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HILGEDOCUMENTATION

Operating manual
MAXA CN

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

Declaration of conformity
in accordance with EC Machine Regulation 98/37/EC1

We - HILGE - hereby declare that the pump unit

MAXA CN
is 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

Heinz Rust
Director of design

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

1. Introduction
Abstract
This section describes the requirements which are important for reading and understanding this manual. You will
learn the symbols and formats that make the reading easier.

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 it
easier to read this document:

• Listed items
Instructions Instructions that must be carried out in a specific sequence
are numbered in the corresponding order.

*
Important information and helpful tips are identified with the
index finger symbol.
Safety instructions The system used to identify safety instructions is described in
section 2.3 .

1.3 References to the document

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

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

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

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

2. Safety
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!

2.1 Instructions for the operator

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

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

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

Storage If the pump is not put into service immediately, it is important


that it is stored properly to ensure that it will function correctly
later. This is just as important as proper installation and main-
tenance.

The pump must be protected from cold, moisture and dust as


well as from mechanical influences.

Specially trained personnel is required to install and maintain


the pump properly.

2.2 Safety instructions in the


operating manual

Read safety instructions! The operating manual contains all basic information required
for the 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 before
installing and starting the pump. The operating manual must
always be available at the site where the machine/system is
being 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 are


identified as shown below.

Fig. 1 Symbol for safety instructions

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

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Safety HILGEDOCUMENTATION

• DANGER
Characterises an imminent hazard with a high risk which
can cause death or grievous bodily harm.
• WARNING
Characterises a possible hazard with medium risk which
can cause death or bodily harm if it is not avoided.
• CAUTION
Characterises a hazard with minor risk which can 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 completely
legible condition.

Damaged or illegible instructions must be replaced.

2.4 Qualifications and training of The employees operating, maintaining, inspecting and install-
personnel ing the pump must have the appropriate qualifications for this
work. The operator must define in detail the tasks for which
the employees are responsible, the tasks of which they are in
charge and the manner in which they are supervised.

If the employees do not have the necessary knowledge, they


must be instructed and trained accordingly. This can be done,
if necessary, by the manufacturer/supplier under contract to
the operator. The operator must also guarantee that the em-
ployees fully understand the contents of the operating manu-
al.

2.5 Hazards upon failure to follow If these safety instructions are not followed, employees, the
the safety instructions machine itself and the environment will be in danger.

Failure to follow the safety instructions can lead to the loss of


the right to file claims for damages.

Failure to follow instructions can, for example, lead in partic-


ular to the following hazards:

• breakdown of important functions of the machine/system


• failure of recommended methods of maintenance and
repair
• endangerment of personnel by electrical, mechanical and
chemical hazards
• endangerment of the environment by leakage of hazard-
ous materials.
2.6 Safety-conscious work The safety instructions given in this operating manual, the ex-
isting national regulations for accident prevention and any ap-
plicable internal working, operating and safety instructions of
the operator must be followed.

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HILGEDOCUMENTATION Safety

2.7 Safety instructions for the


operator / user

Warning
Burn hazard from hot or cold mechanical components.

! Cold or hot mechanical components can cause severe injury.

• Take structural measures to prevent contact with them!

Warning
Trapping hazard!

! Danger from rotating components. Rotating parts can cause


death, serious injury or damage to the equipment.

• Do not remove protection against contact with moving


parts (e.g. coupling guard) while the machine is operat-
ing.
• Replace 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 cause


death, serious injury or damage to the equipment.

• Drain away leakage of hazardous pumping media in such


a way that there is no danger to personnel or to the envi-
ronment!
• Follow legal regulations!
• If shaft seal 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).

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Safety HILGEDOCUMENTATION

Danger
Electrical hazard! Danger of electrical shock from contact with
energised components.

! An electric shock can cause death or bodily harm.

• Only use acceptable electric cables and plugs!

2.8 Unauthorised modifications No modifications or changes to the machine may be made


and production of spare parts without 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 which may
thus be caused.

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

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

Warning
Falling loads are dangerous!

! Falling loads may cause death, severe bodily injuries or prop-


erty damage.

• Transport work must only be performed by persons quali-


fied to do so, and all safety instructions must be
observed.
• Use suitable load-carrying equipment with sufficient
capacity to transport the pump.
• Make certain there are no persons under the suspended
load.
• Make certain the pump is aligned horizontally when it is
lifted!

Caution
Using incorrect lifting points is dangerous!

! Unsuitable lifting points may cause damage to the pump.

• Fasten the rope to suitable lifting points.


• Never fasten a rope to the pump casing or intake/dis-
charge branch!

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

K.0113V1
Fig. 2 Attachment points for CN pumps (example)

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

When special cleaning agents and methods are used, the


supplier must confirm that they are safe for the materials in-
volved.

Warning
Danger from pressure surge! Liquids under high pressure can
be forcibly ejected from the pump.

! Pressure surge can cause bodily injury or damage to the plant


and pump.

• Before sterilisation, always evacuate the system com-


pletely!

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Safety HILGEDOCUMENTATION

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

Examples of legal regulations on work safety:

• the Workplace Act (ArbStättV)


• the Hazardous Materials Act (GefStoffV)
• the accident prevention regulations(BGV A1)
• 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 a
component of the inspection/repair contract. This does not af-
fect our right to refuse acceptance of this contract for other
reasons.

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

HILGE products and their parts will only be inspected/re-


paired if the certificate of non-objection is present and has
been correctly completed by 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 the


careful draining and cleaning of the pump, the necessary in-
formation must be provided.

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

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

3.1 Pump overview

K.0263V1
Fig. 3 Overview of MAXA

• 0102 - volute casing


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

3.2 Description The pump is a single-stage end-suction centrifugal pump with


main dimensions and characteristics according to DIN EN
733 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.

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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 bodily
injury 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 may
not chemically or mechanically attack the pump materials or
lower 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 allowable 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 a 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 con-
necting elements to the pump must conform exactly to the de-
sign standard/specification of the mating connector piece
installed on the pump. The suction line must be absolutely
leak-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 not
be 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.

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

3.4 Technical data

Warning
Danger of overloading the pump!

! Overloading can cause death, grievous harm or damage to


the 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:

MAXA 100-200 CN 125/200 30 2


pump type
size
design
nominal diameter DNs / DND
power [kW]
number of poles
Tab. 1 HILGE pump denomination (example)

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.

Pump serial number (example) 223 / 07 / 1248

The pump serial number includes:

• pump type (223)


• year of manufacture (07)
• registration number (1248).

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Description HILGEDOCUMENTATION

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

HILGE GmbH & Co. KG


Hilgestraße - D - 55294 Bodenheim

Pump -Type
1

K.0109V2
No. 2
Q 3 m3/h H 4
P 5 kW n 6 min -1

Doc. -No.
7
MADE BY HILGE
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 manual
NOTE: The nameplate can deviate from the one shown.

3.4.4 Performance data The performance data of the pump, namely its head and de-
livery rate, are determined in accordance with
DIN EN ISO 9906 - appendix A, class 2, and are documented
on 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 cause


the seals to be destroyed. Hot pumped medium may escape!

• Never exceed the specified operating temperatures!

Tab 2 lists the maximum permissible operating temperatures.

Design Temp. [°C]


Standard design 95
Special design 150
Tab. 2 Operating temperatures

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HILGEDOCUMENTATION Description

3.4.6 Maximum operating pressure

Warning
Pressure overload is dangerous!

! Exceeding the maximum operating pressure may cause the


pump 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


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

4.1 Inspection before pump


installation

4.1.1 Check failure-free running of the Check the failure-free impeller running in this way:
impeller
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 cause


death, 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.

1. SUPER design only.


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

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HILGEDOCUMENTATION Mounting, installation and connection

Warning
Electrical danger due to short circuit!

! Short circuits can cause death, bodily injury or damage to the


plant.

• 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 the
coupling 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®.

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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.

S2 max

Ka
A

K.0159V1
S2 min

S2 max

B Kw

S2 min
Kr

C
Fig. 5 Types of shift (principal figure)

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

4.4 Permissible shift values Never under any circumstances exceed the following shift
Flender H / HDS coupling values of the coupling during operation.

4.4.1 Coupling size

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

Size H Drill hole Ø Size HDS Drill hole Ø


80 30 88 30
95 42 103 42
110 48 118 48
125 55 135 55
140 60 152 60
160 65 172 65
180 75 194 75
Tab. 3 Coupling size for design H

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

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HILGEDOCUMENTATION Mounting, installation and connection

4.4.2 Axial shift US2

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

Size H US2 Size - HDS US2


80 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

4.4.3 Angular shift UKw Angular shift UKw is useful to measure as the difference of
gap dimension (US2=S2max - S2min). Permissible values
for the gap dimension may be seen in tab. 5.

4.4.4 Radial shift UKr The following table lists permissible shaft shift values for radi-
al shift UKrzul and the difference for gap dimension US2zul
(zul = German abbreviation for "permissible").

Type, size Coupling speed in rpm


H HDS 250 500 750 1000 1500 2000 3000 4000 5000
80 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 UKrzul and difference of gap dimension US2zul

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4.5 Permissible shift values ROTEX Never under any circumstances exceed the following shift
DKM values 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 be
connected.

Standard coupling
Shaft diameter 14 19 24 28 38 42 48 55 65 75
Max. axial shift U 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 U Kr [mm] with 0.17 0.20 0.22 0.25 0.28 0.32 0.36 0.38 0.42 0.48
n=1500 min-1
Max. radial shift U Kr [mm] with 0.11 0.13 0.15 0.17 0.19 0.21 0.25 0.26 0.28 0.32
n=3000 min-1
Max. angular shift U Kw [degrees] with 1.2 1.2 0.9 0.9 1.0 1.0 1.1 1.1 1.2 1.2
n=1500 min-1 (0.67) (0.82) (0.85) (1.05 (1.35) (1.7) (2.0) (2.3) (2.7) (3.30)
Max. angular shift U Kw [degrees] with 1.1 1.1 0.8 0.8 0.8 0.8 0.9 1.00 1.0 1.0
n=3000 min-1 (0.62) (0.70) (0.75) (0.84) (1.10) (1.40) (1.60) (2.00) (2.30) (2.90)

Tab. 6 Permissible shift values for standard coupling

Coupling with adapter


Shaft diameter 14 19 24 28 38 42 48 55 65 75
Max. axial shift U Ka [mm] - 1.2 1.4 1.5 1.8 2.0 2.1 2.2 2.6 3.0
Max. radial shift U Kr [mm] with n=1500 - 0.54 0.53 0.60 0.77 0.84 1.00 1.11 1.4 1.59
min-1
Max. radial shift U Kr [mm] with n=3000 - 0.5 0.47 0.53 0.61 0.67 0.82 1.01 1.17 1.33
min-1
Max. angular shift U Kw [degrees] with - 1.2 0.9 0.9 1.0 1.0 1.1 1.1 1.2 1.2
n=1500 min-1
Max. angular shift U Kw [degrees] with - 1.1 0.8 0.8 0.8 0.8 0.9 1.0 1.0 1.0
n=3000 min-1
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 pump


is fitted with a quench, the lubrication for the quench must be
provided from an external source.

Dry running occurs when the lubrication fails. Dry running


may destroy the mechanical seal in few seconds.

For example, see fig. 6.

0433.00

K.0173V2
P A

L
Fig. 6 Lubrication between sliding surfaces

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

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.

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K.0076V2
P M

P M

Fig. 7 Installation in the pipeline

• above: gravity feed mode


• below: suction mode
• P - pump
• M - motor

4.7 Connections for flushing


system

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

Depending on the seal design, the barrier or flushing fluid


flows inside this seal cartridge.

The connection must be carried out as shown in fig. 8. That


way you can ensure that the fluid can flush the mechanical
seal effectively.

A
K.0246V1

0491.00

Fig. 8 Flushing connection

• 0491.00 - seal cartridge


• A - outlet line
• B - feed line

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Caution
Danger of dry running!

! 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 require


a 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 a
sealing 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.

BA.223.CNY.001.12/07.GB 25
HILGEDOCUMENTATION Mounting, installation and connection

4.7.3 Double mechanical seal - tandem


arrangement

Flushing liquid In order to continue functioning, the mechanical seals require


a flushing liquid, some of its purposes being:

• preventing leaks
• 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 a
flushing 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
Mounting, installation and connection HILGEDOCUMENTATION

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

Connect the pump as specified in the order documents. The


figure below shows the schema for star connection.

L1 L2 L3

U1 V1 W1

K.0079V1
W2 U2 V2

Fig. 9 Star connection

4.8.2 Delta connection Delta connection for low voltage.

Connect the pump as specified in the order documents. The


figure below shows the schema for delta connection.

L1 L2 L3

U1 V1 W1

K.0080V1
W2 U2 V2

Fig. 10 Delta connection

4.8.3 Checking the direction of rotation


after connection

Caution
Danger of dry running!

! 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.

BA.223.CNY.001.12/07.GB 27
HILGEDOCUMENTATION Start-up / shutdown

5. Start-up / shutdown
Abstract
This section describes how to start up and shut down the pump. You get to know which inspections contribute to
failure-free operation and increased life of the pump.

5.1 Start-up

5.1.1 Check application conditions Check the application conditions of the pump in this way:

1. Compare the data of the following documents with the


provided application 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 quick


heating 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 .

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. Quick


closing of shut-off devices on discharge side can cause a
pressure 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 - be
caused by a quick blocking of the flow in the discharge pipe.
In case of a pressure surge, the maximum permitted pump
pressure 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 after


shutdown.

• 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.

BA.223.CNY.001.12/07.GB 29
HILGEDOCUMENTATION Maintenance / servicing

6. Maintenance / servicing
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!.

6.1 Safety instructions for


maintenance, inspection and
installation work

Warning
Danger of unprofessional work!

! Unprofessional work can cause bodily injury or damage to the


plant 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 cause


death, 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.

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 rotating
mechanical seal.

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

BA.223.CNY.001.12/07.GB 31
HILGEDOCUMENTATION Maintenance / servicing

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.

Manufacturer Bearing temperature ≤120 °C Bearing temperature ≤60 °C – Danger of water entering
ARAL HL 3 FM 3
BP BP ENERGREASE LS 3 ENERGREASE PR 3
ENERGREASE LS 3
CALTEX CALTEX MULTIFAK 2 CALTEX CUP GREASE 3
CALTEX MULTIFAK 2
ESSO BEACON 3 ESTAN 2 R
BEACON 3
GULF GULFCROWN GULFCROWN
GREASE No. 2 GREASE No. 2
GULFCROWN GULFCROWN GREASE No. 3
GREASE No. 3
MOBIL - OIL MOBILUX GREASE No. 3 GARGOYLE
GREASE B No. 3
MOBILUX
GREASE No. 3
SHELL SHELL ALVANIA GREASE 3 SHELL UNEDO GREASE 3
SHELL ALVANIA GREASE 3
VALVOLINE VALVOLINE LB 2 VALVOLINE LB 2
OKS OKS 4200 (≤200 °C)
SKF LGMT 3/1 LGMT 3/1
Tab. 8 Cylinder bearing greases

6.4.1.2 Grease quantities for roller bearings The hollow areas between the cylinder bodies are factory-
during assembly filled 30% - 50% with grease. This grease filling is sufficient
for operation of the bearing under conditions normally en-
countered.

6.4.2 Bearing replacement To ensure problem-free operation of the pump, replace the
bearing 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.

32 BA.223.CNY.001.12/07.GB
0970.00 0504.10 0330.00 0733.00 0932.02 0869.00 0840.01 0733.01 0800.00 0970.01
0360.00 0560.00 0321.00 0932.01 0517.01 0940.01 0904.01 0867.01 0681.00
6.5 Assembly

0902.01

BA.223.CNY.001.12/07.GB
0920.22
0934.03
6.5.1 Parts overview

0902.02
0920.04
0934.00
Maintenance / servicing

0518.01
0507.02

Fig. 11 Parts overview of MAXA CN with bearing housing


0102.00

0940.00
0211.00
0507.00

0161.00

0901.23
0554.13

0902.02 0914.07 0504.00 0901.22 0183.00 0914.08 0904.00 0940.02 0890.00 0901.02
0920.04 0321.01 0518.02 0554.12 0901.21 0507.05 0840.00 0554.02
0934.00 0360.01 0867.00

K.0265V1

33
HILGEDOCUMENTATION
HILGEDOCUMENTATION Maintenance / servicing

Qty. Part no. Description Fig. Qty. Part no. Description Fig.
1 0102.00 volute casing 11 1 0840.00 coupling 11
1 0161.00 backplate 11 1 0840.01 coupling 14, 15
1 0167.00 casing backplate liner 14, 15 1 0867.00 coupling insert 11
1 0183.00 support foot 11 6 0867.01 coupling insert 11
1 0211.00 pump shaft 11 1 0869.00 coupling spacer 11
1 0321.00 grooved ball bearing 11 1 0890.00 baseplate 11
1 0321.01 grooved ball bearing 11 4 0901.21 hexagon head screw 11
1 0330.00 bearing housing 11 4 0901.02 hexagon head screw 11
1 0360.00 bearing cover 11 4 0901.21 hexagon head screw 11
1 0360.01 bearing cover 11 4 0901.22 hexagon head screw 11
1 0412.01 O-ring 46, 47 4 0901.23 hexagon head screw 11
1 0412.02 O-ring 14, 23, 39, 40 4 0901.29 hexagon head screw 23, 40
1 0412.35 O-ring 23, 40 12 0902.01 stud 11
1 0433.00 mechanical seal 11 12 0902.02 stud 11
1 0433.01 mechanical seal 11 4 0902.08 stud 14, 23, 39, 40
1 0471.00 seal cover 39, 40 1 0904.00 grub screw 11
1 0471.01 seal cover 11 1 0904.01 grub screw 11
1 0491.00 seal cartridge 14, 23, 39, 40 1 0904.02 grub screw 23
1 0504.00 spacer ring 11 4 0914.07 socket head cap screw 11
1 0504.09 spacer ring 14, 15 4 0914.08 socket head cap screw 11
1 0504.10 spacer ring 11 4 0914.09 socket head cap screw 39, 40
1 0507.00 V-ring 11 12 0920.04 hexagon nut 11
1 0507.02 V-ring 11 4 0920.15 hexagon nut 14, 23, 39, 40
1 0507.05 V-ring 11 12 0920.22 hexagon nut 11
1 0516.00 locating ring 23, 39, 40 1 0932.01 circlip 11
1 0516.01 locating ring 15 1 0932.02 circlip 11
1 0517.01 shroud support ring 11 12 0934.00 spring washer 11
1 0518.01 nilos ring 11 12 0934.03 spring washer 11
1 0518.02 nilos ring 11 4 0934.11 spring washer 14, 23, 39, 40
4 0554.02 washer 11 4 0934.23 spring washer 11
2 0554.12 washer 11 12 0934.24 spring washer 23, 40
4 0554.13 washer 11 1 0940.00 key 11
4 0560.00 pin 11 1 0940.01 key 11
1 0681.00 coupling guard 11 1 0940.02 key 11
1 0733.00 pipe clamp 11 1 0970.00 plate 11
1 0733.01 pipe clamp 11 1 0970.01 plate 11
1 0800.00 motor 11
Tab. 9 Parts list for MAXA CN

6.5.2 Instructions for assembly

Danger
Maintenance or assembly work can be dangerous if important
instructions are disregarded.

! • Before you maintenance or assemble the pump note sec-


tion 6.1 on page 30.

34 BA.223.CNY.001.12/07.GB
Maintenance / servicing HILGEDOCUMENTATION

Caution
For pump assembly, important aspects have to be taken into
account:

! A wrong assembly of the pump can cause damage to the


pump. 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.

BA.223.CNY.001.12/07.GB 35
HILGEDOCUMENTATION Maintenance / servicing

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

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

Compare the description with fig. 11.

0518.01 0504.01 0321.00 0517.01


0360.00 0932.01 0321.01
0211.00
0504.01
0932.02

K.0267V1
0940.00
0940.01

0518.02
0507.00
0360.01
0914.07 0914.08
0330.00 0183.00 0901.21
Fig. 12 CN bearing housing

1. Push the circlip 0932.01 over the shaft so that it 2. Press grooved ball bearings 0321.00 and
is positioned loosely between the two grooved 0321.01 onto shaft 0211.00.
ball bearings 0321.00 and 0321.01.
3. Mount spacing ring 0504.00. 4. Assemble circlip 0932.02.
5. Insert circlip 0932.01 into bearing housing 6. Guide grooved ball bearings 0321.00 and
0330.00. 0321.01 into the bearing seats.
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.
7. Optional: Insert Nilos disks 0518.01 and 8. Insert spacing ring 0504.10.
0518.02.a
9. Assemble the bearing cover 0360.00. 10. Assemble the bearing cover 0360.01.
To do this, use socket head cap screw 0914.07. To do this, use socket head cap screw 0914.08.
Torque: M6 - 8 Nm | M8 - 17 Nm 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 14. Push the coupling half 0840.00 onto the shaft
onto the bearing housing 0330.00. stub.
15. Secure the coupling half 0840.00 with grub 16. Install support foot 0183.00.
screw 0904.00. To do this, use hexagon head screw 0901.21.
a. Optional - only for shaft Ø50 mm.

36 BA.223.CNY.001.12/07.GB
Maintenance / servicing HILGEDOCUMENTATION

6.6.1 Overview of mechanical seal


arrangements

K0247V1
C

A D

Fig. 13 Mechanical seal arrangements

Type Seal type Characteristic Page


A Single mechanical seal Seat in seal cartridge 38
B Single mechanical seal Seat in casing backplate liner (only available for MAXA 80-160) 39
C Double mechanical seal Tandem arrangement 41
D Double mechanical seal Back-to-back arrangement with spiral spring 44
E Double mechanical seal Back-to-back arrangement with encapsulated spring 45
Tab. 10 Mechanical seal arrangements

BA.223.CNY.001.12/07.GB 37
HILGEDOCUMENTATION Maintenance / servicing

6.6.2 Assembly of the single mechanical


seal (A)
0412.02 0934.11
0920.15
0902.08
0433.00
0491.00

K.0151V1
0504.09

0167.00
0161.00
Fig. 14 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.

1. At shaft diameter 30 mm and 40 mm: Insert the 2. Insert the O-ring 0412.02 into groove of seal car-
casing backplate liner 0167.00 into backplate tridge 0491.00.
0161.00.
3. Push mechanical seal cartridge 0491.00 into 4. Fasten seal cartridge 0491.00 on the backplate
backplate 0161.00. 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 6. Fasten backplate 0161.00 with seal cartridge
0161.00 and the bearing housing 0330.00. 0491.00 installed on the bearing housing
Use OPTIMOL Paste TA from Hilge assembly 0330.00.
tool kit (pos. 8, fig. 65).
7. Slide the assembly sleeve onto the shaft as far 8. Spray the assembly sleeve and shaft 0211.00
as the stop. with water.
Use spray bottle from HILGE assembly tool kit
(pos. 2, fig. 65).
9. Push the stationary ring of the mechanical seal 10. Push the rotating part of the mechanical seal
0433.00 into the seat. 0433.00 onto the shaft 0211.00 and as far as the
Use installation sleeve from HILGE assembly stop.
tool kit (pos. 12, fig. 65) to do this. 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.

For assembling the impeller and volute casing, read on at


section 6.6.7 on page 46.

38 BA.223.CNY.001.12/07.GB
Maintenance / servicing HILGEDOCUMENTATION

6.6.3 Assembly of the single mechanical


seal (B)

0504.09

K.0140V1
0433.00

0516.01
0167.00

Fig. 15 Single mechanical seal (B)

Features of the mechanical seal • Single mechanical seal


• Seat in 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.

1. Slide the assembly sleeve from HILGE assem- 2. Spray the stationary ring of the mechanical seal
bly tool kit (pos. 3, fig. 65) onto the shaft exten- 0433.00 and the assembly sleeve with clean
sion. water.
Use spray bottle from HILGE assembly tool kit
* (pos. 2, fig. 65).
That way you avoid damages to the mechanical
seal during the further assembly.

Fig. 17 Stationary ring of mechanical seal

Fig. 16 Assembly sleeve


3. Push the stationary ring of the mechanical seal 4. Spray the rotating ring of the mechanical seal
0433.00 into the seat of the casing backplate 0433.00 and the assembly sleeve with clean
liner 0167.00. water.
Use installation sleeve from HILGE assembly Use spray bottle from HILGE assembly tool kit
tool kit (pos. 12, fig. 65) to do this. (pos. 2, fig. 65).

Fig. 18 Assembly sleeve Fig. 19 Rotating ring of mechanical seal

BA.223.CNY.001.12/07.GB 39
HILGEDOCUMENTATION Maintenance / servicing

5. Push the rotating ring of the mechanical seal 6. Insert key 0940.00.
0433.00 onto the shaft 0211.00.
Use installation sleeve from HILGE assembly
tool kit (pos. 12, fig. 65) to do this.

Fig. 21 Key

Fig. 20 Rotating ring of mechanical seal


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

Fig. 22 Spacer ring

For assembling the impeller and volute casing, read on at


section 6.6.7 on page 46.

40 BA.223.CNY.001.12/07.GB
Maintenance / servicing HILGEDOCUMENTATION

6.6.4 Assembly of the double mechanical


seal tandem (C)
0934.11 0920.15 0902.08
0904.02
0412.02
0491.00

K.0251V1
0433.00

0412.35

0471.01

0901.29

0934.24

0516.00 0433.01
Fig. 23 Double mechanical seal tandem (C)

Features of the mechanical seal • Double mechanical seal tandem


• With seal cover 471.01
• With seal cartridge 0491.00.

Assemble the mechanical seal in this way:

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

1. Spray the stationary ring of the atmosphere-side 2. Place the stationary ring of the mechanical seal
mechanical seal 0433.01with clean water. 0433.01 in the seal cover 0471.01.
Use spray bottle from HILGE assembly tool kit
(pos. 2, fig. 65).

Fig. 25 Seal cover

Fig. 24 Stationary ring of mechanical seal


3. Insert the O-ring 0412.35 into the seal cover 4. Push the seal cover 0471.01 onto the shaft
0471.01. 0211.00.

Fig. 26 O-ring on seal cover Fig. 27 Seal cover on shaft

BA.223.CNY.001.12/07.GB 41
HILGEDOCUMENTATION Maintenance / servicing

5. Slide the assembly sleeve from HILGE assem- 6. Spray the rotating ring of the mechanical seal
bly tool kit (pos. 3, fig. 65) onto the shaft exten- 0433.01 with clean water.
sion. 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.
That way you avoid damage to the mechanical seal
during the further assembly. Use installation sleeve from HILGE assembly tool
kit (pos. 12, fig. 65) to do this.

Fig. 28 Assembly sleeve


Fig. 29 Stationary ring of mechanical seal
8. Screw the studs 0904.02 one to two turns into 9. Place the locating ring 0516.00 in the correct
the locating ring 0516.00. position on the shaft 0211.00 and fix it with the
Coat the studs 0904.02 with a screw locking. Use crub screws 0904.02.
Loctite type 243 from HILGE assembly tool kit
(pos. 10, fig. 65) for this.

Fig. 31 Locating ring

Fig. 30 Locating ring


10. Release the spring of the mechanical seal 11. Grease the contact surfaces between the bear-
0433.01 against the locating ring 0516.00. ing housing 0330.00 and the backplate 0161.00.
Use ejector from HILGE assembly tool kit (pos. 5, Use Klüberpaste UH1 96-402 from HILGE as-
fig. 65). sembly tool kit for this (pos. 6, fig. 65).

Fig. 32 Spring of mechanical seal Fig. 33 Backplate


12. Insert the O-ring 0412.02 into the seal cartridge 13. Fix the seal cartridge 0491.00 on the backplate
0491.00. 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
Maintenance / servicing HILGEDOCUMENTATION

14. Push the backplate 0161.00 into the bearing


housing 0330.00 by using a plastic hammer. *
Pay attention to the right direction of the backplate
0161.00.

Fig. 34 Backplate into bearing housing

Fig. 35 Direction of backplate


15. Spray the stationary ring of the mechanical seal 17. Push the stationary ring of the mechanical seal
0433.00 with clean water. 0433.00 into the cartridge 0491.00.
Use spray bottle from HILGE assembly tool kit Use installation sleeve from HILGE assembly tool
(pos. 2, fig. 65). kit (pos. 12, fig. 65) to do this.
16. Slide the assembly sleeve from HILGE assem-
bly tool kit (pos. 3, fig. 65) onto the shaft exten-
sion.

Fig. 36 Stationary ring of mechanical seal


18. Push the rotating ring of the mechanical seal 19. Fix the seal cover 0471.01 onto the cartridge
0433.00 onto the shaft 0211.00. 0491.00 by using the spring washers 0934.24
Use installation sleeve from HILGE assembly and the hexagon head screws 0901.29. Torque:
tool kit (pos. 12, fig. 65) to do this. M6 - 8 Nm.

Fig. 37 Stationary ring of the mechanical seal Fig. 38 Seal cartridge

For assembling the impeller and volute casing, read on at


section 6.6.7 on page 46.

BA.223.CNY.001.12/07.GB 43
HILGEDOCUMENTATION Maintenance / servicing

6.6.5 Assembly of the double mechanical


seal back-to-back (D)
0934.11 0920.15 0902.08 0433.00

0412.02

K.0152V1
0491.00
0914.09
0934.23

0471.00

0433.01

0412.01 0516.00
Fig. 39 Single mechanical seal back-to-back (D)

Features of the mechanical seal • Double mechanical seal back-to-back


• With seal cartridge 0491.00.

Assemble the mechanical seal in this way:

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

1. Insert the O-ring 0412.02 into the seal cartridge 2. Fix the seal cartridge 0491.00 on the backplate
0491.00. 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 4. Slide the assembly sleeve from HILGE assembly
housing 0330.00 by using a plastic hammer. tool kit (pos. 3, fig. 65) onto the shaft extension.

*
That way you avoid damage to the mechanical seal
during the further assembly.
5. Spray the stationary ring of the atmosphere-side 6. Push the stationary ring of the mechanical seal
mechanical seal 0433.01 and the assembly into the seat of the seal cartridge 0491.00.
sleeve with clean water. Use installation sleeve from HILGE assembly tool
Use spray bottle from HILGE assembly tool kit kit (pos. 12, fig. 65) to do this.
(pos. 2, fig. 65).
7. Spray the rotating ring of the mechanical seal 8. Push the rotating ring of the mechanical seal
0433.01 and the assembly sleeve with clean 0433.01 in complete assembly onto the shaft up
water. as far as the stop.
Use spray bottle from HILGE assembly tool kit
(pos. 2, fig. 65).
9. Push the locating ring 0516.00 onto the shaft 10. Mount the rotating ring of the product-side
0211.00. 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 12. Insert the O-ring 0412.01 into the seal cover
mechanical seal 0433.00 and the assembly 0471.00.
sleeve with clean water.
13. Place the stationary ring of the mechanical seal 14. Fix the seal cover 0471.00 together with the sta-
0433.00 in the seal cover 0471.00. 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.

For assembling the impeller and volute casing, read on at


section 6.6.7 on page 46.

44 BA.223.CNY.001.12/07.GB
Maintenance / servicing HILGEDOCUMENTATION

6.6.6 Assembly of the double mechanical


seal back-to-back (E)
0934.11 0920.15 0902.08

0412.02
0491.00
0914.09

K.0153V1
0934.23
0412.35
0471.00

0934.24
0412.01 0901.29

0471.01

0433.00 0516.00 0433.01


Fig. 40 Single 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.

Assemble the mechanical seal in this way:

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

1. Insert the O-ring 0412.35 into the atmosphere- 2. Slide the assembly sleeve from HILGE assembly
side seal cover 0471.01. tool kit (pos. 3, fig. 65) onto the shaft extension.

*
That way you avoid damage to the mechanical seal
during the further assembly.
3. Spray the stationary ring of the mechanical seal 4. Place the stationary ring of the mechanical seal
0433.01 with clean water. 0433.01 in the atmosphere-side seal cover
Use spray bottle from HILGE assembly tool kit 0471.01.
(pos. 2, fig. 65).
5. Push the atmosphere-side seal cover 0471.01 6. Push the rotating ring of the mechanical seal
onto the shaft 0211.00. 0433.01 onto the shaft 0211.00.
7. Slide the locating ring 0516.00 onto the shaft 8. Push the rotating ring of the mechanical seal
0211.00. 0433.00 onto the shaft 0211.00.
9. Fix the mechanical seal 0433.01 and 0433.00 10. Insert the O-ring 0412.02 into the seal cartridge
with the clamping screws on the shaft 0211.00 0491.00.
according to the correct position.
11. Fix the seal cartridge 0491.00 at the backplate 12. Fix the backplate 0161.00 to the respective drive
0161.00 by using the spring washers 0934.11 end parts.
and the hexagon nuts 0920.15. Torque:
M8 -19 Nm.
13. Fix the seal cover 0471.01 with the stationary 14. Insert the O-ring 0412.01 into the seal cover
ring of the mechanical seal 0433.01 at the seal 0471.00.
cartridge 0491.00 by using the spring washers 15. Insert the stationary ring of the product-side
0934.24 and the hexagon head screws 0901.29. mechanical seal 0433.00 into the seat of the seal
Torque: M6 - 8 Nm. cover 0471.00.
16. Push the seal cover 0471.00 onto the shaft 17. Fix the seal cover 0471.00 on the seal cartridge
0211.00 as far as the stop. by using the spring washers 0934.23 and the
socket head cap screws 0914.09. Torque:
M6 - 8 Nm.

For assembling the impeller and volute casing, read on at


section 6.6.7 on page 46.

BA.223.CNY.001.12/07.GB 45
HILGEDOCUMENTATION Maintenance / servicing

6.6.7 Assembly of the impeller and volute Assemble the impeller and volute casing in this way:
casing

1. Insert key 0940.00. 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. 41 Key

Fig. 42 Pump shaft


3. Fit the impeller 0230.00. 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. 43 Impeller

Fig. 44 Nord-lock washers


5. Grease Nord-Lock washers as shown. 6. Insert the Nord-Lock washers 0930.00 into the
impeller nut 0922.00.

0922.00
0412.04
0230.00

A B A

Fig. 45 Schema of Nord-Lock washers greasing


Fig. 46 Nord-Lock washers in impeller nut
• 0230.00 impeller
• 0412.04 O-ring
• 0922.00 impeller nut
• A - fine toothing - greased
• B - thick toothing against each other - greased

46 BA.223.CNY.001.12/07.GB
Maintenance / servicing HILGEDOCUMENTATION

7. Tighten the impeller nut 0922.00 by hand. Leave 8. Wet O-ring 0412.04 with clean water and slide it
about 5 mm space for the O-ring 0412.04.A over the impeller nut 0922.00 into the gap
between impeller nut 0922.00 and impeller
0230.00.A

Fig. 47 Impeller nut

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 10. For double mechanical seal tandem: Release
following torques: the spring of the rotating ring of the mechanical
• M20 - 100-120 Nm seal against the impeller 0230.00.
• M24 - 180-230 Nm
• M30 - 210-250 Nm

Fig. 50 Spring of mechanical seal

Fig. 49 Impeller nut


11. Join the volute casing 0102.00 and the bearing 12. Grease the studs 0902.02 of the volute casing
housing. 0102.00.
Pay attention to the right direction of the volute Use Klüberpaste UH1 96-402 from Hilge assem-
casing 0102.00. bly tool kit (pos. 6., fig. 65).

Fig. 51 Volute casing and bearing housing Fig. 52 Studs of volute casing
13. Assemble the volute casing 0102.00 and the 14. Tighten the hexagon nuts 0920.04 in the order
bearing housing 0330.00 by using the spring shown below.
washers 0934.00 and the hexagon nuts Torque: M10 - 37, M12 - 65 Nm.
0920.04.
1. 7.
5. 4.

3. 6.

8. 2.

Fig. 54 Tightening order


Fig. 53 Volute casing and bearing housing

BA.223.CNY.001.12/07.GB 47
HILGEDOCUMENTATION Maintenance / servicing

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 2. Slide the coupling half 0840.01 onto the motor
0211.00. shaft.
Screw the grub screw 0904.00 one or two turns Screw the grub screw 0904.00 one or two turns
into the spacer coupling half 0840.00. into the coupling half 0840.01.

Fig. 55 Coupling half, pump shaft Fig. 56 Coupling half, motor shaft
3. Fix the support foot 0183.00 on the baseplate 4. Make sure the pump shaft 0211.00 turns
0890.00 by using washer 0554.12 and hexagon smoothly.
head screw 0901.22.
Tighten the hexagon head screw 0901.22 by
hand.

Fig. 58 Pump shaft check

Fig. 57 Support foot


5. Slide the coupling inserts 0867.00 and 0867.01 6. Slide the spacer 0869.00 onto the coupling half
into the spacer 0869.00. 0840.00.

Fig. 59 Coupling inserts Fig. 60 Coupling inserts


7. Slide the coupling half 0840.00 of the motor 8. Align the coupling by using a beveled steel edge.
0800.00 into the spacer 0869.00. For the permitted shift values, see tab. 7 on page
21.

Fig. 61 Spacer
Fig. 62 Coupling, beveled steel edge

48 BA.223.CNY.001.12/07.GB
Maintenance / servicing HILGEDOCUMENTATION

9. Tighten the screws of motor 0800.00, coupling 10. Assemble the coupling guard 0681.00 by using
0840.00/01, volute casing 0102.00 and support the support ring 0517.01 and the pipe clamps
foot 0183.00. See tab. 11 for the correct torques. 0733.00/01.
Check alignment of coupling again after doing
this. Correct it if needed.

Fig. 64 Coupling guard

Fig. 63 Fixing elements

Size thread Torque [Nm]


M8 19
M 10 37
M 12 65
M 16 153
M 20 298
Tab. 11 Tightening torques

6.7 Troubleshooting

Problem Cause Remedy


Pump does not 1. Incorrect electrical hook-up (2 phases). 1. Check the electrical connections and cor-
deliver or deliv- 2. Wrong rotational direction. rect them if necessary.
ers at a reduced 3. Air in the suction line or in the pump.a 2. Reverse the phases of the power supply
rate. 4. Back pressure too high. (reverse the polarity).
5. Suction head too high, NPSH feed too low. 3. Vent the suction line or the pump and refill.
6. Lines clogged or foreign material in the 4. Reset the operating point according to the
impeller. data sheet. Check system for contamina-
7. Air inclusions as a result of a defective tion.
seal. 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 1. Pump jammed because of clogging. 1. Open the pump and fix the problem.
switch turns 2. Pump jammed by contact because pump 2. Install the pump so that there is no stress
motor off. Motor body was twisted by the pipelines. (Check on it. Support the pipelines at fixed points.
is overloaded. for damage). 3. Set the operating point according to the
3. Pump continues to run beyond the rated data sheet.
operating point. 4. If it is acceptable for the performance to be
4. The density or viscosity of the pumping lower than that stated, decrease the deliv-
medium is higher than the value stated in ery rate on the pressure side. Otherwise,
the order. use a more powerful motor.
5. Motor safety switch not properly adjusted. Consult the manufacturer.
6. Motor running on 2 phases. 5. Check the setting. Replace the safety
switch if necessary.
6. Check the electrical connections. Replace
defective fuses.
Tab. 12 Troubleshooting

BA.223.CNY.001.12/07.GB 49
HILGEDOCUMENTATION Maintenance / servicing

Problem Cause Remedy


Pump produces 1. Suction head too high, NPSH feed too low. 1. Raise the liquid level on the suction side.
too much noise. 2. Air in the suction line or in the pump.a Open the shut-off valve in the suction line
Pump runs 3. Back pressure lower than stated. all the way.
roughly and 4. Impeller out of balance. Produce the conditions described in section
vibrates. 5. Internal parts worn. 3.4. Consult the manufacturer.
6. Pump is twisted (causing contact noises). 2. Vent the suction line or the pump and refill.
Check for damage. 3. Set the operating point according to the
7. Bearings are defective. data sheet.
8. Bearings have too little, too much or the 4. Clean, inspect, and rebalance the impeller.
wrong kind of lubricant. 5. Replace parts.
9. Motor cooling fan defective. 6. Install the pump so that there is no stress
10. Gear ring of the coupling (power transmis- on it. Support the pipelines at fixed points.
7. Replace the bearings.
sion) defective.b
8. Add more lubricant, decrease the amount
11. Foreign material in the pump.
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 1. Pump is twisted (causing leaks at the 1. Install the pump so that there is no stress
pump body, at pump body or at the connections). on it. Support the pipelines at fixed points.
the connections, 2. Housing seals and seals at the connec- 2. Replace the housing seals or the seals of
at the mechani- tions are defective. the connections.
cal seal and at 3. Rotating mechanical seal dirty or stuck. 3. Inspect and clean the rotating mechanical
the stuffing box 4. Rotating mechanical seal worn. seal.
or gland seal. 5. Stuffing box packing worn out. 4. Replace mechanical seal.
6. Surface of shaft or shaft safety sleeve worn 5. Tighten the stuffing box packing, add more
down. packing, or replace the packing.
7. Elastomer unsuitable for the pumping 6. Replace the shaft or the shaft safety
medium. sleeve. Repack the stuffing box.
7. Use an elastomer suitable for the pumping
medium and the temperature.
Unallowable 1. Air in the suction line or in the pump.a 1. Vent the suction line or the pump and refill.
temperature 2. Bearings have too little, too much or the 2. Add more lubricant, decrease the amount
increase at the wrong kind of lubricant. or replace it.
pump, bearing 3. Pump and bearing housing are twisted. 3. Install the pump so that there is no stress
housing, or on it. Support the pipelines at fixed points.
4. Axial thrust too high.a
motor. Check the alignment of the coupling.
5. Motor safety switch is defective or not
4. Inspect the relief holes in the impeller and
properly adjusted.
the split rings at the inlet.
6. Pressure valve closed.
5. Check the adjustment. Replace the motor
safety switch if necessary.
6. Open the pressure valve.
Tab. 12 Troubleshooting
a. Does not apply to self-priming pumps.
b. Applies to CN baseplate design.

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.

50 BA.223.CNY.001.12/07.GB
Maintenance / servicing HILGEDOCUMENTATION

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

K.0266V1
Fig. 65 HILGE assembly tool kit

6.9.1 Content and use

Item Description - shaft diameter

125-315 / 150-250 / 150-315


(fig.)

80-200 / 80-250 / 80-315


100-200 / 100-250
100-315 / 125-250

150-400 / 200-400
80-160

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

BA.223.CNY.001.12/07.GB 51
HILGEDOCUMENTATION Certificate of non-objection

7. Certificate of non-objection
Abstract
This section contains a certificate of non-objection. In case of inspection or repairing, send the pump including
this certificate to HILGE.

7.1 Certificate of non-objection The following pump and its accessories, together with this
certificate of non-objection, are herewith contracted out by the
undersigned 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 and
out before it was shipped/made available. (please mark with
a cross)

___ No special safety measures are required in the course of


further 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 and


complete and that shipment is in compliance with legal regu-
lations.

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

Company stamp / signature

52 BA.223.CNY.001.12/07.GB
Certificate of non-objection HILGEDOCUMENTATION

BA.223.CNY.001.12/07.GB 53
HILGEDOCUMENTATION Certificate of non-objection

54 BA.223.CNY.001.12/07.GB
Service addresses HILGEDOCUMENTATION

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

8.1 HILGE companies

8.2 Grundfos companies

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