GEA Hilge NOVALOBE 60 User manual

Hygienic Pumps
GEA Hilge NOVALOBE 60
Operating instruction (Translation from the original language)
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COPYRIGHT
All rights reserved.
Nothing contained in this documentation may be reproduced or distributed in any
form (print, photocopy, microfilm or another method) without the prior written
permission of
GEA Hilge
Niederlassung der GEA Tuchenhagen GmbH
hereinafter referred to as Manufacturer This restriction also applies to the
drawings and diagrams included in the documentation.
LEGAL NOTICE
These instructions are part of the technical documentation, which is part of the
scope of delivery. They contain important information to ensure safe and proper
transportation, mounting, commissioning, economic operation, maintenance, and
repair of the pump. Following these instructions will help you avoid risks, reduce
repair costs and downtime and increase the pump's reliability and service life.
These instructions are aimed at users of the pump and are intended in particular
for the operator and its operating and maintenance personnel.
It is mandatory for the operator and its operating and maintenance personnel to
read these instructions prior to transport, installation, commissioning, use,
maintenance, repair, disassembly and disposal of the pump. The obligation to
read these instructions applies also to persons responsible for carrying out
activities in the phases of the life of the pump.
The operator is required to complement these instructions with information based
on existing national regulations for occupational safety, health protection, and
environmental protection.
In addition to these instructions and the mandatory regulations for accident
prevention applicable in the country and place of use, the recognised technical
rules for safe and proper work must be observed.
These instructions are part of the pump. The entire documentation consists of
these instructions and any additional instructions provided. It must always be kept
within reach at the pump’s location of use. When moving the pump to a different
site and upon selling the pump, the entire documentation must be passed on as
well.
These instructions were written to the best of our conscience. However, the
manufacturer is not liable for any errors that may be contained in this document
or for any resulting consequences.
The manufacturer reserves the right to make technical changes by further
development of the pump described in these instructions.
Illustrations and drawings in these instructions are simplified representations.
Due to enhancements and changes, it is possible that the illustrations do not
exactly match the pump used by you. The technical data and dimensions are not
binding. Claims cannot be derived from them.
The manufacturer assumes no liability for damages
•arising within the warranty period due to
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–unintended operation and usage conditions,
–insufficient maintenance,
–improper operation,
–incorrect installation,
–incorrect or improper connection of electrical components.
•resulting or arising from unauthorised modifications or failure to follow the
instructions,
•caused by use of accessories / spare parts that have not been supplied or
recommended by the manufacturer.
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SYMBOLS USED
Danger
Stands for an immediate danger which leads to heavy physical injuries
or to the death.
Warning!
Stands for a possibly dangerous situation which leads to heavy
physical injuries or to the death.
Caution!
Stands for a possibly dangerous situation which could lead to light
physical injuries or to damages to property.
Hint!
Stands for an important tip whose attention is important for the
designated use and function of the device.
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LAYOUT INFORMATION
Bullet points and numbered list characters
Bullet points are used to separate logical contents within a section:
•Bullet point 1
Types of bullet point 1.
•Bullet point 2
Types of bullet point 2.
Numbered list characters are used to separate enumerations within a
descriptive text:
Descriptive text with consecutive numbering:
–Numbered list point 1
–Numbered list point 2
Handling instructions
Handling instructions require you to do something. Several consecutive steps
result in a handling sequence that should be run in the specified order. The
handling sequence can be divided into separate steps.
Handling sequence
1. Handling sequence step 1
–step 1,
–step 2,
–step 3.
2. Handling sequence step 2
The subsequent handling sequence is the expected result:
®Result of the handling sequence.
Individual handling steps
Individual handling steps are marked thus:
–Individual work steps
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TABLE OF CONTENTS
1 General 9
1.1 Information about this document 9
1.2 Manufacturer address 9
1.3 Customer service 9
1.4 EU Declaration of Conformity for Machines 10
2 Safety 11
2.1 Intended use 11
2.1.1 Pumped fluids 11
Abrasive media 11
Maximum particle size in the pumping medium 11
2.1.2 Connections and piping 11
2.1.3 Switching frequency 11
2.1.4 Types 12
2.2 Safety precautions in these operating instructions 12
2.3 Explanation of the safety symbols used 13
2.4 Safety instructions for the company/operator 13
2.4.1 Dangers of non-compliance with safety information 14
2.4.2 Safety-conscious work behaviour 14
2.5 Unauthorised modification and ordering of spare parts 14
2.6 Staff qualifications and training 15
2.7 Safety equipment 15
3 Description 16
3.1 Pump overview 16
3.2 Description 16
3.2.1 Standard version applications 16
3.3 Pump name 17
3.4 Nameplate 17
4 Transport and Storage 18
4.1 Special personnel qualification for transport and storage 18
4.2 Safety precautions for transport and storage 18
4.3 Dimensions / weights 19
4.4 Unpacking the pump 19
4.5 Storage of the pump 19
4.6 Disposal of packaging material 20
5 Technical data 21
5.1 Serial number 21
5.2 Performance data 21
5.3 Noise emissions 21
5.4 Maximum operating temperatures 21
5.5 Maximum operating pressure 21
5.6 Rotation speed for O-ring seals 22
5.7 Gap dimensions 22
6 Assembly and installation 23
6.1 Safety precautions for setup, installation, and connection 23
6.2 Special personnel qualification 25
6.3 Setup, installation, and connection 25
6.3.1 Checking smooth running of the rotors 25
6.3.2 Setting up and aligning the pump unit 25
6.3.3 Installation in the piping system 26
Using the mechanical seal 26
Space requirements 27
Noise and vibration damping 27
6.3.4 Flush ports 27
Flushing fluid (optional) 27
Flushing systems 28
Connecting the flushing 28
6.3.5 Electrical connection 29
Star connection 29
Delta connection 29
Frequency converter operation 29
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Checking the direction of rotation after connecting 30
Earthing 30
6.3.6 Operation Principle 31
7 Commissioning 32
7.1 Special personnel qualification 32
7.2 Safety instructions for commissioning 32
7.3 Commissioning / initial startup 32
7.3.1 Checking conditions of use 32
7.3.2 Commissioning of the pump 32
7.3.3 Functional testing of the mechanical seal 33
8 Cleaning 34
8.1 Special personnel qualification 34
8.2 Safety instructions 34
8.3 CIP 35
8.4 SIP 36
8.5 Manual exterior cleaning 36
9 Maintenance / servicing 37
9.1 Safety instructions for maintenance and servicing 37
9.1.1 Safety instructions rotors 37
9.2 Special personnel qualification 37
9.3 Pump maintenance 37
9.3.1 Daily maintenance 37
Replacement of O-rings 38
9.3.2 Gear lubrication 38
Relubrication interval 38
Oil quantities 38
Oil types 38
Information on the gear unit nameplate 39
9.4 Maintenance of the motor 39
10 Malfunctions / repairs 41
10.1 Special personnel qualification 41
10.2 Safety instructions 41
10.3 Malfunctions and remedies 42
10.4 Repair 43
10.4.1 Repair order 43
10.4.2 Parts overview NOVALOBE 60 44
10.4.3 Parts overview assembly NOVALOBE 60 46
10.4.4 Parts overview motor installation 48
10.4.5 Installation instructions 50
10.4.6 Seal variants 51
10.4.7 Disassemble rotors and mechanical seals 52
10.4.8 Install mechanical seals and rotors 55
Torques for assembly 59
11 Decommissioning 60
11.1 Special personnel qualification 60
11.2 Safety instructions 60
11.3 Temporary decommissioning 60
11.4 Disposal 60
12 Appendix 61
12.1 Clearance certificate 61
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1 General
1.1 Information about this document
Target group
These operating instructions are intended for:
–the operator/user of the pump,
–the maintenance and service personnel.
The instructions assume a general common technical understanding, which is
necessary for the commissioning, maintenance and servicing of pump units.
Sections that are aimed only at special authorised personnel are indicated by a
preceding note.
Text highlights
The following symbols and text formatting facilitate the reading of this document:
–Bullets and lists points
–Instructions.
Instructions that must be executed in a certain order are numbered according to
the sequence.
For the marking of safety instructions, please refer to Section 2.3, Page 13.
Technical changes
Types, technical data and spare part numbers are subject to technical change.
We reserve the right to implement changes due to technical progress.
1.2 Manufacturer address
GEA Hilge
Niederlassung der GEA Tuchenhagen GmbH
Hilgestraße 37-47
55294 Bodenheim
Germany
Phone [phone]
Fax [phone]
[email protected]
gea.com
1.3 Customer service
Phone [phone] (Sales support)
Phone [phone] (Service)
[email protected]
General
Information about this document
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1.4 EU Declaration of Conformity for Machines
in accordance with the EC Machinery Directive 2006/42/EC, Annex II 1. A
Manufacturer: GEA HILGE
Niederlassung der GEA Tuchenhagen GmbH
Hilgestrasse 37-47
D 55294 Bodenheim Germany
We declare under our sole responsibility that the machine
Designation: Rotary piston pump
Model: GEA Hilge NOVALOBE
Size: 60
conforms with all the relevant provisions of this directive and the following directives:
Relevant EC directives: 2006/42/EC EC Machinery Directive
Applicable harmonized
standards, in particular:
EN 809:1998/A1+AC(D)
EN ISO 12100:2010
Remarks: We also declare that the relevant technical documentation for
this machine has been prepared in accordance with Annex VII,
Part A, and agree to submit the documentation on justified
request of national authorities on a data carrier.
Person authorised for compilation and
handover of technical documentation:
GEA HILGE
Niederlassung der GEA Tuchenhagen GmbH
Hilgestrasse 37-47
55294 Bodenheim Germany
Bodenheim, 30/11/2018
Michael Wulle
Managing Director
p.p. Dr. Boris Kneip
Head, Development Dept. GEA Hilge
General
EU Declaration of Conformity for Machines
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2 Safety
2.1 Intended use
Warning!
Non-intended use!
► Pump only media that are specified in the order. The pump has been
specially designed for them.
► Operate the pump only on the electrical grid that was specified in the
purchase order.
2.1.1 Pumped fluids
Use only clean or lightly polluted liquids as pumped fluids as long as they do not
chemically or mechanically attack the pump materials or reduce their strength. If
you want to pump liquids with higher viscosity than that of water, check for
possible overload of the motor.
2.1.1.1 Abrasive media
Do not pump media with hard or abrasive components.
Caution!
Danger due to hard or abrasive parts in the pumping medium.
Damage to property.
► Ensure that no hard or abrasive components get into the pump
2.1.1.2 Maximum particle size in the pumping medium
Maximum particle size in the pumping medium (for example, pieces of fruit, meat or something
similar)
NOVALOBE Particle size [mm]
(soft, not abrasive)
60/ 2.1 41
2.1.2 Connections and piping
The pipe nominal diameters of the system should be equal to or greater than the
pump nominal diameters DNE (suction side) or DNA (pressure side), and the
fittings to the pump should match exactly the type standard of the fixed mating
connection part on the pump. The suction line must be hermetically sealed and
routed such that no air pockets can form. Avoid tight bends and valves directly in
front of the pump. On the suction side, a straight settling section with a minimum
length of 5 times the pipe diameter should be provided.
2.1.3 Switching frequency
Do not exceed a switching frequency of 15 switching operations per hour.
Safety
Intended use
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2.1.4 Types
All information and descriptions in these operating instructions on the use and
handling of the pumps refer exclusively to the standard versions. Special designs
and customised deviations as well as random external influences in the use and
operation are not included in these instructions.
2.2 Safety precautions in these operating instructions
Read the safety precautions!
These operating instructions contain basic precautions that must be observed
during installation, operation and maintenance. They must therefore be read by
the installer and relevant personnel or operator prior to installation and
commissioning. The operating instructions must always be available at machine/
system site.
In addition to the general safety precautions listed in this chapter on safety, be
sure to read also the other, special safety precautions included.
Safety
Safety precautions in these operating instructions
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2.3 Explanation of the safety symbols used
Danger
Stands for an immediate danger which leads to heavy physical injuries or to
the death.
► Description to avert the danger
Warning!
Stands for a possibly dangerous situation which leads to heavy physical
injuries or to the death.
► Description to avert the dangerous situation.
Caution!
Stands for a possibly dangerous situation which could lead to light physical
injuries or to damages to property.
► Description to avert the dangerous situation.
Notice
Stands for an important tip whose attention is important for the designated
use and function of the product.
► Description of the necessary action for proper operation of the product.
2.4 Safety instructions for the company/operator
Follow the safety instructions contained in this operating manual, the relevant
national accident prevention regulations as well as any internal working,
operating, and safety provisions of the operating company.
Warning!
Hot or cold machine parts
Risk of burns.
► Secure hot or cold machine parts against contact!
Warning!
Rotating machine parts
Hazard of entrapment or entanglement.
► Do not remove contact protection for rotating machine parts (e.g.
coupling)!
► Replace defective safety devices promptly!
Safety
Explanation of the safety symbols used
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Warning!
Hazardous materials
Contact with dangerous substances, e.g. by inhalation.
► Discharge the leakage of dangerous goods such that no danger to
persons and the environment arises!
► Comply with legal provisions!
► Switch off the pump in the event of failure of the mechanical seal.
Replace the mechanical seal before next use!
Warning!
Tripping and falling hazard
Danger due to electrical cables.
► Route the electrical supply line such that there is no risk of tripping (only
for pumps on a chassis).
Danger
Live parts
Electric shock by touching live parts
► Use only technically flawless plugs and cables.
2.4.1 Dangers of non-compliance with safety information
Ignoring the safety instructions can result in bodily harm to persons as well as
environmental harm and machine damage.
Failure to follow the safety instructions will result in the loss of any claims for
damages.
Failure to follow the instructions may entail the following hazards, for example:
–Failure of important functions of the machine/system.
–Failure of prescribed methods for repair and maintenance
–Exposure of persons to electrical, mechanical, and chemical hazards.
–Environmental risks caused by leakage of hazardous substances.
2.4.2 Safety-conscious work behaviour
Follow the safety instructions contained in this operating manual, the relevant
national accident prevention regulations as well as any internal working,
operating, and safety provisions of the operating company.
2.5 Unauthorised modification and ordering of spare parts
Modification or alteration of the machine is only permitted with the written
permission of the manufacturer.
Exclusive use of original spare parts and accessories authorised by the
manufacturer ensures safety. The manufacturer will bear no liability for
consequences arising from the use of unauthorised parts.
Safety
Unauthorised modification and ordering of spare parts
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2.6 Staff qualifications and training
The staff for working on and with the pump must have the appropriate
qualifications. Responsibilities, competencies and supervision of staff must be
clearly defined by the operating company. If personnel do not have the necessary
knowledge, they are to be trained and instructed. If necessary, this can be done
by the product manufacturer/vendor on behalf of the operating company. The
operating company must also ensure that the contents of the operating
instructions are fully understood by the staff.
2.7 Safety equipment
Do not remove instructions from the pump.
Signs attached directly on the machine, such as an arrow to indicate the direction
of rotation, must absolutely be observed and kept in fully legible condition.
Damaged or illegible signs must be replaced.
Safety
Staff qualifications and training
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3 Description
3.1 Pump overview
1
2
3
8
5
6
7
4
Fig.1: Schematic representation of NOVALOBE 60
Pump overview of NOVALOBE 10-50
Item Description Item Description
1 Suction/discharge port 5 Base frame
2 Gear 6 Oil inlet / oil outlet
3 Coupling guard 7 Display gear oil level
4 Gear motor 8 Suction/discharge port
3.2 Description
Pumps of the NOVALOBE series are rotary piston positive displacement pumps.
They have been specially developed for high-viscosity liquids as well as for the
requirements of sterile process technology.
3.2.1 Standard version applications
NOVAlobe pumps are robust rotary piston pumps for pumping highly viscous
liquids. In addition to the special hygiene requirements in sterile processes, the
development focused on careful pumping of the medium. The NOVAlobe pump
range offers reliable, efficient and hygienic operation in a wide range of
demanding conditions. The pumps can be operated in both directions of rotation
and are suitable, for example, for the following applications:
Food and beverage industry
•Dairies (fruit yoghurt, butter, soft cheese, etc.)
•Food production (sauces, dressing, baby food etc.)
Description
Pump overview
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•Soft drinks (syrup, juices etc.)
•Sweets (caramel, chocolate, etc.)
•Meat production (meat, animal fat, etc.)
•Brewery (yeast)
Pharmaceutical industry, biotechnology and cosmetics
•Vaccines
•Fermentation broth
•Blood plasma
•Shampoo, Lotions etc.
Other industrial applications
•Paper industry
•Textile industry
•Chemistry (oils, fats, etc.)
3.3 Pump name
GEA Hilge pump name
GEA Hilge NOVALOBE 60 2.1 100/100 BW 11 4 200
Pump name Size
Displacement
per revolution
[l]
Nominal width
Rotor form
BW: Bi-wing
ML: Multilobe
Motor
performance
[kW]
Number of
poles
Output speed
Operating point
3.4 Nameplate
GEA Hilge
Niederlassung der GEA Tuchenhagen GmbH
Hilgestrasse - D - 55294 Bodenheim
Pump-Type:
Ser.-No.:
Q: H: n:
P:
TAG No.:
YOM: Made in Germany
Fig.2: Nameplate
Pump type: Pump name TAG No.:customer name
Serial No.: Serial number P: Motor rating
Q: Flow rate n: Engine speed
H: Pressure YOM: Year of manufacture
Note: The nameplate may differ from the presented layout.
Description
Pump name
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4 Transport and Storage
4.1 Special personnel qualification for transport and storage
Transports may only be carried out by qualified staff, who must observe the
safety instructions.
4.2 Safety precautions for transport and storage
Warning!
Danger from packaging material with sharp edges!
► Wear gloves when removing the transport belts.
Warning!
Danger from tilting / toppling over of the pump!
► Before removing the transport protection observe the pump’s centre of
gravity.
► Secure the pump against unintentional tilting / falling over.
Warning!
Danger from unintentional rolling away!
► When transporting the pump with a pallet truck of a different industrial
truck, secure the transported goods against unintentional rolling away.
► Secure the pump sufficiently against tipping over and falling down during
transport.
Danger
Falling loads
Danger from falling loads.
► To transport the pump, use suitable load lifting equipment in proper
condition with sufficient carrying capacity.
► Make sure that there are no persons present under suspended loads.
► Make sure that the pump is horizontally aligned when lifting.
Danger
Wrong attachment points!
► Attach the rope to suitable anchor points.
► Never fasten a rope to the pump housing or the suction/discharge port!
► For version with casing: Remove the stainless steel casing before
transport.
Warning!
Danger due to the rotor of the rotary piston pump.
Squeezing or shearing.
► Never put fingers in the connections. The blades of the rotary piston
pump can also rotate without a drive.
Transport and Storage
Special personnel qualification for transport and storage
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Storage of the pump
Caution!
Frost
Risk due to external conditions.
► In case of frost risk, drain the pump completely.
If the pump is not used immediately, proper storage conditions are as important
for later operation as careful installation and proper maintenance.
Protect the pump from cold, moisture and dust, as well as against mechanical
influences.
Qualified personnel is required for proper installation and maintenance.
4.3 Dimensions / weights
The weights may differ from the ones shown here depending on the version and
accessories. Please contact the manufacturer for accurate information and quote
the pump / order number.
These net weights are based on pumps:
–without gear motor
–without coupling
–without base frame
–with DIN 11851 threaded connection
Size Weight [kg]
NOVAlobe 60 233
4.4 Unpacking the pump
All of our pumps leave our warehouse properly packaged to avoid damage in
transit.
Should you nevertheless find any damage after cautious unpacking and exact
inspection of the shipment, immediately notify the carrier (railway, post, freight
forwarder, shipping company). Make claims for damages. The transport risk
passes to the customer once the shipment has left our warehouse.
4.5 Storage of the pump
Follow the following instructions for the storage of the pump:
•The maximum storage period is two years.
•In case of frost risk, drain the pump completely. Protect the pump from low
temperatures.
•If the pump is not used immediately, proper storage conditions are as
important for later operation as careful installation and proper maintenance.
•During storage, the pump should be turned by hand at least once a month.
Parts such as shaft and bearings should change their position.
Transport and Storage
Dimensions / weights
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•After a longer storage period (more than 6 months), all elastomers (O-rings,
shaft seals) must be checked for their elasticity. Brittle elastomers must be
replaced.
•Protect the pump from cold, moisture and dust, as well as from mechanical
influences.
•Qualified personnel is required for proper installation and maintenance.
4.6 Disposal of packaging material
The generation of waste should be avoided or minimized wherever possible.
Surpluses and packaging materials not suitable for recycling should be disposed
of through an approved waste disposal company. Packaging materials not
suitable for recycling must always be disposed of in accordance with the
requirements of environmental protection and waste disposal legislation as well
as the requirements of the local authorities.
Packaging materials suitable for recycling should be reused or reprocessed.
Transport and Storage
Disposal of packaging material
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