GEA HYGIANA I Adapta User manual

HYGIANA I/II/III Adapta®
Operating manual
Translation of the original operating manual
BA.001.ADY.001.09.16.GB

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:
HYGIANA
Series
A
dapta
®
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
Dr. Boris Kneip
Hilgestraße 37-47
55294 Bodenheim, Germany
Bodenheim, 16 September 2016
Dr. Boris Kneip
Development & Engineering Manager

Hilge GmbH & Co. KG | BA.001.ADY.001.09.16.GB 3
Operating manual
GEA Hilge HYGIANAI/II/III Adapta®
1 Introduction ____________________________________________________________________ 5
1.1 Target group ____________________________________________________________ 5
1.2 Symbols and formatting ____________________________________________________ 5
1.3 References to the document ________________________________________________ 5
2 Safety ________________________________________________________________________ 5
2.1 Operator notes ___________________________________________________________ 5
2.1.1 Unpacking the pump ________________________________________________ 5
2.1.2 Storing the pump __________________________________________________ 5
2.2 Safety instructions in the operating manual _____________________________________ 5
2.3 Identification of instructions in the operating manual ______________________________ 6
2.3.1 Structure of safety instructions ________________________________________ 6
2.4 Qualification and training of personnel ________________________________________ 6
2.5 Dangers caused by failure to follow the safety instructions ________________________ 6
2.6 Safety-conscious work _____________________________________________________ 6
2.7 Safety instructions for the operator/user _______________________________________ 6
2.8 Unauthorised modifications and spare parts ____________________________________ 7
2.9 Improper operation ________________________________________________________ 7
2.10 Transport ______________________________________________________________ 7
2.11 Cleaning _______________________________________________________________ 7
2.11.1 CIP ____________________________________________________________ 7
2.11.2 SIP ____________________________________________________________ 8
2.12 Repair contract __________________________________________________________ 8
3 Product description ______________________________________________________________ 9
3.1 Pump overview __________________________________________________________ 9
3.2 Description ______________________________________________________________ 9
3.2.1 Areas of application ________________________________________________ 9
3.3 Proper usage ____________________________________________________________ 9
3.3.1 Pumped liquids ____________________________________________________ 9
3.3.2 Minimum flow rate, Qmin ____________________________________________ 9
3.3.3 Connections and pipelines ___________________________________________ 9
3.3.4 Motor operation ____________________________________________________ 9
3.3.5 Design ___________________________________________________________ 9
3.4 Technical data __________________________________________________________ 10
3.4.1 Type key ________________________________________________________ 10
3.4.2 Pump serial number _______________________________________________ 10
3.4.3 Nameplate ______________________________________________________ 10
3.4.4 Performance data _________________________________________________ 10
3.4.5 Noise emissions __________________________________________________ 10
3.4.6 Weights _________________________________________________________ 10
3.4.7 Maximum operating temperatures ____________________________________ 11
3.4.8 Maximum operating pressure ________________________________________ 11
4 Mounting, installation and connection _______________________________________________ 11
4.1 Inspection before pump installation __________________________________________ 11
4.1.1 How to check free running of the impeller ______________________________ 11
4.2 Set-up and alignment of the pump ___________________________________________ 12
4.3 Installation in the pipeline __________________________________________________ 12
4.3.1 Operation of the mechanical seal _____________________________________ 12
4.3.2 Space requirements _______________________________________________ 13
4.3.3 Reduction of noise and vibration _____________________________________ 13
4.4 Connection of flushing system ______________________________________________ 14
4.4.1 Double mechanical seal, back-to-back arrangement ______________________ 14
4.4.2 Double mechanical seal - tandem arrangement __________________________ 14
4.5 Electrical connections ____________________________________________________ 14
4.5.1 Star connection ___________________________________________________ 15
4.5.2 Delta connection __________________________________________________ 15
4.5.3 Frequency converter operation _______________________________________ 15
4.5.4 Checking the direction of rotation after connection ________________________ 15
5 Start-up / shut-down ____________________________________________________________ 16
5.1 Start-up _______________________________________________________________ 16
5.1.1 Check application conditions ________________________________________ 16
5.1.2 Starting up the pump ______________________________________________ 16
5.1.3 Functional check of the mechanical seal _______________________________ 16

4Hilge GmbH & Co. KG | BA.001.ADY.001.09.16.GB
Operating manual
GEA Hilge HYGIANAI/II/III Adapta®
5.2 Shutting down the pump __________________________________________________ 16
5.2.1 Cleaning the pump after shut-down ___________________________________ 16
6 Maintenance/servicing __________________________________________________________ 17
6.1 Safety instructions for installation, inspection and maintenance work ________________ 17
6.2 Maintenance of the pump _________________________________________________ 17
6.3 Maintenance of the motor _________________________________________________ 17
6.3.1 Motors without lubrication fittings _____________________________________ 17
6.3.2 Motors with lubrication fittings ________________________________________ 17
6.4 Maintenance of the Adapta®bearing housing __________________________________ 18
6.4.1 Bearing housing __________________________________________________ 18
6.4.2 Design of bearing housing, sizes 1 and 2 _______________________________ 18
6.4.3 Design of bearing housing, size 3 _____________________________________ 18
6.5 Assembly ______________________________________________________________ 18
6.5.1 Parts overview ___________________________________________________ 19
6.5.2 Bearing housing, sizes 1 and 2 _______________________________________ 19
6.5.3 Bearing housing, size 3 ____________________________________________ 21
6.5.4 Coupling and motor _______________________________________________ 22
6.5.5 Instructions for disassembly _________________________________________ 22
6.5.6 Instructions for assembly ___________________________________________ 22
6.5.7 Assembly of the bearing housing, sizes 1 and 2 _________________________ 23
6.5.8 Assembly the bearing housing, size 3 _________________________________ 26
6.5.9 Mechanical seal arrangements _______________________________________ 30
6.5.10 Assembly of the single mechanical seal _______________________________ 30
6.5.11 Assembly of impellers and casings ___________________________________ 32
6.6 Troubleshooting _________________________________________________________ 35
6.7 Disposal _______________________________________________________________ 35
6.8 HILGE assembly tool kit ___________________________________________________ 36
6.8.1 Content and use __________________________________________________ 36
7 Certificate of non-objection _______________________________________________________ 37

Hilge GmbH & Co. KG | BA.001.ADY.001.09.16.GB 5
Operating manual
GEA Hilge HYGIANA I/II/III Adapta®Introduction
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 6.
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.

6Hilge GmbH & Co. KG | BA.001.ADY.001.09.16.GB
Operating manual
GEA Hilge HYGIANAI/II/III Adapta®
Safety
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
Signal words
The following signal words are used to classify the safety
instructions:
DANGER (A)
Characterises an imminent hazard with a high risk which can
cause death or serious bodily injury.
WARNING (B)
Characterises a possible hazard with a medium risk which can
cause death or bodily injury if it is not avoided.
CAUTION (C)
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
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 prop-
erty.
►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.
A
BC
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 prop-
erty.
►Do not remove protection against contact
with moving parts (e.g. coupling guard) while
the pump is in operation.
►Replace defective safety equipment immedi-
ately.
WARNING
Contact with hazardous substances (e.g. inhala-
tion)!
▲Death, serious bodily injury, damage to prop-
erty.
►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 porta-
ble pumps).

Hilge GmbH & Co. KG | BA.001.ADY.001.09.16.GB 7
Operating manual
GEA Hilge HYGIANA I/II/III Adapta®Safety
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.
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 circum-
stances.
2.10 Transport
Fig. 2: Attachment points (example)
2.11 Cleaning
To ensure the quality of sensitive liquids, pumps must be cleaned
immediately after each use. Only this will remove adhesions and
sedimentary deposition and avoid the contamination of products.
To reach the best possible cleaning result, Hilge pumps are
optimised with regard to gaps and dead spaces. They are
designed in accordance with DIN EN 13951, and they are
resistant to the detergents mentioned below. The cleaning
happens inside the plant, without the need for disassembly or
removal of parts.
Generally, distinction is made between CIP and SIP. The
procedures must be based on state-of-the-art technology and
guidelines of the EC. In every case the user must make sure that
the cleaning and/or sterilisation processes used as well as the
operating temperature and operating steps meet the targets set
and are used for that purpose.
2.11.1 CIP
CIP means Cleaning In Place. The pump is completely flushed
through with a detergent. The detergent used must be suitable for
the cleaning task in question. The following table shows permitted
detergents, their allowed concentration and specifications
according to DIN 11 483 part 1.
(1)Depends on the maximum permitted temperature of the pump
(2)CrNi-steel (1.4301)
(3)CrNiMo-steel (1.4401 / 1.4571)
WARNING
Electrical hazard!
▲Death, serious bodily injury.
►Use only approved electric cables and plugs.
WARNING
Falling loads!
▲Death, serious bodily injury, damage to prop-
erty.
►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
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
Type of detergent Chemical description Max. concentration Max. temperature*
[°C] Permitted pH value Max. permitted Cl content when mixed with water [mg/l] Max. permitted contact time [h]
Alkalis
NaOH 5 % 140(1) 13-14 500 3
NaOH and
NaClO 5 % 70 ุ11
300
1
NaClO or
KClO
300 mg/l
active chlo-
rine
20
ุ9
2
60 0.5
Acids
H2SO4
1.0 / 1.5 %(2)
3.5 %(3) 60 150(2) 250(3) 1
H3PO4or
HNO3
5 % 90 200(2)
300(3) 1
C2H4O3
0.0075 % 90
300
0.5
0.15 % 20 2
Iodophore 50 mg/l
active iodine 30 ุ33

8Hilge GmbH & Co. KG | BA.001.ADY.001.09.16.GB
Operating manual
GEA Hilge HYGIANAI/II/III Adapta®
Safety
Detergents containing hydrochloric acid (HCl) and/or hydrofluoric
acid (HF) are not allowed. If you want to use special detergents
and cleaning methods, please contact the supplier for information
relating to the pump materials used. For a residue-free removal of
the detergent, the pump must be thoroughly flushed with water.
The maximum permitted temperature can be found in section
Technical data
Disposal of detergent
Dispose of detergent in a professional and environmentally
friendly way.
2.11.2 SIP
SIP means Sterilisation In Place. The pump will be sterilised by
hot steam. For the hot-steam sterilisation or sanitisation,
minimum temperatures of 121 °C must be in contact with all
surfaces. The maximum permitted operating temperature can be
found in section Technical data.
The pump should never be operated during the SIP process.
After the SIP process, a cool-down phase of minimum one hour is
needed.
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 37.
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
Damage caused by detergent!
▲Death, serious bodily injury, damage to prop-
erty.
►Use only suitable detergent.
►Always note the safety instructions of the
product information of the detergent.
►Always wear suitable safety equipment when
working with detergent.
►Do not exceed the maximum permitted con-
centration of the detergent.
►Corrosive acids should be avoided, because
they promote pitting corrosion.
Warning
Hot surfaces!
▲Death, serious bodily injury, damage to prop-
erty
►Do not touch the pump during cleaning.
Pump surfaces can be very hot.
WARNING
Hot surfaces!
▲Death, serious bodily injury, damage to prop-
erty.
►Do not touch the pump during the sterilisation
and cool-down phases. Pump surfaces can
have a temperature of more than 100 °C!
Warning
Dry running!
▲Damage to property.
►Never operate the pump during the SIP pro-
cess. The mechanical shaft seal will be
destroyed.
Warning
Pressure surge!
▲Death, serious bodily injury, damage to prop-
erty.
►Before sterilisation, always evacuate the sys-
tem completely of pumped liquid!

Hilge GmbH & Co. KG | BA.001.ADY.001.09.16.GB 9
Operating manual
GEA Hilge HYGIANA I/II/III Adapta®Product description
3 Product description
Overview
In this section you will get to know the pump as well as its design
and application. The section "Technical Data" describes the limits
of application. You must know and observe these limits.
3.1 Pump overview
Fig. 3: HYIANA III Adapta®
0107 - discharge housing
0153 - suction port
0156 - discharge port
0180 - Adapta®foot
0330 - bearing housing
0801 - flanged motor.
3.2 Description
The pump is a multi-stage end-suction centrifugal pump with a
modular design. All parts which come in contact with the medium
are in accordance with „hygienic design“ guidelines.
3.2.1 Areas of application
Standard design
Pumps of the standard design are used for:
• industrial applications
• CIP processes
• surface treatment for environmental technologies
• all systems and processes employed in the production of food-
stuffs, 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 the pump below the minimum flow rate of Qmin =
10-15 % 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.
K.0444V1
0153
0107
0156
0801
0330
0180
WARNING
Improper usage!
▲Death, serious bodily injury, damage to prop-
erty.
►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 net-
work specified in the order.

10 Hilge GmbH & Co. KG | BA.001.ADY.001.09.16.GB
Operating manual
GEA Hilge HYGIANAI/II/III Adapta®
Product description
3.4 Technical data
3.4.1 Type key
The HILGE pump designation is structured as shown below:
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. 4: 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
Design features of the described standard pumps:
Caution:
The weights can - depending on design and accessories - differ
from those presented. The manufacturer gives you when given
the pump / order number precise information.
• HYGIANA I and II combi foot mounting
• Single mechanical seal
• SIEMENS motor
WARNING
Overloading the pump!
▲Death, serious bodily injury, damage to prop-
erty.
►Use the pump only under the indicated oper-
ating conditions.
►Also avoid brief overpressure situations (e.g.
caused by pressure surges).
HYGIANA I ADY 40/40 3 2
Pump type
Size
Design
Nominal diameter DNs/ DND
Power [kW]
Number of poles
TM05 6440 4912
Pump-Type
No.
Qm3/h H
P kW n min-1
Doc.-No.
MADE BY HILGE
Hilgestraße - D - 55294 Bodenheim
HILGE GmbH & Co. KG
Motor power
kW
Lpfa
[dB (A)] Number of poles
1,5 67
2
2,2 67
373
473
5,5 73
7,5 74
11 74
15 75
18,5 76
22 76
30 77
37 77
Motor power [kW] Motor size Stages Weight [kg]
1.5 090S 233
335
2.2 090L
238
340
443
3 100L
243
345
447
4 112M 350
452
5.5 132M 565
667