rate
of Qmin = 20-25 % Qopt.
3.3.3 Connections and pipelines
The nominal diameters of the system pipelines should be equal to
or greater than the nominal diameters of the pump, i.e. DNE
(suction side) and DNA (pressure side), and the elements that are
to be connected to the pump must conform exactly to the design
standard/specification of the mating connector piece installed on
the pump. The suction line must be absolutely leakproof and if
possible laid out in such a way that no air pockets can form. Avoid
tight elbows and do not install valves immediately upstream of the
pump. On the suction side, provide a straight pipe section with a
minimum length of five times the pipe diameter. The suction head
of the system may not exceed the suction head guaranteed by
the pump.
3.3.4 Motor operation
Do not start and stop the motor more than 15 times per hour.
3.3.5 Design
All information and descriptions in this operating manual
concerning the use and operation of the pumps are based
exclusively on the standard designs.
These rules do not apply to special designs, customer-specific
modifications, or random external influences that may occur
during use and operation.
3.4 Technical data
3.4.1 Type key
The HILGE pump designation is structured as shown below:
TM05 6439 4912TM05 6438 4912
0153
0156
0102
0346
0802
01830182
0153
0156
0102
0346
0802
WARNING
Improper usage!
▲Death, serious bodily injury, damage to property.
►Pump only liquids that are specified in the order.
The pump has been specially designed for that
purpose.
►Operate the pump only in the electrical network
specified in the order.
WARNING
Overloading the pump!
▲Death, serious bodily injury, damage to property.
►Use the pump only under the indicated operating
conditions.
►Also avoid brief overpressure situations (e.g.
caused by pressure surges).
MAXA 80-160 Bloc 100/80 15 2
Pump type
Size
Design
Nominal diameter DNs/DNd
Power [kW]
Number of poles

7
3.4.2 Pump serial number
The pump can be identified by the pump serial number. When
ordering spare parts, always state the pump serial number.
3.4.3 Nameplate
Fig. 5 Example of HILGE nameplate
1 - pump type
2 - pump serial number
3 - capacity [Q]
4 - head [H]
5 - motor power [P]
6 - speed [n]
7 - number of operating manual.
NOTE: The nameplate can deviate from the nameplate shown.
3.4.4 Performance data
The performance data of the pump, head and flow rate are
determined in accordance with ISO 9906:2012, grade 3B and
documented on the acceptance records.
3.4.5 Noise emissions
Measured values according to DIN EN ISO 3746 for pump units.
Uncertainty of measurement: 3 dB(A).
Noise emissions caused by a pump are significantly affected by
its application and construction. For this reason, no guarantee of
accuracy is given for the values indicated here.
3.4.6 Weights
Please note that, depending on design and accessories, the
weights may differ from those indicated. If presented with the
pump/order number, the manufacturer can give you more precise
information.
• Motor foot mounting
• Single mechanical seal
• SIEMENS motor.
3.4.7 Maximum operating temperatures
The following table lists the maximum permissible temperatures.
TM05 6440 4912
Motor power [kW] Lpfa [dB(A)] Number of poles
0.75 52
4
1.1 55
1.5 55
2.2 61
361
461
5.5 70
5.5 73
2
7.5 73
11 75
15 75
18.5 75
22 72
Pump-Type
No.
Qm3/h H
P kW n min-1
Doc.-No.
MADE BY HILGE
Hilgestraße - D - 55294 Bodenheim
HILGE GmbH & Co. KG
Pump size DNs DNd P2 [kW] IEC size Net weight [kg]
65-160 80 65 0.75 90S 36
65-160 80 65 1.1 90S 39
65-160 80 65 1.5 90L 42.5
65-160 80 65 2.2 100L 49
65-160 80 65 3 100L 51
65-160 80 65 5.5 112M 67
65-160 80 65 7.5 132S 77
65-160 80 65 11 132S 96
65-160 80 65 15 160M 109
65-160 80 65 18.5 160L 126
65-160 80 65 22 160L 147
65-200 80 65 1.5 90L 50
65-200 80 65 2.2 100L 56
65-200 80 65 3 100L 58
65-200 80 65 4 112M 63
65-200 80 65 5.5 112M 76
65-200 80 65 11 132S 103
65-200 80 65 15 160M 116
65-200 80 65 18.5 160L 133
65-200 80 65 22 160L 154
80-160 100 80 1.1 90S 63
80-160 100 80 1.5 90L 67
80-160 100 80 2.2 100L 75
80-160 100 80 3 100L 77
80-160 100 80 4 112M 82
80-160 100 80 11 160M 118
80-160 100 80 15 160M 131
80-160 100 80 18.5 160L 148
80-160 100 80 22 160L 164
Caution
Exceeding the maximum permitted operating
temperature!
▲Death, serious bodily injury, damage to property.
►Never exceed the specified operating
temperatures!
Design Temp. [°C]
Standard design 95
Special design 150
Sterilisation (SIP) 140

8
3.4.8 Maximum operating pressure
Pump operating pressure
The maximum permissible operating pressure depends on
various factors:
• pump type
• design of connections
• design of mechanical seal.
For the values that apply to your pump, please refer to the order
documents.
4. Mounting, installation and connection
Overview
This section describes how to mount, install and connect 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.
4.1 Inspection before pump installation
4.1.1 How to check free running of the impeller
1. Remove motor shroud (if applicable).
2. Remove fan cover of motor.
3. Consider direction of rotation (arrow).
4. Rotate shaft slowly by hand via the fan.
The shaft must rotate easily. If the impeller rubs against the
pump housing, it has been damaged (for example during
transport).
If the impeller rubs against the housing, contact HILGE
Service.
If the impeller runs freely:
5. Re-fit fan cover of the motor.
6. Re-fit motor shroud (if applicable).
4.2 Set-up and alignment of the pump
Align the pump in this way
1. Use an engineer’s spirit level laid across the machined
surface of the discharge port to align the pump.
2. After aligning the pump, tighten the mounting bolts uniformly
in a crosswise manner.
4.3 Installation in the pipeline
Fig. 6 Installation in the pipeline
Above: gravity feed mode | below: suction operation mode | P-
pump | M- motor
WARNING
Pressure overload!
▲Death, serious bodily injury, damage to property.
►The pump must be operated according to the
order data.
►Never exceed the specified maximum operating
pressures.
WARNING
Misalignment of the pump due to improper
foundation!
▲Death, serious bodily injury, damage to property.
►Ensure that the foundation on which the pump is
set up is clean and flat and has sufficient load
capacity.
►The mounting points provided must be bolted to
the foundation according to the standard rules of
mechanical engineering to ensure the
satisfactory set-up of the pump.
WARNING
Mechanical overload!
▲Death, bodily injury, damage to property.
►Do not use the pump or its connecting sleeves to
support the pipeline (EN 809 5.2.1.2.3 and EN
ISO 14847).
►In addition to the general rules of machine-
building and system construction, also follow the
instructions provided by the manufacturer of the
connecting elements used (e.g. flanges) when
installing the pump in the pipeline or system.
These specifications will contain data on torques,
maximum permissible angular offset and tools/
auxiliary materials to be used.
►After connecting the pipes, check the alignment
of the coupling.
►It is absolutely necessary to avoid twisting the
pump.
Caution
CAUTION
Mechanical overload due to foreign objects!
▲Damage to property.
►The suction and discharge ports are sealed with
sheets of plastic, and the flushing and drain lines
with plastic caps. These must be removed before
the pump is installed in the system.
Caution
CAUTION
Dry running!
▲Damage to property.
►The suction line must be absolutely leakproof
and laid in such a way that no air pockets can
form.
►Avoid tight elbows and valves immediately
upstream of the pump. They interfere with the
incoming flow to the pump and thus with the
NPSH of the system.
►The nominal pipeline diameters of the system
should be equal to or greater than the connectors
of the pump.
►A foot valve should be used in suction operation
mode.
►To prevent air pockets from forming, the suction
line must be laid so that it rises to the pump,
whereas a gravity feed line must be laid with a
slight downward gradient to the pump.
►If local conditions do not allow the suction line to
ascend continuously, install a venting device at
the highest point of the line.
►An isolating valve should be installed in the
suction line near the pump. This valve must be
completely open during operation and may never
be used as a control valve.
►An isolating valve should be installed in the
discharge line, near the pump, to control the flow
rate.
TM05 6442 4912
P M
PM

9
4.3.1 Operation of the mechanical seal
Mechanical seals require a lubricating film in the sealing gap
which prevents contact between the two sliding surfaces.
Generally, this lubricating film consists of the pumped liquid or an
externally supplied flushing or barrier liquid.
Due to the frictional heat between the sliding surfaces, the
lubricating film will evaporate to the atmosphere. If the pumped
liquid is water, watery liquids or volatile liquids, the leakage will
thus not be visible. For perfect operation, the amount of leakage
is usually only a few ml/h, but - depending on other
circumstances - it may rise.
Particularly during the run-in period, and independent of size,
shape or design, mechanical shaft seals may discharge a low
leakage. In some cases it may be necessary to tolerate a small,
visible leakage or to counteract this with appropriate measures.
Dry running
To achieve a proper sealing, mechanical seals require a
lubricating film between the sliding surfaces.
Dry running occurs if the lubricant film between the sliding
surfaces is missing or wears away. The frictional heat generated
by direct contact of the sliding surfaces will damage the
mechanical seal. Depending on the material combination, this will
happen within a few seconds. (see fig. 7).
Fig. 7 Lubricating film between the sliding surfaces
PPump side | AAtmospheric side
LLubricating film | 0433.00 Mechanical seal
Space requirements
Pay attention to motor power. Maintain the minimum
distances.
Fig. 8 Minimum distances
4.3.2 Reduction of noise and vibration
Noise and vibration are generated by the flow in pipes and
fittings. The effect on the environment depends on correct
installation and the state of the rest of the system. One way of
reducing noise and vibrations is by installing expansion joints.
Fig. 9 Expansion
• A - expansion joints
• B - foundation
• C - vibration dampers.
Function of expansion joints:
• Dampening of expansions/contractions in the pipework
caused by changing the temperature of the pumped liquid
• reduction of mechanical strains in connection with pressure
surges in the pipework
• insulation of mechanical structure-borne noise in the pipework
(only rubber bellows expansion joints).
Do not install expansion joints to compensate for inaccuracies in
the pipework such as centre displacement of flanges. Fit
expansion joints at a distance of minimum 1 to 1½ times the
nominal flange diameter away from the pump on the suction as
well as on the discharge side. This will prevent the development
of turbulence in the expansion joints, resulting in better suction
conditions and a minimum pressure loss on the pressure side. At
high viscosity or velocities, we recommend that you install larger
expansion joints corresponding to the pipework.
Vibrations may have the following effects:
• damage to pump and motor bearings
• damage to the mechanical shaft seal
• increased coupling wear
• damage to shaft/hub connections
• cracks in the pump connections
• loosening bolts
• cable breaks at the motor connection
• tarnishing of impeller caused by friction heat.
TM05 6444 4912
WARNING
Overheating!
▲Damage to property.
►Ensure sufficient ventilation.
►Make sure not to reabsorb warm cooling air.
Consider other heat sources in the area.
►Maintain minimum distances.
TM05 1038 3112
PA
0433.00
L
0.55-4kW
5. 5 k W
300 mm
1000 mm
300 mm
TM05 6445 4912
WARNING
Vibration!
▲Damage to property.
►Make sure that pipes and pumps are fixed firmly
to foundation or building. Insufficiently rigid
structures may cause oscillations if operating
conditions are changed, e.g. by fluctuations in
hydraulic and/or motor forces.

10
4.4 Connection of flushing system
4.4.1 Double mechanical seal
HILGE pumps with double mechanical seal are equipped with a
cartridge seal.
Depending on the seal design, the barrier or flushing liquid flows
inside this cartridge seal.
The connection must be carried out as shown in fig. 10 to ensure
that the liquid is able to flush the mechanical seal effectively.
Fig. 10 Connection of flushing system
0491.00 - cartridge seal
A - feed line
B - outlet line
N - direction of rotation.
Connect the flushing system in this way:
1. Connect feed line A. Note the dependence between
arrangement and direction of rotation. See fig. 10.
2. Connect outlet line B.
3. Check tightness of connections.
4.4.2 Double mechanical seal - tandem arrangement
Flushing liquid
In order to continue functioning, the mechanical seals require a
flushing liquid, some of its purposes being:
• preventing leaks
• protecting against dry-running
• lubricating and cooling the mechanical seals
• cutting off the air from substances which react unfavourably
with oxygen.
Use a pure flushing liquid which is compatible with the pumped
liquid.
Ensure proper functioning in this way:
1. Open feed line for flushing liquid.
2. Bleed cartridge seal.
3. Ensure unpressurised circulation.
Use a pure flushing liquid which is compatible with the pumped
liquid.
In case of abrasive liquids, provide a reservoir into which the
flushing liquid is discharged directly.
4.5 Electrical connections
4.5.1 Star connection
Star connection of three-phase system for high voltage.
Connect the pump as specified in the order documents. The
figure below shows star connection.
Fig. 11 Star connection
4.5.2 Delta connection
Delta connection for low voltage.
Connect the pump as specified in the order documents. The
figure below shows delta connection.
Fig. 12 Delta connection
4.5.3 Frequency converter operation
All three-phase motors can be connected to a frequency
converter. Frequency converter operation can subject the motor
insulation to enhanced strain. This may lead to more motor noise
than normal as a result of eddy currents caused by transients.
Large motors operated via a frequency converter are subject
to bearing currents. For motors size 37 kW and higher in
pumps that are operated by an external frequency converter,
HILGE recommends the use of insulated motor bearings to
avoid increased wear of motor bearings by bearing currents.
TM05 6446 4912
WARNING
Dry running!
▲Damage to property!
►Connect the lines of the flushing system so as to
guarantee a liquid supply.
►Always keep the filling level of the liquid pot
between the upper and lower marks.
►In case of unpressurised flushing, ensure that the
pressure in the cartridge seal never exceeds 0.2
bar.
0491.00
A
B
N
WARNING
Electric shock!
▲Death, serious bodily injury.
►The electrical connections must be made by a
qualified electrician.
►VDE specifications and any local regulations
must be followed, especially those pertaining to
safety measures.
DANGER
Motors with frequency converters (Tronic) - risk
of electric shock from live parts!
▲Death and serious bodily injury.
►Even if the power supply is switched off, touching
electrical components can lead to electric shock.
►Before touching electrical components,
disconnect the power supply and wait at least
four minutes.
WARNING
Capacity overload!
▲Death, serious bodily injury, damage to property.
►Check that the operating voltage corresponds to
the voltage stated on the nameplate of the motor!
►Install an electrical circuit breaker.
CAUTION
Transients during frequency converter operation
▲Damage to property.
►Use a motor which is suitable for frequency
converter operation.
►Use a dU/dt filter or a motor with reinforced
windings to avoid transients.
TM05 6448 4912TM05 6447 4912
U1 V1 W1
W2 U2 V2
L1 L2 L3
U1 V1 W1
W2 U2 V2
L1 L2 L3

11
Please consider the following operating conditions if the pump is
operated using a frequency converter:
Please follow the manufacturer's instructions when installing and
operating a frequency converter.
4.5.4 Checking the direction of rotation after connection
Check the direction of rotation in this way:
1. After electrical connection, mount all safety equipment again.
2. Check tightness of hydraulic connection.
3. Open isolating valves.
4. Fill pump (system).
5. Observe the direction-of-rotation arrow.
6. Switch on motor for a short time (1-2 seconds).
7. Compare directions (motor/arrow).
8. Correct connection if necessary.
Operation with frequency converter
See the manufacturer’s documentation.
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. Compare the data of the following documents with the
provided application conditions of the pump:
–purchasing documents (confirmation of the order)
–nameplate
–operating manual.
2. Make sure that the pump will operate under the specified
conditions only. Theses conditions apply to (e.g.) pressure,
temperature, and pumped liquid.
5.1.2 Starting up the pump
Start-up the pump in this way:
1. Check tightness of connection.
2. Make sure that all safety equipment is installed.
3. Make sure that all electrical connections are correct.
4. Open the isolating valves in the system.
5. Fill the pump together with the system.
6. Vent the pump and system.
7. Fully open the isolating valve on the suction side.
8. Close the isolating valve on the discharge side.
9. Start the pump.
10. Slowly open the isolating valve on the discharge side.
If the discharge head does not rise after the pump has been
turned on:
1. Switch off the pump.
2. Vent the pump (system) again.
3. Repeat steps 7. to 10.
5.1.3 Functional check of the mechanical seal
Check the function of the mechanical seal in this way:
1. Watch the pump and check the mechanical seal for fault-free
functioning (leak test).
2. An intact mechanical seal works virtually without leakage.
If the pumped liquid or flushing liquid leaks:
1. Switch off the pump.
2. Replace the mechanical seal.
Observe safety instructions in chapter 6.1.
Operating
conditions Actions
Noise-sensitive
applications
Install a dU/dt filter between the motor
and the frequency converter (reduces
transients and thus also noise).
Highly noise-
sensitive
applications
Install a sinus filter.
Cable length
Use a cable that satisfies the conditions
specified by the frequency converter
manufacturer.
The length of the cable between the
motor and the frequency converter
impacts motor load. Keep the cable as
short as possible.
Use a sinus filter for cable lengths of 150
m and up.
Supply voltage up to
500 V
Check if the motor is suitable for
frequency converter operation.
Supply voltage
between 500 V and
690 V
Install a dU/dt filter between the motor
and the frequency converter (reduces
transients and thus also noise), or check
whether the motor has reinforced
insulation.
Supply voltage of
690 V and up
Install a dU/dt filter between the motor
and the frequency converter and check
whether the motor has reinforced
insulation.
Caution
CAUTION
Danger of dry running!
▲Damage to property.
►Before checking the direction of rotation, fill and
vent the pump.
►Connect the motor and briefly (for about 2
seconds) check the direction of rotation. Note the
direction-of-rotation arrow (red) on the pump. If
the pump turns in the wrong direction, the
mechanical seal can be destroyed.
Caution
CAUTION
Overheating and pressure overloading!
▲Damage to property.
►Never operate the pump against a closed
isolating valve. Operation with a closed isolating
valve must on no account continue for longer
than 30 seconds.
►Never exceed the permissible operating
conditions.

12
5.2 Shutting down the pump
A pressure surge is an abrupt pressure increase in the
system. This pressure increase can, for example, be caused
by a quick blocking of the flow in the discharge pipe. In the
event of a pressure surge the maximum permissible pump
pressure is temporarily exceeded considerably.
Shut down the pump in this way:
1. Switch off the pump.
2. Close the isolating valve on the discharge side.
3. Close the isolating valve on the suction side.
4. Switch off the flushing system (if applicable).
5. Make sure that the pump is depressurised.
6. Switch off the pressure in the barrier system (if applicable).
5.2.1 Cleaning the pump after shut-down
See section 2.11, page 5.
6. Maintenance/servicing
Overview
This section gives important information about maintenance and
servicing of the pump. Read this section before you carry out
maintenance work or troubleshooting measures!
6.1 Safety instructions for installation, inspection and
maintenance work
6.2 Maintenance of the pump
The pump is a low-maintenance pump. In addition to cleaning,
the only point to be kept in mind is the wear to the rotating
mechanical seal.
WARNING
Pressure surge!
▲Death, serious bodily injury, damage to property.
►Always close isolating valves slowly!
Caution
CAUTION
Jamming!
▲Damage to property.
►Clean the pump appropriately after shut-down.
WARNING
Unprofessional work!
▲Death, bodily injury, damage to property.
►The operations manager must ensure that all
installation, inspection and maintenance work is
carried out by authorised and qualified technical
personnel, who have acquired the required
knowledge through study of the operating
instructions.
DANGER
Electric shock if electrical parts are touched!
▲Death, bodily injury.
►Always turn off the power supply to the pump
before rectifying any fault.
DANGER
For motors with frequency converters (Tronic) -
risk of electric shock from live parts!
▲Death and serious bodily injury.
►Even if the power supply is switched off, touching
electrical components can lead to electric shock.
►Before touching electrical components,
disconnect the power supply and wait at least
four minutes.
WARNING
Pressurised spray!
▲Death, bodily injury, damage to property.
►Depressurise the pump before rectifying any
fault.
WARNING
Hot components!
▲Death, bodily injury, damage to property.
►Always allow the pump to cool down before
rectifying any fault.
WARNING
Unintentional switching on of the pump!
▲Death, bodily injury, damage to property.
►Take appropriate measures to ensure that the
pump cannot be unintentionally turned on again.
WARNING
Contact with or inhalation of hazardous
substances!
▲Death, bodily injury, damage to property.
►Pumps or systems which convey hazardous
liquids must be decontaminated.
WARNING
Missing protection and safety equipment!
▲Death, bodily injury, damage to property.
►Immediately after completing the work, re-install
the protection and safety equipment and make
sure it functions correctly.
Caution
CAUTION
Unsuitable tools!
▲Damage to property.
►In accordance with the design standard (3A0.01
to 3A3.37), ensure that all parts of the pump can
be assembled without damage (e.g. scratches).
►Use HILGE assembly tool kit.
Caution
CAUTION
Frost!
▲Damage to property.
►When there is danger of frost, drain the pump
completely.

13
6.3 Maintenance of the motor
6.3.1 Motors without lubrication fittings
Motors without lubrication fittings are greased for life. The grease
service lifetime is based on the bearing service lifetime. The
prerequisite is that the motor is used according to catalogue
specifications.
6.3.2 Motors with lubrication fittings
On motors equipped with lubrication fittings, information
regarding re-lubrication intervals, grease types, grease volumes
and additional information as needed is listed on the lubricating
plate or nameplate.
Fig. 13 Example of lubricating plate, MGE motor
1 - drive-end bearing
2 - grease type
3 - ambient temperature
4 - ambient temperature
5 - non-drive-end bearing
6 - grease quality
7 - lubricating interval
8 - lubricating interval.
TM04 2075 1908
1
2
3
4
5
6
7
8

14
6.4 Assembly
6.4.1 Parts overview, MAXA
Valid for pump sizes 65-160/200/250.
Fig. 14 Parts overview
* In the Bloc version, the backplate 0161.00 will be replaced by
an intermediate ring 0346.01.
DANGER
Disregard of instructions!
▲Death, bodily injury or damage to property.
►Before assembly or maintenance work of the
pump, see section 6.1.
TM05 4143 4912
0236.00
0103.00
0412.04
0930.00
0922.00
0902.02
0934.00
0920.04
0230.00
0504.09
0433.00
0412.00
0167.00
0161.00 (0346.01)*
Pos. Part no. Designation Pos. Part no. Designation
1 0103.00 Annular casing 1 0433.00 Mechanical seal
1 0161.00 Backplate (not applicable in Bloc version) 1 0504.09 Spacer ring
1 0167.00 Backplate liner 8 0902.02 Stud
1 0230.00 Impeller 8 0920.04 Hexagon nut
1 0236.00 Inducer (optional) 1 0922.00 Impeller nut
1 0412.00 O-ring 2 0930.00 Toothed lock washer
1 0412.04 O-ring 8 0934.00 Spring washer

15
6.4.2 Parts overview, MAXA
Pump size 80-160.
Fig. 15 Parts overview
* In the Bloc version, the backplate 0161.00 will be replaced by
an intermediate ring 0346.01.
TM05 6750 0213
0236.00
0102.00
0412.04
0930.00
0922.00
0902.02
0934.00
0920.04
0230.00
0504.09
0433.00
0412.00
0167.00
0161.00 (0346.01)*
Qty. Part no. Designation Qty. Part no. Designation
1 0102.00 Volute casing 1 0433.00 Mechanical seal
1 0161.00 Backplate (not applicable in Bloc version) 1 0504.09 Spacer ring
1 0167.00 Backplate liner 8 0902.02 Stud
1 0230.00 Impeller 8 0920.04 Hexagon nut
1 0236.00 Inducer (optional) 1 0922.00 Impeller nut
1 0412.00 O-ring 2 0930.00 Toothed lock washer
1 0412.04 O-ring 8 0934.00 Spring washer

16
6.4.3 Bloc intermediate ring
Fig. 16 Parts overview, bloc intermediate ring
TM05 6452 4912
0902.06
0346.01
0686.01
0950.00
0183.00
0934.06
0920.09
Qty. Part no. Designation Qty. Part no. Designation
1 0183.00 Supporting foot (up to motor size 112) 4 0920.09 Hexagon nut
1 0346.01 Intermediate ring 4 0934.06 Spring washer
1 0686.01 Guard 1 0950.00 Tension spring
4 0902.06 Stud

17
6.4.4 Bloc motor
Fig. 17 Parts overview, Bloc motor
6.4.5 Instructions for disassembly 6.4.6 Instructions for assembly
TM05 6886 0213
0802.00
0940.00
Qty. Part no. Designation Qty. Part no. Designation
1 0802.00 Bloc motor 1 0940.00 Key
DANGER
Disregarding important instructions!
▲Death, serious bodily injury, damage to property.
►Before you disassemble the pump, note section
6.1 Safety instructions for installation, inspection
and maintenance work on page 12.
Caution
CAUTION
Important!
▲Damage to property.
►Use tools from the HILGE assembly tool kit in
order to disassemble the pump without damage
and scratches.
DANGER
Disregarding important instructions!
▲Death, serious bodily injury, damage to property.
►Before you assemble or do maintenance work on
the pump, note section 6.1 Safety instructions for
installation, inspection and maintenance work on
page 12.
Caution
CAUTION
Important!
▲Damage to property.
►Use tools from the HILGE assembly tool kit in
order to assemble the pump without damage or
scratches.
►To ensure a good sealing, use only O-ring seals
with the original dimensions.
►Never use grease containing mineral oil when
assembling the wet-end parts. Wet-end parts
come into contact with the pumped liquid.
►When replacing mechanical seals, always
replace all parts.
►To tighten impeller nut 0922.00, use either a
screw device or the impeller nut installing device
as the torque applied to tighten it must be
absolutely concentric. Otherwise the pump shaft
0211.00 will be bent.

18
6.4.7 Single mechanical seal
Fig. 18 Single mechanical seal
Parts overview
0167.00 - backplate liner
0433.00 - mechanical seal
0504.09 - spacer ring
0516.01 - locating ring.
Characteristics
– Single mechanical seal
– seat in backplate liner 0167.00.
Prior to installation
• Check the shaft and the counter-ring seat for contamination
and damage (sharp edges). Clean the parts or replace them
as needed.
• Check all O-rings in the mechanical seal to make sure they are
properly situated and correct if necessary.
• In order to reduce friction, moisten all of the O-ring sliding
surfaces with water.
Assembly
1. Insert the backplate liner 0167.00 into the intermediate ring
0346.01.
2. Grease the surfaces between the intermediate ring 0346.01
and the Bloc motor 0802.00. Use Klüberpaste UH1 96-402 to
do this.
3. Mount the intermediate ring 0346.01 on the Bloc motor
0802.00.
4. Slide the assembly sleeve onto the shaft extension.
5. Push the stationary ring of the mechanical seal 0433.00 into
the seat of the backplate liner 0167.00. Use an assembly
sleeve to do this.
6. Push the rotating ring of the mechanical seal 0433.00 onto the
shaft 0211.00. Use an assembly sleeve to do this.
7. Push the spacer ring 0504.09 onto the shaft 0211.00.
For assembly of the impeller and volute casing, see section
6.4.10 Assembly of the impeller and volute casing.
6.4.8 Single mechanical seal with backplate liner
Fig. 19 Single mechanical seal
Parts overview
0161.00 - backplate
0167.00 - backplate liner
0412.02 - O-ring
0433.00 - mechanical seal
0491.00 - cartridge seal
0504.09 - spacer ring
0557.00 - seal spacer
0902.08 - stud
0920.15 - hexagon nut
0934.11 - spring washer.
Characteristics
–Single mechanical seal
– seat in cartridge seal
–with backplate liner.
Prior to installation
• Check the shaft and the counter-ring seat for contamination
and damage (sharp edges). Clean the parts or replace them
as needed.
• Check all O-rings in the mechanical seal to make sure they are
properly situated and correct them, if necessary.
• In order to reduce friction, moisten all of the O-ring sliding
surfaces with water.
Assembly
1. Insert the backplate liner 0167.00 into the intermediate ring
0346.01.
2. Insert the O-ring 0412.02 into the groove of the cartridge seal
0491.00.
3. Push the mechanical cartridge seal 0491.00 into the
backplate liner 0167.00.
4. Fasten the cartridge seal 0491.00 on the intermediate ring
0346.01. Use spring washers 0934.11 and hexagon nuts
0920.15 to do this. Torque: M8 - 19 Nm.
5. Grease the locating ring between the intermediate ring
0346.01 and the Bloc motor 0802.00. Use Klüberpaste UH1
96-402 to do this.
6. Fasten the intermediate ring 0346.01 with the cartridge seal
0491.00 installed on the Bloc motor 0802.00.
7. Slide the assembly sleeve onto the shaft up to the stop.
8. Push the stationary ring of the mechanical seal 0433.00 into
the seat. Use an assembly sleeve to do this.
9. Push the rotating ring of the mechanical seal 0433.00 onto the
shaft 0211.00 and up to the stop. Use an assembly sleeve to
do this.
10. Push the spacer ring 0504.09 onto the shaft.
For assembly of the impeller and volute casing, see section
6.4.10 Assembly of the impeller and volute casing on page 20.
TM05 6453 4912
TM05 6454 4912

19
6.4.9 Double mechanical seal, tandem
Fig. 20 Double mechanical seal, tandem
Parts overview
0167.00 - backplate liner
0230.00 - impeller
0346.01 - intermediate ring
0412.02 - O-ring
0412.83 - O-ring
0433.00 - mechanical seal
0433.01 - mechanical seal
0491.00 - cartridge seal
0504.09 - spacer ring.
Characteristics
– Double mechanical seal
– seat in cartridge seal 0491.00
– space saving - with spacer ring 0504.09.
Prior to installation
• Check the shaft and the counter-ring seat for contamination
and damage (sharp edges). Clean the parts or replace them
as needed.
• Check all O-rings in the mechanical seal to make sure they are
properly situated and correct them, if necessary.
• In order to reduce friction, moisten all of the O-ring sliding
surfaces with water.
Assembly
1. Insert the backplate liner 0167.00 into the intermediate ring
0346.01.
2. Insert the O-ring 0412.02 into the seal cartridge 0491.00.
3. Press the cartridge seal 0491.00 into the intermediate ring
0346.01.
4. Mount the cartridge seal 0491.00 in the intermediate ring
0346.01. Use spring washers 0934.11 and hexagon nuts
0920.15 to do this.
5. Grease the contact surfaces between the intermediate ring
0346.01 and the Bloc motor 0802.00. Use Klüberpaste UH1
96-402 to do this.
6. Mount the intermediate ring 0346.01 on the Bloc motor
0802.00.
7. Slide the assembly sleeve onto the shaft extension.
8. Insert the stationary ring of the mechanical seal 0433.01 into
the seat. Use an assembly sleeve to do this.
9. Slide the rotating ring of the mechanical seal 0433.01 onto the
shaft 0211.00. Use an assembly sleeve to do this.
10. Slide the stationary ring of the mechanical seal 0433.00 into
the seat on the shaft. Use an assembly sleeve to do this.
11. Slide the rotating ring of the mechanical seal 0433.00 onto the
spacer ring 0504.09 up to the stop.
12. Remove the assembly sleeve.
13. Insert the O-ring 0412.83 into the spacer ring 0504.09. Slide
the spacer ring 0504.09 onto the shaft 0211.00.
For assembly of the impeller and volute casing, see section
6.4.10.
TM05 6455 4912
0167.00 0346.01
0491.00
0412.02
0433.00
0433.01
0504.09
0230.00
0412.83

20
6.4.10 Assembly of the impeller and volute casing
1. Insert the key 0940.00. 2. Grease the impeller seat and threaded pump shaft 0211.00.
Use Klüberpaste UH1 96-402 from the HILGE assembly tool kit
for this (pos. 6, fig. 35).
MF-343
Fig. 21 Key
MF-583
Fig. 22 Pump shaft
3. Mount the impeller 0230.00. 4. Grease the toothed lock washer 0930.00.
Use Klüberpaste UH1 96-402 from the HILGE assembly tool kit
for this (pos. 6, fig. 35).
MF-573
Fig. 23 Impeller
MF-619
Fig. 24 Toothed lock washer
5. Grease the toothed lock washer 0930.00 as well as the threads
of the impeller nut 0922.00a as shown.
6. Insert the toothed lock washer 0930.00 into the impeller nut
0922.00.a
K.0225V1
Fig. 25 Schematic drawing of toothed lock washer
0230.00 - impeller
0412.04 - O-ring
0922.00 - impeller nut
A - fine toothing - greased
B - thick toothing against each other - greased.
MF-377
Fig. 26 Toothed lock washer in impeller nut
7. Tighten the impeller nut 0922.00a by hand. Leave about 5 mm
space for the O-ring 0412.04.b8. Wet the O-ring 0412.04 with clean water and slide it over the
impeller nut 0922.00ainto the gap between impeller nut and
impeller 0230.00.b
MF-406
Fig. 27 Impeller nut
MF-528
Fig. 28 O-ring
a) Optional inducer 0236.00 b) Applies to EPDM and Viton O-rings.
In case of other O-ring materials or use of an inducer, insert O-ring
into impeller nut 0922.00 or inducer 0236.00 before it is screwed
on.
9. Tighten the impeller nut 0922.00ato the following torques:
M20 - 100-120 Nm
M24 - 180-230 Nm
M30 - 210-250 Nm.
10.Release the spring of the mechanical seal’s rotating ring
against the impeller 0230.00.
ABA
0922.00
0230.00
0412.04