Operation Manual MAXA CN

HILGEDOCUMENTATION

Operating manualMAXA CN

BA.223.CNY.001.12/07.GB

HILGEDOCUMENTATION

Declaration of conformityin accordance with EC Machine Regulation 98/37/EC1

We - HILGE - hereby declare that the pump unit

MAXA CNis in compliance with the following requirements:

• Directive 98/37/EC(Machine Directive, Appendix II A)

• Directive 73/23/EEC(Low-Voltage Directive, Appendix III B)

• Directive 89/336/EEC(EMC Directive).

Harmonised standards employed:

• DIN EN ISO 12100-1, Safety of machines; basic terms, general principles of design – Part 1: Basic terminology

• DIN EN ISO 12100-2, Safety of machines; basic terms, general principles of design – Part 2: Basic technical prin-ciples

• DIN EN 809, Pumps and pump units for liquids• DIN EN 60204-1, Safety of machines - electrical equip-

ment of machines.

December 2007

1. This declaration of conformity in combination with the CE symbol applies only to pumps with motor.

Heinz RustDirector of design

Introduction HILGEDOCUMENTATION

1. Introduction

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 tech-nical background required for the start-up, maintenance and repair of pump systems.

Sections aimed only for specially authorised personnel are in-dicated by a preceding notation to this effect.

1.2 Symbols and formatting The following symbols and formats are intended to make iteasier to read this document:

• Listed items

Instructions Instructions that must be carried out in a specific sequenceare numbered in the corresponding order.

Important information and helpful tips are identified with the index finger symbol.

Safety instructions The system used to identify safety instructions is described insection 2.3 .

1.3 References to the document

Copyright This document may not be copied, translated into other lan-guages or made available to third parties without our explicitwritten approval.

Technical changes Design variants, technical data and spare part numbers aresubject to technical change.

The right to make changes for the sake of further technical de-velopment is reserved.

Abstract

This section describes the requirements which are important for reading and understanding this manual. You willlearn the symbols and formats that make the reading easier.

5BA.223.CNY.001.12/07.GB

SafetyHILGEDOCUMENTATION

2. Safety

2.1 Instructions for the operator

2.1.1 General information All our pumps are professionally packed before they leave ourwarehouse to avoid damage during transport.

Unpacking If, after carefully unpacking and inspecting the shipment, youhowever find damage, you must promptly inform the shippingagent (railway, post office, lorry driver, shipping line, etc.).

Your claim should be filed with the shipping agent. The ship-ping risk passes to the customer as soon as the shipmentleaves our warehouse.

Storage If the pump is not put into service immediately, it is importantthat it is stored properly to ensure that it will function correctlylater. This is just as important as proper installation and main-tenance.

The pump must be protected from cold, moisture and dust aswell as from mechanical influences.

Specially trained personnel is required to install and maintainthe pump properly.

2.2 Safety instructions in the operating manual

Read safety instructions! The operating manual contains all basic information requiredfor the setup, operation and maintenance of the pump. The in-staller as well as the technical personnel or operator respon-sible for the pump must therefore read this manual beforeinstalling and starting the pump. The operating manual mustalways be available at the site where the machine/system isbeing used. Not only the general safety instructions present-ed in this section but also the specific safety instructions in lat-er sections must be followed.

2.3 Identification of instructions in the operating manual

Symbol The safety instructions presented in this operating manual areidentified as shown below.

Fig. 1 Symbol for safety instructions

Signal words In order to classify the safety labels they are distinguished bythe following signal words:

Abstract

This section describes what you have to consider for your own safety. You will learn the structure and identifica-tion of safety instructions. Read this important section attentively!

6 BA.223.CNY.001.12/07.GB

Safety HILGEDOCUMENTATION

• DANGERCharacterises an imminent hazard with a high risk which can cause death or grievous bodily harm.

• WARNINGCharacterises a possible hazard with medium risk which can cause death or bodily harm if it is not avoided.

• CAUTIONCharacterises a hazard with minor risk which can cause minor or medium bodily harm if it is not avoided.

Do not remove instructions from machine Instructions attached directly to the machine, such as rota-tional direction arrow, must be noted and kept in completelylegible condition.

Damaged or illegible instructions must be replaced.

2.4 Qualifications and training of personnel

The employees operating, maintaining, inspecting and install-ing the pump must have the appropriate qualifications for thiswork. The operator must define in detail the tasks for whichthe employees are responsible, the tasks of which they are incharge and the manner in which they are supervised.

If the employees do not have the necessary knowledge, theymust be instructed and trained accordingly. This can be done,if necessary, by the manufacturer/supplier under contract tothe operator. The operator must also guarantee that the em-ployees fully understand the contents of the operating manu-al.

2.5 Hazards upon failure to follow the safety instructions

If these safety instructions are not followed, employees, themachine itself and the environment will be in danger.

Failure to follow the safety instructions can lead to the loss ofthe right to file claims for damages.

Failure to follow instructions can, for example, lead in partic-ular to the following hazards:

• breakdown of important functions of the machine/system• failure of recommended methods of maintenance and

repair• endangerment of personnel by electrical, mechanical and

chemical hazards• endangerment of the environment by leakage of hazard-

ous materials.2.6 Safety-conscious work The safety instructions given in this operating manual, the ex-

isting national regulations for accident prevention and any ap-plicable internal working, operating and safety instructions ofthe operator must be followed.

7BA.223.CNY.001.12/07.GB


2.7 Safety instructions for the operator / user

Warning

!Burn hazard from hot or cold mechanical components.

Cold or hot mechanical components can cause severe injury.

• Take structural measures to prevent contact with them!

Warning

!Trapping hazard!

Danger from rotating components. Rotating parts can causedeath, serious injury or damage to the equipment.

• Do not remove protection against contact with moving parts (e.g. coupling guard) while the machine is operat-ing.

• Replace defective safety equipment immediately!

Danger

!Danger generated by contact with or by inhaling hazard liq-uids, exhalations or steams.

Inhaling hazardous liquids, condensates or sprays can causedeath, serious injury or damage to the equipment.

• Drain away leakage of hazardous pumping media in such a way that there is no danger to personnel or to the envi-ronment!

• Follow legal regulations!• If shaft seal fails, switch off the pump. Replace seal

before next start-up!

Warning

!Tripping hazard from electric power cable.

• Route the electric power cable in such a way that no one can trip over it. (In case of portable pumps).

8 BA.223.CNY.001.12/07.GB


Danger

!Electrical hazard! Danger of electrical shock from contact withenergised components.

An electric shock can cause death or bodily harm.

• Only use acceptable electric cables and plugs!

2.8 Unauthorised modifications

and production of spare partsNo modifications or changes to the machine may be madewithout written approval of the manufacturer. In the interest ofsafety, only original spare parts and accessories authorisedby the manufacturer may be used. The use of other parts canexempt the manufacturer from liability for damage which maythus be caused.

2.9 Improper operation The operational reliability of the delivered machine can beguaranteed only when it is used properly as indicated in thefollowing sections.

The given limit values may not be exceed under any circum-stances.

2.10 Transport

Warning

!Falling loads are dangerous!

Falling loads may cause death, severe bodily injuries or prop-erty damage.

• Transport work must only be performed by persons quali-fied to do so, and all safety instructions must be observed.

• Use suitable load-carrying equipment with sufficient capacity to transport the pump.

• Make certain there are no persons under the suspended load.

• Make certain the pump is aligned horizontally when it is lifted!

Caution

!Using incorrect lifting points is dangerous!

Unsuitable lifting points may cause damage to the pump.

• Fasten the rope to suitable lifting points.• Never fasten a rope to the pump casing or intake/dis-

charge branch!

9BA.223.CNY.001.12/07.GB


2.11 Cleaning CIP and SIP methods must be in accordance with the latestcurrent guidelines of the EC.

When special cleaning agents and methods are used, thesupplier must confirm that they are safe for the materials in-volved.

Warning

!Danger from pressure surge! Liquids under high pressure canbe forcibly ejected from the pump.

Pressure surge can cause bodily injury or damage to the plantand pump.

• Before sterilisation, always evacuate the system com-pletely!

Fig. 2 Attachment points for CN pumps (example)

K.0

113V

1

10 BA.223.CNY.001.12/07.GB


2.12 Repair contract The duty to follow the legal regulations on work safety and theregulations on environmental protection means that all com-mercial enterprises must protect their employees, the publicat large and the environment from the harmful effects of haz-ardous materials.

Examples of legal regulations on work safety:

• the Workplace Act (ArbStättV)• the Hazardous Materials Act (GefStoffV)• the accident prevention regulations(BGV A1)• all applicable laws, rules, guidelines, regulations etc. in

the country of operation.

Examples of regulations on environmental protection:

• the Recycling and Waste Law (KrW/AbfG)• the Water Economy Law (WHG)• 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 acomponent of the inspection/repair contract. This does not af-fect our right to refuse acceptance of this contract for otherreasons.

The certificate of non-objection can be found on page 52.

HILGE products and their parts will only be inspected/re-paired if the certificate of non-objection is present and hasbeen correctly completed by authorised and qualified techni-cal personnel.

Pumps which have been operated in media exposed to radi-ation will not be accepted.

If any additional safety measures are required even after thecareful draining and cleaning of the pump, the necessary in-formation must be provided.

11BA.223.CNY.001.12/07.GB

DescriptionHILGEDOCUMENTATION

3. Description

3.1 Pump overview

3.2 Description The pump is a single-stage end-suction centrifugal pump withmain dimensions and characteristics according to DIN EN733 respectively DIN EN 22858.

3.2.1 Areas of application

Standard design Pumps of the standard design are used for:

• industrial application• textile technology• surface treatment for environmental technologies• all systems and processes involved in the food product,

dairy and beverage industries.

Abstract

This section describes the pump as well as its design and application. The section „Technical Data“ describeslimits for application. You must know and keep these limits.

Fig. 3 Overview of MAXA

• 0102 - volute casing• 0153 - suction branch• 0156 - discharge branch• 0330 - bearing housing• 0800 - motor• 0840 - coupling• 0890 - baseplate

K.02

63V

1

12 BA.223.CNY.001.12/07.GB

Description HILGEDOCUMENTATION

3.3 Proper usage

Warning

!Improper usage is dangerous.

Operating the pump in a manner that differs from the informa-tion provided in the order may result in death, severe bodilyinjury or damage to property.

• Only media that are specified in the order must be pumped. The pump has been specially designed for that purpose!

• The pump must only be operated in the electrical network specified in the order!

3.3.1 Pumped liquids Only pure or slightly contaminated liquids with a maximum

particle size of 0.4 mm may be pumped. These liquids maynot chemically or mechanically attack the pump materials orlower their strength. If liquids with a viscosity greater than thatof water are to be pumped, make sure that the motor will notbe overloaded. The pump may not be operated beyond themaximum allowable values. Even short periods of pressureoverload (e.g. as a result of a pressure surge) should beavoided.

3.3.2 Minimum flow rate Qmin Do not operate the pump below a minimum flow rate ofQmin = 10 - 15 % Qopt.

3.3.3 Connections and pipelines The nominal diameters of the system pipelines should beequal to or greater than the nominal diameters of the pump,i.e. DNE (suction side) and DNA (pressure side), and the con-necting elements to the pump must conform exactly to the de-sign standard/specification of the mating connector pieceinstalled on the pump. The suction line must be absolutelyleak-tight and laid in such a way that no air pockets can form.Avoid tight elbows and do not install valves immediately up-stream of the pump. The suction head of the system may notbe greater than the suction head guaranteed by the pump.

3.3.4 Motor activation 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 con-cerning the use and operation of the pumps are based exclu-sively on the standard designs.

These rules do not apply to special designs, customer specif-ic modifications or random external influences which may oc-cur during use and operation.

13BA.223.CNY.001.12/07.GB


3.4 Technical data

Warning

!Danger of overloading the pump!

Overloading can cause death, grievous harm or damage tothe plant.

• The pumpe must only be used under the indicated oper-ating conditions!

• Also avoid short overpressure situation (e.g. caused by pressure surge)!

3.4.1 Pump denomination The HILGE pump denomination is structured as shown be-

low:

3.4.2 Pump serial number The pump can be identified by the pump serial number. Whenordering spare parts, always state the pump serial number.

Pump serial number (example) 223 / 07 / 1248

The pump serial number includes:

• pump type (223)• year of manufacture (07)• registration number (1248).

MAXA 100-200 CN 125/200 30 2pump typesizedesignnominal diameter DNs / DND

power [kW]number of poles

Tab. 1 HILGE pump denomination (example)

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Description HILGEDOCUMENTATION

3.4.3 Nameplate The nameplate is shown in fig. 4 and contains the followingdata:

3.4.4 Performance data The performance data of the pump, namely its head and de-livery rate, are determined in accordance withDIN EN ISO 9906 - appendix A, class 2, and are documentedon the acceptance records.

3.4.5 Maximum operating temperature

Caution

!It is dangerous to exceed the maximum operating tempera-ture!

Exceeding the maximum operating temperatures may causethe seals to be destroyed. Hot pumped medium may escape!

• Never exceed the specified operating temperatures!

Tab 2 lists the maximum permissible operating temperatures.

Fig. 4 HILGE nameplate, example

• 1 - pump type• 2 - pump serial number• 3 - capacity Q• 4 - head H• 5 - motor power P• 6 - drive speed n• 7 - number of operating manualNOTE: The nameplate can deviate from the one shown.

K.01

09V

2Pump -Type

No.Q m3/h H P kW n min -1

Doc. -No.MADE BY HILGE

1

53

24

6

7

Hilgestraße - D - 55294 BodenheimHILGE GmbH & Co. KG

Design Temp. [°C]Standard design 95Special design 150

Tab. 2 Operating temperatures

15BA.223.CNY.001.12/07.GB


3.4.6 Maximum operating pressure

Warning

!Pressure overload is dangerous!

Exceeding the maximum operating pressure may cause thepump to be destroyed.

• The pump must be operated according to the order data.• Never exceed the specified maximum operating pres-

sures!

Pump operating pressure The maximum permitted operating pressure depends on var-

ious factors:

• pump type• design of connections• design of mechanical seal.

For the values that apply to your pump, please refer to the or-der documents.

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Mounting, installation and connection HILGEDOCUMENTATION

4. Mounting, installation and connection

4.1 Inspection before pump installation

4.1.1 Check failure-free running of the impeller

Check the failure-free impeller running in this way:

1. Remove motor shroud1.2. 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 casing (for example due to transport damage), it has been damaged.

When the impeller rubs against the casing: Contact HILGE Service.

When the impeller runs failure-free:

5. Refit fan cover of the motor.6. Refit motor shroud1.

4.2 Setup and alignment of the pump assembly

Warning

!Danger of misalignment of the pump due to an improper foun-dation.

A misaligned pump due to an improper foundation can causedeath, grievous bodily harm or damage to the plant.

• Ensure that the foundation on which the pump is set up is clean and flat and has sufficient load capacity.

• Mount the pump – especially when it is to be set up verti-cally2 – with the use of suitable heavy-duty anchors. As the centre of gravity is higher, the pump can tip.

Abstract

This section describes how to mount, adjust and install the pump. You get to know what to consider when youconnect the pump to the electric mains supply and how to improve the flow in order to avoid dry running of theshaft seals.

1. SUPER design only.2. Not applicable for F&B-HYGIA®, SIPLA, NOVAlobe and for all base plate design (CN).

17BA.223.CNY.001.12/07.GB

Mounting, installation and connectionHILGEDOCUMENTATION

Warning

!Electrical danger due to short circuit!

Short circuits can cause death, bodily injury or damage to theplant.

• In case of a vertical installation: Under no circumstances the motor should be positioned underneath the pump. If there is a leakage, the motor could be damaged.

Align the pump in this way:

1. Use an engineer’s spirit level laid across the machined surface of the discharge branch connection to align the assembly.

2. After aligning the assembly, tighten the mounting bolts uniformly in a crosswise manner.

For base plate design (CN)1: The pump assembly is aligned with steel shims, which are placed directly adjacent to each mounting bolt, under the lugs. The shims may be placed only under the lugs for alignment. The base plate must rest flush on the lugs before the bolts are tightened.

4.3 Aligning the coupling

Why is alignment important? Careful alignment significantly increases the service life of thecoupling as well as the shaft bearing and sealings.

Fig. 5 shows the possible types of deviation in coupling align-ment.

Warning

!When aligning the coupling, pay close attention to safety in-structions in section 2.2.

1. Not available for F&B-HYGIA®.

18 BA.223.CNY.001.12/07.GB


To align the coupling, proceed as follows:

1. Disassemble the coupling protection.2. Place the hairline ruler on four points facing each other

(in 90° increments) over the two halves of the coupling.3. The hairline ruler must have the same distance (open

gap) everywhere.4. For a radial or angular shift: Place the calibrated underlay

plates under the motor or pump casing1. 5. Remount the coupling protection.

4.4 Permissible shift values Flender H / HDS coupling

Never under any circumstances exceed the following shiftvalues of the coupling during operation.

4.4.1 Coupling size

Design H and HDS The following table contains a list of coupling designationsand drill hole diameters.

1. For vertical pump setup (CNV), place the underlay plates between the pump casing and vertical frame.

Fig. 5 Types of shift (principal figure)

• A - axial shift• B - angular shift• C - radial shift

K.01

59V

1

S2 min

Ka

Kw

S2 max

Kr

A

B

C

S2 max

S2 min

Size H Drill hole Ø Size HDS Drill hole Ø80 30 88 3095 42 103 42110 48 118 48125 55 135 55140 60 152 60160 65 172 65180 75 194 75

Tab. 3 Coupling size for design H

19BA.223.CNY.001.12/07.GB


4.4.2 Axial shift S2

Design H and HDS The following tables contain lists of permissible values for ax-ial shift.

4.4.3 Angular shift Kw Angular shift Kw is useful to measure as the difference ofgap dimension ( S2=S2max - S2min). Permissible valuesfor the gap dimension may be seen in tab. 5.

4.4.4 Radial shift Kr The following table lists permissible shaft shift values for radi-al shift Krzul and the difference for gap dimension S2zul(zul = German abbreviation for "permissible").

Size H S2 Size - HDS S280 5 88 5 95 5 103 5 110 5 118 5 125 5 135 5 140 5 152 5 160 6 172 6 180 6 194 6

Tab. 4 Axial shift for design H

Type, size Coupling speed in rpmH HDS 250 500 750 1000 1500 2000 3000 4000 500080 88 0.4 0.3 0.25 0.2 0.2 0.15 0.15 0.1 0.1 95 103 0.5 0.35 0.25 0.25 0.2 0.2 0.15 0.1 0.1 110 118 0.5 0.35 0.3 0.25 0.2 0.2 0.15 0.1 0.1 125 135 0.5 0.4 0.3 0.25 0.25 0.2 0.15 0.15 0.1 140 152 0.6 0.4 0.35 0.3 0.25 0.2 0.2 0.15 160 172 0.6 0.5 0.4 0.35 0.3 0.25 0.2 0.15 180 194 0.6 0.5 0.4 0.35 0.3 0.25 0.2

Tab. 5 Permissible shaft shift values for radial shift Krzul and difference of gap dimension S2zul

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4.5 Permissible shift values ROTEX DKM

Never under any circumstances exceed the following shiftvalues of the coupling during operation.

4.5.1 Design Rotex DKM Note for reading 6 and 7: To determine the deviation values,always select the smaller shaft diameter of the shaft pair to beconnected.

Standard couplingShaft diameter 14 19 24 28 38 42 48 55 65 75Max. axial shift Ka [mm] 1.0 1.2 1.4 1.5 1.8 2.0 2.1 2.2 2.6 3.0

Max. radial shift Kr [mm] with n=1500 min-1

0.17 0.20 0.22 0.25 0.28 0.32 0.36 0.38 0.42 0.48


0.11 0.13 0.15 0.17 0.19 0.21 0.25 0.26 0.28 0.32

Max. angular shift Kw [degrees] with n=1500 min-1

1.2 (0.67)

1.2 (0.82)

0.9 (0.85)

0.9 (1.05

1.0 (1.35)

1.0 (1.7)

1.1 (2.0)

1.1 (2.3)

1.2 (2.7)

1.2 (3.30)


1.1 (0.62)

1.1 (0.70)

0.8 (0.75)

0.8 (0.84)

0.8 (1.10)

0.8 (1.40)

0.9 (1.60)

1.00 (2.00)

1.0 (2.30)

1.0 (2.90)

Tab. 6 Permissible shift values for standard coupling

Coupling with adapterShaft diameter 14 19 24 28 38 42 48 55 65 75Max. axial shift Ka [mm] - 1.2 1.4 1.5 1.8 2.0 2.1 2.2 2.6 3.0


- 0.54 0.53 0.60 0.77 0.84 1.00 1.11 1.4 1.59


- 0.5 0.47 0.53 0.61 0.67 0.82 1.01 1.17 1.33


- 1.2 0.9 0.9 1.0 1.0 1.1 1.1 1.2 1.2


- 1.1 0.8 0.8 0.8 0.8 0.9 1.0 1.0 1.0

Tab. 7 Permissible shift values for coupling with adapter

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4.6 Installation in the pipeline

Warning

!Danger of mechanical overload!

A mechanical overload can cause death, bodily harm or dam-age to the plant. Pumped liquid can leak under high pressure.

• Do not use the pump or its connecting sleeves to support the pipeline. (EN809 5.2.1.2.3 and EN ISO 14847).

• In addition to the general rules of machine-building and plant 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 plant.These specifications will contain data on torques, maxi-mum allowable angular offset and tools / auxiliary materi-als to be used.

• It is absolutely necessary to avoid twisting the pump!• After connecting the pipes, check the alignment of the

coupling1.

Caution

!Danger of mechanical overload due to closing caps or foil!

An overload can cause damage to pump or plant.

• The suction and delivery ports are sealed with sheets of plastic, the flushing and drain lines with plastic caps. These must be removed before the pump is installed in the system.

1. For base plate design (CN) only

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Details about dry running What is dry running?

To seal the pump shaft against the pump casing, the mechan-ical seal needs lubrication between its rotating faces.

This lubrication is provided by the pumped liquid. If the pumpis fitted with a quench, the lubrication for the quench must beprovided from an external source.

Dry running occurs when the lubrication fails. Dry runningmay destroy the mechanical seal in few seconds.

For example, see fig. 6.

Caution

!Danger of dry running!

Dry running causes damage to the pump and plant.

When installing the pump, take the following into account:

• 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 head of the system may not be greater than the head guaranteed by the pump.

• The nominal pipeline diameters of the system should be equal to or greater than the DNS or DND connectors of the pump.

• A foot valve should be used in suction mode.• To prevent air pockets from forming, the suction line must

be laid so that it rises to the pump; 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.

• A shut-off valve should be installed in the suction line near the pump. This valve must be completely open dur-ing operation and may never be used as a control valve.

• A shut-off valve should be installed in the discharge line, near the pump, to control the delivery rate.

Fig. 6 Lubrication between sliding surfaces

• P - pump side• 0433.00 - mechanical seal• L - lubrication• A - atmosphere side

K.0

173V

2

0433.00

P A

L

23BA.223.CNY.001.12/07.GB


4.7 Connections for flushing system

4.7.1 Double mechanical seal HILGE pumps with double mechanical seal are equipped witha seal cartridge.

Depending on the seal design, the barrier or flushing fluidflows inside this seal cartridge.

The connection must be carried out as shown in fig. 8. Thatway you can ensure that the fluid can flush the mechanicalseal effectively.

Fig. 7 Installation in the pipeline

• above: gravity feed mode• below: suction mode• P - pump• M - motor

K.00

76V2

P M

P M

Fig. 8 Flushing connection

• 0491.00 - seal cartridge• A - outlet line• B - feed line

K.02

46V

1

0491.00

A

B

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Caution


Dry running will destroy the mechanical seal within seconds!

• Connect the lines of the flushing system so that a liquid supply is guaranteed.

• Always keep the fill level in the liquid pot between the upper and lower marks.

Connect the flush in this way:

1. Connect feed line B.Note the dependence between arrangement and rotating direction. See fig. 8

2. Connect outlet line A.3. Check tightness of connection.

4.7.2 Double mechanical seal - back-to-back arrangement

Barrier liquid In order to continue functioning, the mechanical seals requirea barrier liquid, some of its purposes being:

• pressurisation in the sealing space• preventing the feed liquid from penetrating into the seal-

ing gap• dry-run protection• lubrication and cooling of the mechanical seals.A pure liquid, compatible with the pumped liquid, serves as asealing liquid.

Ensure the functioning in this way:

1. Open feed line of barrier liquid.2. Bleed seal cartridge.3. Ensure liquid is circulating at required barrier pressure.

The barrier pressure should be at least 1.5 - 2 bar above the highest pressure to be sealed. The sealing liquid should not be above 60 °C on exit and should on no account exceed the boiling point.

A pure liquid, compatible with the pumped liquid, serves as a sealing liquid.

25BA.223.CNY.001.12/07.GB


4.7.3 Double mechanical seal - tandem arrangement

Flushing liquid In order to continue functioning, the mechanical seals requirea flushing liquid, some of its purposes being:

• preventing leaks• dry-run protection• lubrication and cooling of the mechanical seals• cutting off the air from substances which react unfavoura-

bly with oxygen.A pure liquid, compatible with the pumped liquid, serves as aflushing liquid.

Ensure the functioning in this way:

1. Open feed line for flushing liquid.2. Bleed seal cartridge.3. Ensure unpressurised circulation.

A pure liquid, compatible with the pumped liquid, serves as a flushing liquid.

In case of abrasive media, provide a „lost“ flushing, i.e. where the flushing liquid is discharged directly.

4.8 Electrical connections

Warning

!Danger of electric shock!

Electric shock can cause death or bodily harm.

• The electrical connections must be made by a qualified electrician.

• VDE specifications and any local regulations must be fol-lowed, especially those pertaining to safety measures!

Warning

!Danger of capacity overload!

Electrical overloading can cause death, bodily harm or dam-age to plant or motor.

• Check the voltage stated on the rating plate of the motor against the operating voltage!

• Install an electrical circuit breaker!

26 BA.223.CNY.001.12/07.GB


4.8.1 Star connection Star-connection 3-phase system for high voltage.

Connect the pump as specified in the order documents. Thefigure below shows the schema for star connection.

4.8.2 Delta connection Delta connection for low voltage.

Connect the pump as specified in the order documents. Thefigure below shows the schema for delta connection.

4.8.3 Checking the direction of rotation after connection

Caution


Dry running causes damage to pump and plant!

• Before checking of 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 directional arrow (red) on the pump. If the pump is turning in the wrong direction, the mechanical seal can be destroyed.

Check the rotating direction in this way:

1. After electrical connection: Mount all safety equipment again.

2. Check tightness of hydraulic connection.3. Fill pump (plant).4. Observe arrow of rotation.5. Switch on motor shortly (1-2 seconds).6. Compare directions (motor / arrow).7. Correct connection if need be.

Operation with frequency inverter See documentation of manufacturer.

Fig. 9 Star connection

K.00

79V

1

U1 V1 W1

W2 U2 V2

L1 L2 L3

Fig. 10 Delta connection

K.00

80V

1

U1 V1 W1

W2 U2 V2

L1 L2 L3

27BA.223.CNY.001.12/07.GB

Start-up / shutdownHILGEDOCUMENTATION

5. Start-up / shutdown

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 condition of the pump:- purchasing documents (confirmation of the order)- nameplate- operating manual.

2. Make sure that the pump will operate under the men-tioned conditions only. This conditions apply to (e.g.) pressure, temperature, liquid pumped.

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 check valves in the system.5. Fill the pump together with the system.6. Vent the pump and system.7. Fully open the check valve on the suction side.8. Close the check valve on the discharge side.9. Start the pump.10. Slowly open the check valve on discharge side.

Caution

!Danger of overheating and pressure overloading!

Continues operation against a shut-off device causes a quickheating of the liquid pumped and a pressure increase.

• Never operate the pump against a closed shut-off device. Operation with a shut-off device must on no account con-tinue for longer than 30 seconds.

If delivery 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. , section 5.1.2 .

Abstract

This section describes how to start up and shut down the pump. You get to know which inspections contribute tofailure-free operation and increased life of the pump.

28 BA.223.CNY.001.12/07.GB

Start-up / shutdown HILGEDOCUMENTATION

5.1.3 Functional check of mechanical seal Check the function of the mechanical seal in this way:

1. Watch the pump and check the mechanical seal for flaw-less functioning (leak test).An intact mechanical seal works virtually without leakage.

If liquid pumped or flushing liquid leaks:

1. Switch off the pump.2. Renew the mechanical seal.

Observe section 6.1 on page 30.5.2 Shutdown

5.2.1 Shutting down the pump

Caution

!Danger of pressure surge!

Pressure surge can cause damage to pump or plant. Quickclosing of shut-off devices on discharge side can cause apressure surge.

• Always close shut-off devices (gates, valves) slowly!

What is a pressure surge? A pressure surge is an abruptly pressure increase in the sys-

tem. This pressure increase can - among other causes - becaused by a quick blocking of the flow in the discharge pipe.In case of a pressure surge, the maximum permitted pumppressure is temporarily exceeded manifold.

Shut down the pump in this way:

1. Close the check valve on the discharge side.2. Switch off the pump.3. Close the check valve on the suction side.4. Switch off the flushing system1. 5. Make sure that the pump is depressurised.6. Switch off the pressure in the barrier system2.

5.2.2 Cleaning pump after shutdown

Caution

!Danger of jamming.

Sticky or highly viscous liquids can damage the pump aftershutdown.

• Clean the pump appropriately after shutdown.

See section 2.11 on page 10.

1. Only for double mechanical seal or quench design.2. Only for back-to-back arrangement.

29BA.223.CNY.001.12/07.GB

Maintenance / servicingHILGEDOCUMENTATION

6. Maintenance / servicing

6.1 Safety instructions for maintenance, inspection and installation work

Warning

!Danger of unprofessional work!

Unprofessional work can cause bodily injury or damage to theplant and pump!

• The operator must ensure that all maintenance, inspec-tion and installation work is carried out by authorised and qualified technical personnel, who have acquired the req-uisite knowledge through study of the operating instruc-tions.

Warning

!Danger of electrical shock, pressurized or hot components.

Electrical shock, pressurized or hot components can causedeath, bodily injury or damage to the plant and pump.

When correcting problems with the pump, do as follows:

• Always turn off the electrical supply!• Release all the pressure.• Allow to cool.• Take appropriate measures to ensure that the machine

cannot be unintentionally turned on again.

As soon as the work is completed, do as follows:

• Reinstall or reactivate all safety devices and protection measures.

• Before starting the unit up again, check the points listed in section 5.1.2 on page 28.

Abstract

In this section you will get important information concerning maintenance and servicing the pump. Read this sec-tion before you carry out maintenance work or troubleshooting measures!.

30 BA.223.CNY.001.12/07.GB

Maintenance / servicing HILGEDOCUMENTATION

Warning

!Danger of hazardous substances!

Hazardous substances can cause death, bodily injury or dam-age to the plant and pump!

• Pumps or systems which convey hazardous media must be decontaminated!

Caution

!Danger of frost!

Frost causes damage to the plant and pump.

• When there is danger of frost, drain the pump completely.

Caution

!Danger of improper tools!

Improper tools can cause damage to the pump and plant.

• In accordance with the design standard (3A0.01 to 3A3.37), all tools, possible support surfaces and other auxiliary materials must ensure that all parts of the pump can be assembled without damage (e.g. scratches).

See section 6.9 on page 51.

6.2 Maintenance of the pump The pump is a low-maintenance pump. In addition to clean-

ing, the only point to be kept in mind is the wear to the rotatingmechanical seal.

6.3 Maintenance of the motor See the operating manual of the motor manufacturer.

31BA.223.CNY.001.12/07.GB


6.4 Maintenance of CN bearing

6.4.1 Bearing lubrication

6.4.1.1 Cylinder bearing greases Use only the cylinder bearing greases listed here or demon-strably comparable ones to lubricate the roller bearings.

6.4.1.2 Grease quantities for roller bearings during assembly

The hollow areas between the cylinder bodies are factory-filled 30% - 50% with grease. This grease filling is sufficientfor operation of the bearing under conditions normally en-countered.

6.4.2 Bearing replacement To ensure problem-free operation of the pump, replace thebearing after about 15,000 to 20,000 hours of operation.

6.4.2.1 Premature bearing replacement If persistent external conditions such as dust, splashed water,aggressive ambient air or high temperatures promote wear,bearings should be replaced after about 5000 hours of oper-ation.

Manufacturer Bearing temperature ≤ 120 °C Bearing temperature ≤ 60 °C – Danger of water enteringARAL HL 3 FM 3BP BP ENERGREASE LS 3 ENERGREASE PR 3

ENERGREASE LS 3CALTEX CALTEX MULTIFAK 2 CALTEX CUP GREASE 3

CALTEX MULTIFAK 2ESSO BEACON 3 ESTAN 2 R

BEACON 3GULF GULFCROWN GULFCROWN

GREASE No. 2 GREASE No. 2GULFCROWN GULFCROWN GREASE No. 3GREASE No. 3

MOBIL - OIL MOBILUX GREASE No. 3 GARGOYLEGREASE B No. 3MOBILUXGREASE No. 3

SHELL SHELL ALVANIA GREASE 3 SHELL UNEDO GREASE 3SHELL ALVANIA GREASE 3

VALVOLINE VALVOLINE LB 2 VALVOLINE LB 2OKS OKS 4200 (≤ 200 °C)SKF LGMT 3/1 LGMT 3/1

Tab. 8 Cylinder bearing greases

32 BA.223.CNY.001.12/07.GB


6.5 Assembly

6.5.1 Parts overview

Fig. 11 Parts overview of MAXA CN with bearing housing

K.02

65V

1

0330

.00

0211

.00

0321

.01

0321

.00

0504

.10

0360

.00

0914

.07

0932

.01

0504

.00

0932

.02

0507

.05

0914

.08

0840

.00

0518

.01

0518

.02

0901

.21

0161

.00

0183

.00

0554

.12

0901

.22

0554

.02

0901

.02

0554

.13

0901

.23

0940

.00

0940

.02

0869

.00

0904

.01

0904

.00

0840

.01

0800

.00

0970

.01

0970

.00

0560

.00

0890

.00

0681

.00

0733

.00

0507

.02

0360

.01

0940

.01

0867

.00

0867

.01

0517

.01

0733

.01

0507

.00

0902

.02

0934

.00

0920

.04

0902

.02

0920

.04

0934

.00

0902

.01

0920

.22

0934

.03

0102

.00

33BA.223.CNY.001.12/07.GB


6.5.2 Instructions for assembly

Danger

!Maintenance or assembly work can be dangerous if importantinstructions are disregarded.

• Before you maintenance or assemble the pump note sec-tion 6.1 on page 30.

Qty. Part no. Description Fig. Qty. Part no. Description Fig.1 0102.00 volute casing 11 1 0840.00 coupling 111 0161.00 backplate 11 1 0840.01 coupling 14, 151 0167.00 casing backplate liner 14, 15 1 0867.00 coupling insert 111 0183.00 support foot 11 6 0867.01 coupling insert 111 0211.00 pump shaft 11 1 0869.00 coupling spacer 111 0321.00 grooved ball bearing 11 1 0890.00 baseplate 111 0321.01 grooved ball bearing 11 4 0901.21 hexagon head screw 111 0330.00 bearing housing 11 4 0901.02 hexagon head screw 111 0360.00 bearing cover 11 4 0901.21 hexagon head screw 111 0360.01 bearing cover 11 4 0901.22 hexagon head screw 111 0412.01 O-ring 46, 47 4 0901.23 hexagon head screw 111 0412.02 O-ring 14, 23, 39, 40 4 0901.29 hexagon head screw 23, 401 0412.35 O-ring 23, 40 12 0902.01 stud 111 0433.00 mechanical seal 11 12 0902.02 stud 111 0433.01 mechanical seal 11 4 0902.08 stud 14, 23, 39, 401 0471.00 seal cover 39, 40 1 0904.00 grub screw 111 0471.01 seal cover 11 1 0904.01 grub screw 111 0491.00 seal cartridge 14, 23, 39, 40 1 0904.02 grub screw 231 0504.00 spacer ring 11 4 0914.07 socket head cap screw 111 0504.09 spacer ring 14, 15 4 0914.08 socket head cap screw 111 0504.10 spacer ring 11 4 0914.09 socket head cap screw 39, 401 0507.00 V-ring 11 12 0920.04 hexagon nut 111 0507.02 V-ring 11 4 0920.15 hexagon nut 14, 23, 39, 401 0507.05 V-ring 11 12 0920.22 hexagon nut 111 0516.00 locating ring 23, 39, 40 1 0932.01 circlip 111 0516.01 locating ring 15 1 0932.02 circlip 111 0517.01 shroud support ring 11 12 0934.00 spring washer 111 0518.01 nilos ring 11 12 0934.03 spring washer 111 0518.02 nilos ring 11 4 0934.11 spring washer 14, 23, 39, 404 0554.02 washer 11 4 0934.23 spring washer 112 0554.12 washer 11 12 0934.24 spring washer 23, 404 0554.13 washer 11 1 0940.00 key 114 0560.00 pin 11 1 0940.01 key 111 0681.00 coupling guard 11 1 0940.02 key 111 0733.00 pipe clamp 11 1 0970.00 plate 111 0733.01 pipe clamp 11 1 0970.01 plate 111 0800.00 motor 11

Tab. 9 Parts list for MAXA CN

34 BA.223.CNY.001.12/07.GB


Caution

!For pump assembly, important aspects have to be taken intoaccount:

A wrong assembly of the pump can cause damage to thepump. Therefore follow the instructions for the assembly list-ed here.

• Use tools from HILGE assembly tool kit in order to assemble the pump without damage and scratches.

• To guarantee a good seal, use only O-ring seals with the original dimensions.

• Never use grease which contains mineral oil when assembling the wet end parts1.

• Replace mechanical seals always in complete assembly.• As the impeller nut is being fitted, it must be possible to

feel the self-locking action2. It must be possible to tighten the nut without any problems. Tighten manually for the first two turns, so that the thread insert sits correctly on the shaft.

• To tighten impeller nut 0922.00, use either a screw device or the impeller nut installing device because the torque applied to tighten must be absolutely concentric. Otherwise there is a danger that the pump shaft 0211.00 will be bent.

1. Parts which come in contact with the pumped medium.2. Only applies to impeller nut with Helicoil thread insert.

35BA.223.CNY.001.12/07.GB


6.6 Assembly of MAXA-CN Assemble the CN bearing housing in this way:

Please note Unless specially noted in individual cases, the part numbersgiven in the following instructions may be found in tab. 9.

Compare the description with fig. 11.

Fig. 12 CN bearing housing

K.0

267V

1

0211.00

0940.00

0518.01 0504.01 0321.000932.01

0517.010321.01

0504.010932.02

0940.01

0518.02

0360.01

0914.080901.210183.00

0914.07

0507.00

0360.00

0330.00

1. Push the circlip 0932.01 over the shaft so that it is positioned loosely between the two grooved ball bearings 0321.00 and 0321.01.

2. Press grooved ball bearings 0321.00 and 0321.01 onto shaft 0211.00.

3. Mount spacing ring 0504.00. 4. Assemble circlip 0932.02.5. Insert circlip 0932.01 into bearing housing

0330.00.To do this, push shaft 0211.00 from the motor side far enough onto the backplate 0330.00 so that you can insert the circlip 0932.01.

6. Guide grooved ball bearings 0321.00 and 0321.01 into the bearing seats.

7. Optional: Insert Nilos disks 0518.01 and 0518.02.a

8. Insert spacing ring 0504.10.

9. Assemble the bearing cover 0360.00.To do this, use socket head cap screw 0914.07.Torque: M6 - 8 Nm | M8 - 17 Nm

10. Assemble the bearing cover 0360.01.To do this, use socket head cap screw 0914.08.Torque: M6 - 8 Nm | M8 - 17 Nm

11. Push the tip ring 0507.00 onto the shaft 0211.00. 12. Insert key 0940.01 into shaft 0211.00.13. Optional: Push the shroud support ring 0517.01

onto the bearing housing 0330.00.14. Push the coupling half 0840.00 onto the shaft

stub.15. Secure the coupling half 0840.00 with grub

screw 0904.00.16. Install support foot 0183.00.

To do this, use hexagon head screw 0901.21.

a. Optional - only for shaft Ø50 mm.

36 BA.223.CNY.001.12/07.GB


6.6.1 Overview of mechanical seal arrangements

Fig. 13 Mechanical seal arrangementsK

0247

V1

E

D

CB

A

Type Seal type Characteristic PageA Single mechanical seal Seat in seal cartridge 38B Single mechanical seal Seat in casing backplate liner (only available for MAXA 80-160) 39C Double mechanical seal Tandem arrangement 41D Double mechanical seal Back-to-back arrangement with spiral spring 44E Double mechanical seal Back-to-back arrangement with encapsulated spring 45

Tab. 10 Mechanical seal arrangements

37BA.223.CNY.001.12/07.GB


6.6.2 Assembly of the single mechanical seal (A)

Features of the mechanical seal • Single mechanical seal• Seat in seal cartridge 0491.00• With casing backplate liner 0167.00.

Assemble the mechanical seal in this way:

Please note The assembly aids listed here may be found on page 51.

For assembling the impeller and volute casing, read on atsection 6.6.7 on page 46.

Fig. 14 Single mechanical seal (A)

K.0

151V

1

0167.00

0504.09

0433.00

0934.110920.150902.08

0491.00

0161.00

0412.02

1. At shaft diameter 30 mm and 40 mm: Insert the casing backplate liner 0167.00 into backplate 0161.00.

2. Insert the O-ring 0412.02 into groove of seal car-tridge 0491.00.

3. Push mechanical seal cartridge 0491.00 into backplate 0161.00.

4. Fasten seal cartridge 0491.00 on the backplate 0161.00. Use spring washers 0934.11 and hexa-gon nut 0920.15 to do this. Torque: M8 - 19 Nm.

5. Grease the centring between the backplate 0161.00 and the bearing housing 0330.00.Use OPTIMOL Paste TA from Hilge assembly tool kit (pos. 8, fig. 65).

6. Fasten backplate 0161.00 with seal cartridge 0491.00 installed on the bearing housing 0330.00.

7. Slide the assembly sleeve onto the shaft as far as the stop.

8. Spray the assembly sleeve and shaft 0211.00 with water.Use spray bottle from HILGE assembly tool kit (pos. 2, fig. 65).

9. Push the stationary ring of the mechanical seal 0433.00 into the seat.Use installation sleeve from HILGE assembly tool kit (pos. 12, fig. 65) to do this.

10. Push the rotating part of the mechanical seal 0433.00 onto the shaft 0211.00 and as far as the stop.Use installation sleeve from HILGE assembly tool kit (pos. 12, fig. 65) to do this.

11. Push the spacing ring 0504.09 onto the shaft. 12. Pull the assembly sleeve from the shaft 0211.00.

38 BA.223.CNY.001.12/07.GB


6.6.3 Assembly of the single mechanical seal (B)

Features of the mechanical seal • Single mechanical seal• Seat in casing backplate liner 0167.00.



Fig. 15 Single mechanical seal (B)

K.0

140V

1

0504.09

0433.00

0516.01

0167.00

1. Slide the assembly sleeve from HILGE assem-bly tool kit (pos. 3, fig. 65) onto the shaft exten-sion.

That way you avoid damages to the mechanical seal during the further assembly.

Fig. 16 Assembly sleeve

2. Spray the stationary ring of the mechanical seal 0433.00 and the assembly sleeve with clean water.Use spray bottle from HILGE assembly tool kit (pos. 2, fig. 65).

Fig. 17 Stationary ring of mechanical seal

3. Push the stationary ring of the mechanical seal 0433.00 into the seat of the casing backplate liner 0167.00.Use installation sleeve from HILGE assembly tool kit (pos. 12, fig. 65) to do this.


4. Spray the rotating ring of the mechanical seal 0433.00 and the assembly sleeve with clean water.Use spray bottle from HILGE assembly tool kit (pos. 2, fig. 65).

Fig. 19 Rotating ring of mechanical seal

39BA.223.CNY.001.12/07.GB



5. Push the rotating ring of the mechanical seal 0433.00 onto the shaft 0211.00.Use installation sleeve from HILGE assembly tool kit (pos. 12, fig. 65) to do this.

Fig. 20 Rotating ring of mechanical seal

6. Insert key 0940.00.

Fig. 21 Key

7. Push the spacer ring 0504.09 onto the shaft 0211.00.

Fig. 22 Spacer ring

40 BA.223.CNY.001.12/07.GB


6.6.4 Assembly of the double mechanical seal tandem (C)

Features of the mechanical seal • Double mechanical seal tandem• With seal cover 471.01• With seal cartridge 0491.00.



Fig. 23 Double mechanical seal tandem (C)

K.0

251V

1

0516.00

0904.02

0934.24

0433.00

0901.29

0471.01

0433.01

0412.35

0412.02

0934.11 0920.15 0902.08

0491.00

1. Spray the stationary ring of the atmosphere-side mechanical seal 0433.01with clean water.Use spray bottle from HILGE assembly tool kit (pos. 2, fig. 65).


2. Place the stationary ring of the mechanical seal 0433.01 in the seal cover 0471.01.

Fig. 25 Seal cover

3. Insert the O-ring 0412.35 into the seal cover 0471.01.

Fig. 26 O-ring on seal cover

4. Push the seal cover 0471.01 onto the shaft 0211.00.

Fig. 27 Seal cover on shaft

41BA.223.CNY.001.12/07.GB



That way you avoid damage to the mechanical seal during the further assembly.


6. Spray the rotating ring of the mechanical seal 0433.01 with clean water.Use spray bottle from HILGE assembly tool kit (pos. 2, fig. 65).

7. Push the rotating part of the mechanical seal 0433.01 onto the shaft 0211.00.Use installation sleeve from HILGE assembly tool kit (pos. 12, fig. 65) to do this.


8. Screw the studs 0904.02 one to two turns into the locating ring 0516.00.Coat the studs 0904.02 with a screw locking. Use Loctite type 243 from HILGE assembly tool kit (pos. 10, fig. 65) for this.

Fig. 30 Locating ring

9. Place the locating ring 0516.00 in the correct position on the shaft 0211.00 and fix it with the crub screws 0904.02.

Fig. 31 Locating ring

10. Release the spring of the mechanical seal 0433.01 against the locating ring 0516.00.Use ejector from HILGE assembly tool kit (pos. 5, fig. 65).

Fig. 32 Spring of mechanical seal

11. Grease the contact surfaces between the bear-ing housing 0330.00 and the backplate 0161.00.Use Klüberpaste UH1 96-402 from HILGE as-sembly tool kit for this (pos. 6, fig. 65).

Fig. 33 Backplate

12. Insert the O-ring 0412.02 into the seal cartridge 0491.00.

13. Fix the seal cartridge 0491.00 on the backplate 0161.00 by using the spring washers 0934.11 and the hexagon nuts 0920.15. Torque: M8 - 19 Nm.

42 BA.223.CNY.001.12/07.GB



14. Push the backplate 0161.00 into the bearing housing 0330.00 by using a plastic hammer.

Fig. 34 Backplate into bearing housing

Pay attention to the right direction of the backplate 0161.00.

Fig. 35 Direction of backplate

15. Spray the stationary ring of the mechanical seal 0433.00 with clean water.Use spray bottle from HILGE assembly tool kit (pos. 2, fig. 65).


17. Push the stationary ring of the mechanical seal 0433.00 into the cartridge 0491.00.Use installation sleeve from HILGE assembly tool kit (pos. 12, fig. 65) to do this.


18. Push the rotating ring of the mechanical seal 0433.00 onto the shaft 0211.00.Use installation sleeve from HILGE assembly tool kit (pos. 12, fig. 65) to do this.

Fig. 37 Stationary ring of the mechanical seal

19. Fix the seal cover 0471.01 onto the cartridge 0491.00 by using the spring washers 0934.24 and the hexagon head screws 0901.29. Torque: M6 - 8 Nm.

Fig. 38 Seal cartridge

43BA.223.CNY.001.12/07.GB


6.6.5 Assembly of the double mechanical seal back-to-back (D)

Features of the mechanical seal • Double mechanical seal back-to-back• With seal cartridge 0491.00.




Fig. 39 Single mechanical seal back-to-back (D)

K.01

52V

1

0433.01

0433.00

0412.01

0471.00

0934.11 0920.15 0902.08

0491.00

0934.23

0914.09

0516.00

0412.02


2. Fix the seal cartridge 0491.00 on the backplate 0161.00 by using the spring washers 0934.11 and the hexagon nuts 0920.15. Torque: M8 - 19 Nm.

3. Push the backplate 0161.00 into the bearing housing 0330.00 by using a plastic hammer.

4. Slide the assembly sleeve from HILGE assembly tool kit (pos. 3, fig. 65) onto the shaft extension.


5. Spray the stationary ring of the atmosphere-side mechanical seal 0433.01 and the assembly sleeve with clean water.Use spray bottle from HILGE assembly tool kit (pos. 2, fig. 65).

6. Push the stationary ring of the mechanical seal into the seat of the seal cartridge 0491.00.Use installation sleeve from HILGE assembly tool kit (pos. 12, fig. 65) to do this.

7. Spray the rotating ring of the mechanical seal 0433.01 and the assembly sleeve with clean water.Use spray bottle from HILGE assembly tool kit (pos. 2, fig. 65).

8. Push the rotating ring of the mechanical seal 0433.01 in complete assembly onto the shaft up as far as the stop.

9. Push the locating ring 0516.00 onto the shaft 0211.00.

10. Mount the rotating ring of the product-side mechanical seal 0433.00.Use installation sleeve from HILGE assembly tool kit (pos. 12, fig. 65) to do this.

11. Spray the stationary ring of the product-side mechanical seal 0433.00 and the assembly sleeve with clean water.


13. Place the stationary ring of the mechanical seal 0433.00 in the seal cover 0471.00.

14. Fix the seal cover 0471.00 together with the sta-tionary ring of the mechanical seal 0433.00 on the seal cartridge 0491.00 by using the spring washers 0934.23 and the socket head cap screws 0914.09. Torque: M6 - 8 Nm.

44 BA.223.CNY.001.12/07.GB


6.6.6 Assembly of the double mechanical seal back-to-back (E)

Features of the mechanical seal • Double mechanical seal back-to-back• With seal cartridge 0491.00• With seal covers 0471.00 and 0471.01.




Fig. 40 Single mechanical seal back-to-back (E)

K.01

53V

1

0433.010433.00

0412.01

0471.00

0934.11 0920.15 0902.08

0491.00

0934.23

0914.09

0516.00

0412.02

0934.240901.29

0412.35

0471.01

1. Insert the O-ring 0412.35 into the atmosphere-side seal cover 0471.01.

2. Slide the assembly sleeve from HILGE assembly tool kit (pos. 3, fig. 65) onto the shaft extension.


3. Spray the stationary ring of the mechanical seal 0433.01 with clean water.Use spray bottle from HILGE assembly tool kit (pos. 2, fig. 65).

4. Place the stationary ring of the mechanical seal 0433.01 in the atmosphere-side seal cover 0471.01.

5. Push the atmosphere-side seal cover 0471.01 onto the shaft 0211.00.

6. Push the rotating ring of the mechanical seal 0433.01 onto the shaft 0211.00.

7. Slide the locating ring 0516.00 onto the shaft 0211.00.

8. Push the rotating ring of the mechanical seal 0433.00 onto the shaft 0211.00.

9. Fix the mechanical seal 0433.01 and 0433.00 with the clamping screws on the shaft 0211.00 according to the correct position.


11. Fix the seal cartridge 0491.00 at the backplate 0161.00 by using the spring washers 0934.11 and the hexagon nuts 0920.15. Torque: M8 -19 Nm.

12. Fix the backplate 0161.00 to the respective drive end parts.

13. Fix the seal cover 0471.01 with the stationary ring of the mechanical seal 0433.01 at the seal cartridge 0491.00 by using the spring washers 0934.24 and the hexagon head screws 0901.29. Torque: M6 - 8 Nm.


15. Insert the stationary ring of the product-side mechanical seal 0433.00 into the seat of the seal cover 0471.00.

16. Push the seal cover 0471.00 onto the shaft 0211.00 as far as the stop.

17. Fix the seal cover 0471.00 on the seal cartridge by using the spring washers 0934.23 and the socket head cap screws 0914.09. Torque: M6 - 8 Nm.

45BA.223.CNY.001.12/07.GB


6.6.7 Assembly of the impeller and volute casing

Assemble the impeller and volute casing in this way:

1. Insert key 0940.00.

Fig. 41 Key

2. Grease the impeller seat and the pump shaft 0211.00.Use Klüberpaste UH1 96-402 from HILGE as-sembly tool kit for this (pos. 6, fig. 65).

Fig. 42 Pump shaft

3. Fit the impeller 0230.00.

Fig. 43 Impeller

4. Grease the Nord-Lock washers 0930.00 by using Klüberpaste UH1 96-402 from the HILGE assembly tool kit (pos. 6, fig. 65).

Fig. 44 Nord-lock washers

5. Grease Nord-Lock washers as shown.

Fig. 45 Schema of Nord-Lock washers greasing

• 0230.00 impeller• 0412.04 O-ring• 0922.00 impeller nut• A - fine toothing - greased• B - thick toothing against each other - greased

6. Insert the Nord-Lock washers 0930.00 into the impeller nut 0922.00.

Fig. 46 Nord-Lock washers in impeller nut

A B A

0922.00

0230.00

0412.04

46 BA.223.CNY.001.12/07.GB


7. Tighten the impeller nut 0922.00 by hand. Leave about 5 mm space for the O-ring 0412.04.A

Fig. 47 Impeller nut

8. Wet O-ring 0412.04 with clean water and slide it over the impeller nut 0922.00 into the gap between impeller nut 0922.00 and impeller 0230.00.A

Fig. 48 O-ring

A) Applies to EPDM and Viton O-ring.In case of other O-ring materials, insert O-ring into impeller nut 0922.00 before the nut is screwed on.

9. Tighten the impeller nut 0922.00 by using the following torques: • M20 - 100-120 Nm• M24 - 180-230 Nm• M30 - 210-250 Nm

Fig. 49 Impeller nut

10. For double mechanical seal tandem: Release the spring of the rotating ring of the mechanical seal against the impeller 0230.00.

Fig. 50 Spring of mechanical seal

11. Join the volute casing 0102.00 and the bearing housing.Pay attention to the right direction of the volute casing 0102.00.

Fig. 51 Volute casing and bearing housing

12. Grease the studs 0902.02 of the volute casing 0102.00.Use Klüberpaste UH1 96-402 from Hilge assem-bly tool kit (pos. 6., fig. 65).

Fig. 52 Studs of volute casing

13. Assemble the volute casing 0102.00 and the bearing housing 0330.00 by using the spring washers 0934.00 and the hexagon nuts 0920.04.

Fig. 53 Volute casing and bearing housing

14. Tighten the hexagon nuts 0920.04 in the order shown below. Torque: M10 - 37, M12 - 65 Nm.

Fig. 54 Tightening order

1.

2.

3.

4.5.

6.

7.

8.

47BA.223.CNY.001.12/07.GB


6.6.8 Assembly of coupling and motor Assemble the coupling and the motor in this way:

1. Slide the coupling half 0840.00 onto the shaft 0211.00.Screw the grub screw 0904.00 one or two turns into the spacer coupling half 0840.00.

Fig. 55 Coupling half, pump shaft

2. Slide the coupling half 0840.01 onto the motor shaft.Screw the grub screw 0904.00 one or two turns into the coupling half 0840.01.

Fig. 56 Coupling half, motor shaft

3. Fix the support foot 0183.00 on the baseplate 0890.00 by using washer 0554.12 and hexagon head screw 0901.22.Tighten the hexagon head screw 0901.22 by hand.

Fig. 57 Support foot

4. Make sure the pump shaft 0211.00 turns smoothly.

Fig. 58 Pump shaft check

5. Slide the coupling inserts 0867.00 and 0867.01 into the spacer 0869.00.

Fig. 59 Coupling inserts

6. Slide the spacer 0869.00 onto the coupling half 0840.00.

Fig. 60 Coupling inserts

7. Slide the coupling half 0840.00 of the motor 0800.00 into the spacer 0869.00.

Fig. 61 Spacer

8. Align the coupling by using a beveled steel edge.For the permitted shift values, see tab. 7 on page 21.

Fig. 62 Coupling, beveled steel edge

48 BA.223.CNY.001.12/07.GB


6.7 Troubleshooting

9. Tighten the screws of motor 0800.00, coupling 0840.00/01, volute casing 0102.00 and support foot 0183.00. See tab. 11 for the correct torques.Check alignment of coupling again after doing this. Correct it if needed.

Fig. 63 Fixing elements

10. Assemble the coupling guard 0681.00 by using the support ring 0517.01 and the pipe clamps 0733.00/01.

Fig. 64 Coupling guard

Size thread Torque [Nm]M 8 19M 10 37M 12 65M 16 153M 20 298

Tab. 11 Tightening torques

Problem Cause RemedyPump does not deliver or deliv-ers at a reduced rate.

1. Incorrect electrical hook-up (2 phases).2. Wrong rotational direction.3. Air in the suction line or in the pump.a4. Back pressure too high.5. Suction head too high, NPSH feed too low.6. Lines clogged or foreign material in the

impeller.7. Air inclusions as a result of a defective

seal.

1. Check the electrical connections and cor-rect them if necessary.

2. Reverse the phases of the power supply (reverse the polarity).

3. Vent the suction line or the pump and refill.4. Reset the operating point according to the

data sheet. Check system for contamina-tion.

5. Raise the liquid level on the suction side. Open the shut-off valve in the suction line all the way.Produce the conditions described in section 3.3. Consult the manufacturer.

6. Open the pump and fix the problem.7. Check the pipeline seals, the volute casing

seals, and the shaft seals. Replace if nec-essary.

Motor safety switch turns motor off. Motor is overloaded.

1. Pump jammed because of clogging.2. Pump jammed by contact because pump

body was twisted by the pipelines. (Check for damage).

3. Pump continues to run beyond the rated operating point.

4. The density or viscosity of the pumping medium is higher than the value stated in the order.

5. Motor safety switch not properly adjusted.6. Motor running on 2 phases.

1. Open the pump and fix the problem.2. Install the pump so that there is no stress

on it. Support the pipelines at fixed points.3. Set the operating point according to the

data sheet.4. If it is acceptable for the performance to be

lower than that stated, decrease the deliv-ery rate on the pressure side. Otherwise, use a more powerful motor.Consult the manufacturer.

5. Check the setting. Replace the safety switch if necessary.

6. Check the electrical connections. Replace defective fuses.

Tab. 12 Troubleshooting

49BA.223.CNY.001.12/07.GB


6.8 Disposal This product or parts of it must be disposed of in an environ-mentally sound way:

1. Use the public or private waste collection service.2. If this is not possible, contact the nearest Hilge/Grundfos

company or service workshop.

Pump produces too much noise. Pump runs roughly and vibrates.

1. Suction head too high, NPSH feed too low.2. Air in the suction line or in the pump.a3. Back pressure lower than stated.4. Impeller out of balance.5. Internal parts worn.6. Pump is twisted (causing contact noises).

Check for damage.7. Bearings are defective.8. Bearings have too little, too much or the

wrong kind of lubricant.9. Motor cooling fan defective.10. Gear ring of the coupling (power transmis-

sion) defective.b11. Foreign material in the pump.

1. Raise the liquid level on the suction side. Open the shut-off valve in the suction line all the way.Produce the conditions described in section 3.4. Consult the manufacturer.

2. Vent the suction line or the pump and refill.3. Set the operating point according to the

data sheet.4. Clean, inspect, and rebalance the impeller.5. Replace parts.6. Install the pump so that there is no stress

on it. Support the pipelines at fixed points.7. Replace the bearings.8. Add more lubricant, decrease the amount

or replace the lubricant.9. Replace the motor cooling fan.10. Replace the gear ring of the coupling. Rea-

lign the coupling.11. Open the pump and clean it (install a

screen in front of self-priming pumps, if necessary).

Leakage at the pump body, at the connections, at the mechani-cal seal and at the stuffing box or gland seal.

1. Pump is twisted (causing leaks at the pump body or at the connections).

2. Housing seals and seals at the connec-tions are defective.

3. Rotating mechanical seal dirty or stuck.4. Rotating mechanical seal worn.5. Stuffing box packing worn out.6. Surface of shaft or shaft safety sleeve worn

down.7. Elastomer unsuitable for the pumping

medium.

1. Install the pump so that there is no stress on it. Support the pipelines at fixed points.

2. Replace the housing seals or the seals of the connections.

3. Inspect and clean the rotating mechanical seal.

4. Replace mechanical seal.5. Tighten the stuffing box packing, add more

packing, or replace the packing.6. Replace the shaft or the shaft safety

sleeve. Repack the stuffing box.7. Use an elastomer suitable for the pumping

medium and the temperature. Unallowable temperature increase at the pump, bearing housing, or motor.

1. Air in the suction line or in the pump.a2. Bearings have too little, too much or the

wrong kind of lubricant.3. Pump and bearing housing are twisted.4. Axial thrust too high.a5. Motor safety switch is defective or not

properly adjusted.6. Pressure valve closed.

1. Vent the suction line or the pump and refill.2. Add more lubricant, decrease the amount

or replace it.3. Install the pump so that there is no stress

on it. Support the pipelines at fixed points. Check the alignment of the coupling.

4. Inspect the relief holes in the impeller and the split rings at the inlet.

5. Check the adjustment. Replace the motor safety switch if necessary.

6. Open the pressure valve.

a. Does not apply to self-priming pumps.b. Applies to CN baseplate design.

Problem Cause Remedy

Tab. 12 Troubleshooting

50 BA.223.CNY.001.12/07.GB


6.9 HILGE assembly tool kit Remove and install the mechanical seals safely and reliablyby using tools of the HILGE assembly tool kit.

6.9.1 Content and use

Fig. 65 HILGE assembly tool kit

K.02

66V

1

Item (fig.)

Description - shaft diameter

80-1

60

100-

200

/ 100

-250

100-

315

/ 125

-250

80-2

00 /

80-2

50 /

80-3

1512

5-31

5 / 1

50-2

50 /

150-

315

150-

400

/ 200

-400

2 spray bottle • • •3a assembly sleeve Ø 50 •3b assembly sleeve Ø 40 •3c assembly sleeve Ø 30 •4a plastic adapter Ø 40 •4d plastic adapter Ø 30 •5 ejector for mechanical seal - stationary ring • • •6 Klüberpaste UH1 96-402 • • •7 socket wrench SW 32 •7 socket wrench SW 50 •7 plastic socket spanner insert SW 27 •8 Optimol Paste TA • • •9 socket wrench SW 27 •10 screw locking Loctite type 243 • • •12a mechanical seal installation sleeve with plastic adapter Ø 50 •12b mechanical seal installation sleeve with plastic adapter Ø 38 and Ø 40 •12c mechanical seal installation sleeve with plastic adapter Ø 28 and Ø 30 •

Tab. 13 HILGE-assembly tool kit, tools for MAXA

51BA.223.CNY.001.12/07.GB

Certificate of non-objectionHILGEDOCUMENTATION

7. Certificate of non-objection

7.1 Certificate of non-objection The following pump and its accessories, together with thiscertificate of non-objection, are herewith contracted out by theundersigned for inspection/repair:

Pump data • Model:• No.:• Delivery date:

Reason for inspection / repair contract:

________________________________________________________________________________________________________________________________________________________________________________________________

The pump (please mark with a cross)

___ was not used in media hazardous to health

___ was used for the following: _______________________.

Please state the last medium to be pumped, if known:

________________________________________________

The pump was carefully drained and also cleaned inside andout before it was shipped/made available. (please mark witha cross)

___ No special safety measures are required in the course offurther handling.

___ The following safety measures pertaining to flushing me-dia, residual liquids and disposal are required:

________________________________________________________________________________________________________________________________________________________________________________________________

We confirm that the information given above is correct andcomplete and that shipment is in compliance with legal regu-lations.

Abstract

This section contains a certificate of non-objection. In case of inspection or repairing, send the pump includingthis certificate to HILGE.

Company (address):Telephone, fax, e-mail Name (please print), titleDate

Company stamp / signature

52 BA.223.CNY.001.12/07.GB

Certificate of non-objection HILGEDOCUMENTATION

�

53BA.223.CNY.001.12/07.GB

Certificate of non-objectionHILGEDOCUMENTATION

54 BA.223.CNY.001.12/07.GB

Service addresses HILGEDOCUMENTATION

8. Service addresses

8.1 HILGE companies

8.2 Grundfos companies

Abstract

For questions and comments, please contact service addresses of companies below.

55BA.223.CNY.001.12/07.GB

Operation Manual MAXA CN

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