Instruction Manual - LKH UltraPure Centrifugal Pump
Contents
1. 4 Operation The pump is designed for cleaning in place CIP CIP Cleaning In Place Study the instructions carefully and pay special attention to the warnings NaOH Caustic soda HNO3 Nitric acid 4 3 Recommended cleaning Step 1 Always handle lye and acid with great care Caustic danger Always use rubber gloves Always use protective goggles Step 2 A Never touch the pump or the pipelines when sterilising Danger of burns E N all N 3007 0018 Y pig rk A Step 3 Examples of cleaning agents Use clean water free from chlorides 1 1 by weight NaOH at 70 C 158 F 1 kg 2 2 lb 100 26 4 gal Cleaning agent 1 Avoid excessive concentration NaOH water of the cleaning agent gt Dose gradually 2 2 0 6 gal 1001 26 4 gal Cleaning agent 2 Adjust the cleaning flow to the 33 NaOH water process Sterilisation of milk viscous liquids O o o 2 0 5 by weight HNO at 70 C 158 F gt Increase the cleaning flow 0 7 0 2 gal F 100 26 4 gal Cleaning agent 53 HNO3 water Step 4 Always rinse A Always rinse well with clean water after using a cleaning agent Water Cleaning agent NOTE The cleaning agents must be stored disposed of in accordance with current regulations directives 16 5 Maintenance Maintain the pump carefully2. 34 6 Technical data It is important to observe the technical data during installation operation and maintenance Inform personnel about the technical data 6 4 Weight kg Pump Type LKH UltraPure Size 90 100 112 132 160 180 1 5kW 2 2kW 3kW 4kW 5 5kW 7 5kW 11kw 15kW 18 5kW 22kW 10 53 55 70 19 20 55 57 72 ue 94 108 25 81 98 112 171 185 35 81 98 112 171 185 40 115 174 188 206 225 Weight can vary depending of configuration Weihgt is only to be seen as a reference value during handling transporting and packaging 6 Technical data It is important to observe the technical data during installation operation and maintenance Inform personnel about the technical data 6 5 Noise emission Pump Type Sound pressure level dBA LKH 5 60 LKH 10 69 LKH 15 72 LKH 20 70 LKH 25 74 LKH 35 71 LKH 40 75 LKH 45 70 LKH 50 75 LKH 60 77 LKH 70 88 LKH 75 79 LKH 85 86 LKH 90 5 LKH 112 70 LKH 113 69 LKH 114 68 LKH 122 75 LKH 123 77 LKH 124 80 SolidC 1 68 SolidC 2 72 SolidC 3 73 SolidC 4 72 MR 166 76 MR 185 82 MR 200 81 MR 300 82 GM 54 FM OS 61 The above LKH noise levels are the same for LKHPF LKHI LKH UltraPure LKH Evap and LKHex The above SolidC noise levels are the same for SolidC UltraPure The noise measurements have been carried out on the original motor and shroud at the approximate Best Efficiency Point BEP with
3. O Product wetted part 7 Parts list and service kits The drawing shows the LKH UltraPure pump sanitary version The items refer to the parts lists in the following sections 7 2 LKH UltraPure Product wetted parts Parts list Pos Qty Denomination 1 Tool complete 1 1 Motor 2 1 Shroud 3 4 Screw 5a 1 Compression ring with thread 5b 1 Compression ring without thread 6 6 Screw 6a 6 Washer 7 1 Shaft 8 1 Connex pin 9 1 Retaining ring 16 1 Adaptor 17 4 Screw for adaptor 18 4 Nut for adaptor 19 4 Washer for adaptor 22 Safety guard set 23 1 Screw for safety guard 30a 1 Support bar right 30b 1 Support bar left 31 4 Leg 32 4 Screw 33 4 Nut 34 4 Spring washer 35 4 Screw 35a 4 Washer 39 4 Nut 46 4 Distance sleeve 41 7 Parts list and service kits The drawing shows the LKH UltraPure pump sanitary version The items refer to the parts lists in the following sections 7 2 LKH UltraPure Product wetted parts 7 4 LKH UltraPure Single shaft seal Single shaft seal TD 200 372_1 PP 0 6 11 42 7 Parts list and service kits The drawing shows the LKH UltraPure pump sanitary version The items refer to the parts lists in the following sections 7 2 LKH UltraPure Product wetted parts Parts list Pos Qty Denomination o Complete single shaft seal iC SIC f Complete double mechanical shaft seal SiC SiC Alfa Laval Q doc service kit Drive ring Single shaft seal
4. Study the instructions carefully and pay special attention to the warnings Always keep spare shaft seals and rubber seals in stock See separate motor instructions 5 1 General maintenance Step 1 A Always read the technical data thoroughly See chaper 6 Technical data Always disconnect the power supply when servicing the pump NOTE All scrap must be stored disposed of in accordance with current rules directives Step 2 Danger of burns A Never service the pump when it is hot 3007 0015 E Step 3 A Never service the pump with pump and pipelines under pressure Atmospheric pressure required CAUTION Fit the electrical connections correctly if they have been removed from the motor during service See pre use check in section 2 3 Safety precautions Pay special attention to the warnings S 3007 0019 E IL Step 4 Recommended spare parts Order service kits from the service kits list see chapter 7 Parts list and service kits Ordering spare parts Contact your local Alfa Laval sales company Note If the pump is supplied with FEP O rings Alfa Laval recommends that the casing O ring is replaced during pump maintenance 17 5 Maintenance Maintain the pump carefully Study the instructions carefully and pay special attention to the warnings Always keep spar
5. Step 1 1 Loosen screws 6 2 Pull off stub shaft 7 together with compression rings 5a 5b 10 20 mm 0 39 0 78 inch Step 2 1 Push stub shaft 7 together with compression rings 5a 5b onto the motor shaft 2 Check that the clearance between the end of the stub shaft and the motor flange is 10 20 mm 0 39 0 78 inch Step 3 1 Tighten screws 6 lightly and evenly 2 Ensure that stub shaft 7 can be moved on the motor shaft Step 4 1 For double mechanical shaft seal Fit drive ring 62 on stub shaft 7 2 Fit back plate 25 washers 21 and nuts 20 and tighten 29 5 Maintenance Study the instructions carefully The items refer to the parts list and service kits section Lubricate the rubber seals before fitting them x Relates to the shaft seal Step 5 Distance 0 5 mm 0 02 inch 1 Fit impeller 37 on stub shaft 7 2 Ensure that the clearance between the impeller and back plate 25 is correct 0 5 mm 0 02 inch 3 Tighten screws 6 evenly until the stub shaft 7 cannot move on the motor shaft Step 6 1 Remove impeller 87 back plate 25 and drive ring 62 2 Tighten screws 6 evenly to 15 Nm 11 lbf ft 15Nm 11 Ibf ft 30 6 Technical data It is important to observe the technical data during installation operation and maintenance Inform personnel about the technical data 6 1 Technical data The LKH UltraPure
6. Technical data CAUTION Alfa Laval cannot be held responsible for incorrect unpacking WARNING Be aware that certain pump configurations can tilt and therefore cause injuries to feet or fingers The pump should be supported underneath the adaptor when not installed in the process line Step 2 Remove any packing materials from the inlet and the outlet Avoid damaging the inlet and the outlet f Remove packing materials a 3007 0003 Step 3 Inspection Inspect the pump for visible transport damage Step 4 Caution Avoid damaging the flushing liquid connections if supplied OOj el o o o 3007 0004 3 lt lt 3 Installation Step 5 Remove the shroud before lifting Always remove the shroud if fitted before lifting the pump 3007 0005 3 Installation Read the instructions carefully and pay special attention to the warnings Always check the pump before operation See pre use check in section 3 3 Pre use check pump with impeller screw 3 2 Installation Step 1 A Always read the technical data thoroughly See chaper 6 Technical data Always use a lifting crane when handling the pump A Always have the pump elec
7. pump is a highly efficient and economical centrifugal pump which meets the requirements of the pharmaceutical industries It provides gentle product treatment and is chemically resistant LKH UltraPure is available in the following sizes LKH UltraPure 10 20 25 35 and 40 The instruction manual is part of the delivery Study the instructions carefully Data Max system pressure Temperature range Max speed Materials Product wetted steel parts Other steel parts Finish Product wetted seals Other O rings Alternative seals Shaft seal Seal types Max temperature flush media Material stationary seal ring Material rotating seal ring Material O rings Alternative material O rings Motor ug insulation class F xe Motor sizes kW 50 Hz Motor sizes kW 60 Hz Motor sizes Hp 50 Hz Motor sizes Hp 60 Hz Max water pressure double mechanical seal Water consumption double mechanical seal 1000 kPa 10 bar 145 psi 10 C to 140 C EPDM 14 F to 284 F 4000 rpm AISI 316L Stainless steel Polished EPDM standard EPDM standard FPM and FEP External single or double mechanical seal 70 C Normally atmospheric max 5 bar max 72 5 psi 0 25 0 5 l min 0 006 0 13 gpm Acid resistant steel with sealing surface of silicon carbide Silicon carbide EPDM standard FPM and FEP Foot flanged motor acc to IEC metric standard 2 poles 3000 3600 rpm at 50 60 Hz I
8. Instruction Manual 3007 0062 ESEO1703 EN7 2015 03 Original manual Table of contents The information herein is correct at the time of issue but may be subject to change without prior notice 1 EC Declaration of Conformity 2 c cece eee ee eee eens A A NO 2 1 Important information wav cigsy cc a a Pea cad By vas FAN aa oa da 2 23 WaN SIGAS eaaa A SRT ioe eared SOI ee are A 2 3 Dafely precautions iia A A eee eels Odia Se ANSTANAUON pira o A IRAN EA jale 1D E Ara Salk Unpacking delVSiy Fara Ache adan rad 22 Stallone da a asa 3 3 Pre use check pump with impeller SCrew ooocccccccccccccccccccccccnn ana nnn rro BA ReCyclIMg IMTONMALION coi a dv A RR 4 11 Operatlon Control escindida res Sue a drid Ree 4 2 Trouble SHOOUNG inicios 4 3 Recommended cleaning 6 cece cece cece cece cence eee eee e rttr rr rr narrar 5 MaintenanGe ii A A A AS cate 5 1 General maintenance oo cece e eee e ence ence estes eee ea eea eee eeeeeteseneeeeeanenenaeennns O22 CIEANING O 5 3 Dismantling of pump Shatt SeallS s acaxeorsmnevie ra dadas 5 4 Assembly of pump single shaft Seal oo cece cece eee ee cece e eee rra 5 5 Assembly of pump double mechanical shaft Seal kee ccc cece cece cece sees eeeeeeeeenneees 5 6 Assembly of flushing set if not supplied with PUMP 1 eke eceeee cece eee e eee e eee eeees 5 0 Adjustment of shaft a id 6 Technical data oso
9. P55 drain hole with labyrinth 1 5 22 kW 1 75 25 kW 2 0 4 29 5 Hp 2 4 33 5 Hp For further information see PD sheet 31 6 Technical data It is important to observe the technical data during installation operation and maintenance Inform personnel about the technical data 6 2 Relubrication intervals The table is for an internal bearing temperature of 100 C An increase in temperature of 15 C ambient or internal in bearings will reduce the greasing interval and bearing lifetime by 50 The lubrication interval for vertically mounted pumps is half the value stated in the table ABB IEC motors IES Motor LKH5 90 LKHPF 10 60 LKHPF 70 LKH 85 power LKHI10 60 LKHI 10 60 LKH 120 7300 Bearing kW LKH 110 LKH 110 7200 Bearing 50 60 Hz LKHSP 3300 Bearing 50 60 Hz LKH UltraPure 50 60 Hz 50 60_Hz 0 75 Permanently lubricated Vel Permanently lubricated 1 5 Permanently lubricated Not available 2 2 Permanently lubricated Permanently lubricated 3 0 Permanently lubricated Not available 4 0 Permanently lubricated Permanently lubricated 5 5 Permanently lubricated 3600h 3000h DE NDE 15g 7 5 Permanently lubricated 3600h 3000h DE NDE 15g 1 Permanently lubricated 3100h 2300h DE NDE 25g 15 Permanently lubricated 3100h 2300h DE NDE 259 18 5 Permanently lubricated 3100h 2300h DE NDE 25g 22 Permanently lubricated 2600h 2000h DE NDE 42g 4000
10. by means of special signs Always read the manual before using the pump 2 1 Important information WARNING E Indicates that special procedures must be followed to avoid serious personal injury CAUTION Indicates that special procedures must be followed to avoid damage to the pump NOTE Indicates important information to simplify or clarify procedures 2 2 Warning signs General warning Dangerous electrical voltage gt gt gt Caustic agents 2 Safety All warnings in the manual are summarised on this page Pay special attention to the instructions below so that severe personal injury and or damage to the pump are avoided 2 3 Safety precautions Installation Always read the technical data thoroughly See chapter 6 Technical data Always use a lifting crane when handling the pump Pump without impeller screw Always remove the impeller before checking the direction of rotation Never start the pump if the impeller is fitted and the pump casing is removed Pump with Impeller screw Never start in the wrong direction of rotation with liquid in the pump Always have the pump electrically connected by authorised personnel See the motor instruction Operation Always read the technical data thoroughly See chapter 6 Technical data Never touch the pump or the pipelines when pumping hot liquids or when sterilising Never run the pump with both the suction side and the pressure s
11. cated 11 Permanently lubricated 18 5 Permanently lubricated 30 10000 10000h DE NDE 21g 45 Not available 75 5000 5000h DE NDE 27g inlet pressure lt 10 bar 145 psi Recommended grease types Mobil POLYREX EM 103 33 6 Technical data It is important to observe the technical data during installation operation and maintenance Inform personnel about the technical data Table 1 Sterling Nema motors Motor RPM Frame Type of service VS HP Standard Heavy duty 8 hrs day 24 hrs day 143T 286TS A y 1 5 30 3600 324TS 455TS 40 150 6 Months 2 Months 143T 2561 s A 1 20 284T 326T 1800 25 50 4 Months 18 Months 364T 445T 60 150 9 Months 3 Months 143T 2561 3 A 0 75 10 284T 326T 1200 15 30 4 Years 16 Years 364T 445T 40 125 1 Year 4 Months Motors of this size normally do not have bearings that can be re lubricated These bearings should be replaced at least every 5 years for 8 hr day service or every 2 years for 24 hr day service Warning Bearing grease is Kl ber NBU 15 DO NOT SUBSTITUTE 6 3 Torque specifications The table below specifies the tightening torques for the screws bolts and nuts in this pump Always use the following torques if no other values are stated This can be a matter of personal safety Size Tightening torque Nm lbf ft M8 20 14 8 M10 40 29 5 M12 67 49 0 M14 110 eu
12. e shaft seals and rubber seals in stock See separate motor instructions Preventive maintenance Maintenance after leakage Planned maintenance Lubrication leakage normally starts slowly Shaft seal Replace after 12 months one shift Complete shaft seal Replace at the end of the day Complete shaft seal Regular inspection for leakage and smooth operation Keep a record of the pump Use the statistics for planning of inspections Replace after leakage Complete shaft seal Before fitting Lubricate the Quad O rings with silicone grease or silicone oil Rubber seals Replace when replacing the shaft seal Replace when replacing the shaft seal Replace when replacing the shaft seal Before fitting Silicone grease or silicone oil Motor bearings Yearly inspection is recommended Replace complete bearing if worn Ensure that the bearing is axially locked See motor instructions See section 6 2 Relubrication intervals Pre use check CAUTION Fit the electrical connections correctly if they have been removed from the motor during service See 3 3 Pre use check pump with impeller screw Pay special attention to warnings 1 Start and stop the motor momentarily 2 Ensure that the pump operates smoothly 18 5 Maintenance 5 2 Cleaning procedure Cleaning procedure for soiled impeller screw tapped hole Remove stub shaft 7 per s
13. ealing surfaces with contact cleaner 2 Fit seal housing 40a on the back plate 25 and tighten screws 41 3007 0055 Step 4 1 To enable fitting of the back plate 25 with the shaft seal remove connex pin 8 from stub shaft 7 if fitted 2 Carefully guide back plate 25 onto adaptor 16 3 Fit washers 21 and nuts 20 Step 5 Lubricate O ring 26 and slide it onto back plate 25 Step 6 1 Lubricate O ring 38 and fit it in impeller 37 2 Lubricate the impeller hub with silicone grease or oil 3 Screw impeller 27 onto stub shaft 7 4 Fit impeller screw 36 and tighten Torque 20 Nm 15 lbf ft 25 5 Maintenance Read the instructions carefully The items refer to the parts list and service kits section Lubricate the rubber seals before fitting them x Relates to the shaft seal Step 7 1 Wind Teflon tape on the thread end of tubes 42 2 Screw tube ends into seal housing 40a 3 Tighten using a spanner Step 8 Fit safety guard 22 and screw 23 and tighten If the pump is not supplied with flush connections the holes in the adaptor must be covered by the guard Step 9 1 Fit pump casing 29 washers 24a and cap nuts 24 2 Tighten nuts 20 for back plate 25 3 Tighten nuts 20 for back plate 25 and tighten cap nuts 24 Step 10 Flushing set for double mechanical shaft seal A Up 1 Fit membrane valve on drain on pum
14. ection 4 of Service manual Submerge and soak the stub shaft for 5 minutes in a COP tank with 2 caustic wash Scrub the blind tapped impeller screw hole vigorously by plunging a clean 1 2 diameter sanitary bristle pipe brush in and out of the hole for two minutes while submerged Soak stub shaft 7 in acid sanitiser for 5 minutes then scrub blind tapped hole as described in step 3 above Rinse well with clean water and blow dry the blind tapped hole with clean air Swab test the inside of the tapped hole to determine cleanliness Should the swab test fail repeat steps 2 to 6 above until swab test is passed ONNI NOOR Should swab testing continue to fail or time is of the essence install a new Spare stub shaft 7 19 5 Maintenance Read the instructions carefully The items refer to the parts list and service kits section Handle scrap correctly x Relates to the shaft seal 5 3 Dismantling of pump shaft seals Step 1 Flushing set for double mechanical shaft seal 1 Remove flow meter and pressure gauge 2 Remove flushing set 54 from pump casing 29 and lower tube Step 2 Unscrew cap nuts 24 and remove washers 24a and pump casing 29 Step 3 Double mechanical shaft seal Unscrew tubes 42 using a spanner Step 4 Remove screw 23 and safety guard 22 20 5 Maintenance Read the instructions carefully The items refer to the parts list and service kits sect
15. er hub with silicone grease or oil 3 Screw the impeller onto stub shaft 7 4 Fit impeller screw 39 and tighten Torque 20 Nm 15 lbf ft Step 8 Fit safety guards 22 and screw 23 and tighten If pump is not supplied with flush connections the holes in the adaptor must be covered by the guard Step 9 1 Fit pump casing 29 washers 24a and cap nuts 24 2 Adjust pump casing to the right position 3 Tighten nuts 20 for back plate 25 and tighten cap nuts 24 Note Cap nuts must be tightened according to the torque values in chapter 6 Technical data 24 5 Maintenance Read the instructions carefully The items refer to the parts list and service kits section Lubricate the rubber seals before fitting them x Relates to the shaft seal 5 5 Assembly of pump double mechanical shaft seal Step 1 1 Fit O rings 15 in rotating seal rings 14 2 Fit spring 13 on one of the rotating seal rings 14 and place the drive ring 62 in between 3 Fit the second rotating seal ring 14 on the other end of the spring Note Ensure that both drive pins on the drive ring enter the notches in rotating seal rings 4 Place the parts on the stationary seal ring fitted in back plate 25 Step 2 1 Lubricate O ring 44 and slide onto seal housing 40a 2 Lubricate O ring 60 and fit on stationary seal ring 61 and fit this in the seal housing Step 3 1 Clean the s
16. g Overloading of the pipelines al 3007 0000 El Note In case of shaft seal leakage the media will drip from the slot in the bottom of the adaptor In case of shaft seal leakage Alfa laval recommends putting a drip tray underneath the slot for collecting the leakage 10 3 Installation Read the instructions carefully and pay special attention to the warnings LKH UltraPure is not supplied with an impeller screw as standard but can be supplied with one Check the direction of rotation of the impeller before operation See the indication label on the pump 3 3 Pre use check pump with impeller screw See the indication label Step 1 A Never start in the wrong direction of rotation with liquid in the pump 1 Start and stop the motor momentarily 2 Ensure that the direction of rotation of the motor fan is clockwise as viewed from the rear end of the motor View from rear end of motor 11 3 Installation 3 4 Recycling information e Unpacking Packing material consists of wood plastics cardboard boxes and in some cases metal straps Wood and cardboard boxes can be reused recycled or used for energy recovery Plastics should be recycled or burnt at a licensed waste incineration plant Metal straps should be sent for material recycling Maintenance During maintenance oil and wear parts in the machine are replaced All metal part
17. h 2200h DE NDE 42g 30 Permanently lubricated 4000h 2800h DE NDE 55g 8000h DE NDE 40g 37 Permanently lubricated 4000h 2800h DE NDE 55g 8000h DE NDE 40g 45 Permanently lubricated 2500h 1000h DE NDE 55g 8000h DE NDE 40g 55 Permanently lubricated 2500h 1000h DE NDE 73g 8000h 3000h DE NDE 60g 75 Permanently lubricated 1500h 500h DE NDE 73g 4000h 1500h DE NDE 60g 90 4000h 2800h DE NDE 45g 110 4000h 2800h DE NDE 45g inlet pressure less than 10 bar 145 psi Recommended grease types LKHPF 10 70 LKH 110 LKH 120 Esso Unirex N2 or N3 Lithium complex base Mobil Mobilith SHC 100 Lithium complex base Shell Shell Gadus S5 V100 2 Lithium complex base Kl ber Kl berplex BEM 41 132 Special Lithium base FAG Arcanol TEMP110 Lithium complex base Lubcon Turmogrease L 802 EP PLUS Lithium complex base LKHPF 10 60 LKH 110 Kl ber Kl ber Asonic HQ72 102 Polyurea base LKH 85 KlUber KlUberplex Quiet BQH 72 102 Polyurea base Lubcon Turmogrease PU7O3 Polyurea base WARNING Polyurea based grease must not be mixed with Lithium complex base grease and vice versa 32 6 Technical data It is important to observe the technical data during installation operation and maintenance Inform personnel about the technical data WEG IEC Motors IE3 0 75 Permanently lubricated 1 5 Permanently lubricated 3 0 Permanently lubricated 5 5 Permanently lubri
18. ide blocked Never run the pump when partially installed or not completely assembled Necessary precautions must be taken if leakage occurs as this can lead to hazardous situations Always handle lye and acid with great care Never use the pump for products not mentioned in Alfa Laval pump selection program The Alfa Laval pump selection program can be acquired from your local Alfa Laval sales company Maintenance Always read the technical data thoroughly See chapter 6 Technical data Never service the pump when it is hot Never service the pump if pressurised Motors with grease nipples Remember lubrication according to information plate label on the motor Always disconnect the power supply when servicing the pump Always use Alfa Laval genuine spare parts Transportation Transportation of the pump or the pump unit Never lift or elevate in any way other than described in this manual Always drain the pump head and accessories of any liquid Always ensure that no leakage of lubricants can occur Always transport the pump in its upright position Always ensure that the unit is securely fixed during transportation Always use original packaging or similar during transportation 3 Installation 3 1 Unpacking delivery Step 1 Check the delivery for 1 Complete pump A 2 Delivery note 8 Motor instructions Always use a lifting crane when handling the pump see 6 4 Instructions for flushing set IF ORDERED
19. ion Handle scrap correctly Relates to the shaft seal Step 5 1 Remove impeller screw 36 2 Remove impeller 37 If necessary loosen the impeller by tapping gently on the impeller vanes 3 Remove the O ring 38 from the impeller Counterhold with a screwdriver GN If necessary Step 6 1 Pull off the O ring 26 from back plate 25 2 Unscrew nuts 20 and remove washers 21 and the back plate 3007 0025 y Step 7 1 Remove the stationary seal ring 11 2 Remove the O ring 12 from back plate 25 Use the tool supplied n Left hand amp thread Step 8 fas nes Ms housing 40a E D 2 Remove rotating seal rings 14 and drive ring 52 from spring S D 3 ae O rings 15 from rotating seal rings 14 a SE 3007 0027 Step 9 Double mechanical shaft seal 1 Remove stationary seal ring 51 from seal housing 40a 40b 2 Remove O ring 50 from stationary seal ring 51 3 Remove O ring 44 from seal housing 40a 40b 21 5 Maintenance Read the instructions carefully The items refer to the parts list and service kits section Handle scrap correctly x Relates to the shaft seal Step 10 Single shaft seal 1 Remove the complete shaft seal from stub shaft 7 2 Remove spring 13 and rotating seal ring 14 from the drive ring 10 3007 0029 22 5 Maintenance Read the instructions carefully The items
20. iter tase dd a Std o O a a Sl Belts e e RA o NA 6 2 Relubricatiom Mtra o VEN ERE EM 6 3 Torque Specifications tai dd da GAs WeIGhtA KO Fi AA A N E SNA O A eat be be ote ied wou has debi es Ts Parts listand SOrviCe Kits ui A ds Telo LKA UtraPure 10 20 25 30 A0 erradk rA ap Aaa aa da kaiak eA 7 2 LKH UltraPure Product wetted partS 2 0 0 0 cece eee e eect eet e ete e tees eeeeeneeeeeees 7 3 LKH UltraPure Motor depended pats cc cece cece eect eee eee e eee anar 7 4 LKH UltraPure Single shaft Seal oo cece cece cece cece eee e teen caca arar rr 1 EC Declaration of Conformity Revision of Declaration of Conformity 2009 12 29 The Designated Company Alfa Laval Kolding A S Company Name Albuen 31 DK 6000 Kolding Denmark Address 45 79 32 22 00 Phone No hereby declare that Pump Designation LKH Ultrapure 10 LKH Ultrapure 20 LKH Ultrapure 25 LKH Ultrapure 35 LKH Ultrapure 40 Type From serial number 10 000 to 1 000 000 is in conformity with the following directive with amendments Machinery Directive 2006 42 EC The person authorised to compile the technical file is the signer of this document QHSE Manager Quality Health and safety amp Environment Annie Dahl Title Name Kolding 2013 12 03 Place Date Signature sel 2 Safety Unsafe practices and other important information are emphasised in this manual Warnings are emphasised
21. ow to CAUTION run dry Never throttle the inlet side 3007 0017 Step 5 Control Reduce the capacity and the power consumption by means of Throttling the pressure side of the pump Reducing the impeller diameter Throttling Reducing the speed of the motor 14 4 Operation Pay attention to possible faults Study the instructions carefully 4 2 Trouble shooting NOTE Study the maintenance instructions carefully before replacing worn parts Problem Cause result Remedy Overloaded motor Cavitation Damage Pressure reduction sometimes to zero Increasing of the noise level Leaking shaft seal Leaking O ring seals Pumping of viscous liquids Pumping of high density liquids Low outlet pressure counter pressure Lamination of precipitates from the liquid Low inlet pressure High liquid temperature Dry run Incorrect rubber grade Abrasive particles in the liquid Incorrect rubber grade Larger motor or smaller impeller Higher counter pressure throttling Frequent cleaning Increase the inlet pressure Reduce the liquid temperature Reduce the pressure drop before the pump Reduce speed Replace All wearing parts If necessary Change rubber grade Select stationary and rotating seal ring in silicon carbide silicon carbide Change rubber grade 15
22. p casing Ensure the B 26 mm bypass tube is in the right position see drawing C 37 6 mm 2 Fit lower tube to the needle valve 3 Fit pressure gauge to upper tube 3007 0040 4 Fit flow meter 26 5 Maintenance Read the instructions carefully The items refer to the parts list and service kits section Lubricate the rubber seals before fitting them x Relates to the shaft seal Step 11 Adjustment of flushing set 1 Drain valve is used for draining the pump 2 Before adjusting the flow the valve in the flow meter has to be completely opened Flushing water is then adjusted by the needle valve until the flow meter reads between 15 and 30 0 25 0 5 l min 0 066 0 132 gpm 3 The non return valve in the flow meter prevents flushing water from returning into the flushing housing 4 The pressure gauge is for monitoring water pressure in the flushing housing Max water pressure is 5 bar 72 5 psi 3007 0041 27 5 Maintenance Study the instructions carefully The items refer to the parts list and service kits section Lubricate the rubber seals before fitting them x Relates to the shaft seal 5 6 Assembly of flushing set if not supplied with pump Step 1 If the pump has a single shaft seal rebuild it to a double mechanical shaft seal see section 5 5 Assembly of pump double mechanical shaft seal Step 2 1 Fit membrane valve on pump casing drain 2 Ensure the by
23. pass tube is in the right position see section 5 5 Assembly of pump double mechanical shaft seal step 10 3 07 0042 H 3 8 Step 3 1 Fit needle valve to bypass tube from membrane valve 2 Adjust the length of the bypass tube to ensure the outlet of q needle valve is aligned with the inlet in the bottom of the gl flushing house g ail sob gt A 3007 0043 Step 4 1 Fit Hex tube 65mm to bottom hole in flush housing 2 Fit 6mm connection to Hex tube 3 Cut and fit 6mm tube in between needle valve and 6mm connection ij 4 ia i 7 Ea baba Step 5 1 Fit Hex tube 140mm to top hole of flush housing 2 Fit 6mm connection to HEX tube e 3 Cut and fit 6mm tube supplied in between 6mm connection Ea and tee g l 4 Fit pressure gauge to tee q 5 Cut and fit 6mm tube supplied in between 6mm connection and elbow 6 Fit flow meter to elbow pH 7 Threaded outlet from flow meter to be connected to on site flush water installation alil 007 0045 E A 28 5 Maintenance Study the instructions carefully The items refer to the parts list and service kits section Lubricate the rubber seals before fitting them x Relates to the shaft seal 5 7 Adjustment of shaft
24. refer to the parts list and service kits section Handle scrap correctly x Relates to the shaft seal 5 4 Assembly of pump single shaft seal Step 1 1 Remove spring 13 NOTE Make sure that O ring 15 has max clearance from the sealing surface Step 2 1 Refit spring 13 on rotating seal ring 14 2 Fit the spring and the rotating seal ring on drive ring 10 CAUTION Ensure that the driver on the drive ring enters the notch in the rotating seal ring Step 3 Fit the complete shaft seal on stub shaft 7 CAUTION Make sure that connex pin 8 on the stub shaft enters the notch in drive ring 10 Step 4 1 Fit O ring 12 on stationary seal ring 11 and lubricate rane Use the tool 2 Screw the stationary seal ring into back plate 25 supplied CAUTION Must be tightened by hand to avoid deforming the stationary seal ring Max 7Nm 5 lbf ft Left hand thread 3007 0033 23 5 Maintenance Read the instructions carefully The items refer to the parts list and service kits section Handle scrap correctly x Relates to the shaft seal Step 5 1 Clean the sealing surfaces with contact cleaner before fitting back plate 25 2 Carefully guide the back plate onto adaptor 16 3 Fit washers 21 and nuts 20 Step 6 Lubricate O ring 26 and slide it onto back plate 25 Step 7 1 Lubricate O ring 38 and fit it in impeller 37 2 Lubricate impell
25. s should be sent for material recycling Worn out or defective electronic parts should be sent to a licensed handler for material recycling Oil and all non metal wear parts must be taken care of in accordance with local regulations e Scrapping At end of use the equipment must be recycled according to relevant local regulations Beside the equipment itself any hazardous residues from the process liquid must be considered and dealt with in a proper manner When in doubt or in the absence of local regulations please contact your local Alfa Laval sales company 12 4 Operation Read the instructions carefully and pay special attention to the warnings 4 1 Operation control Step 1 Always read the technical data thoroughly See chapter 6 Technical data CAUTION Alfa Laval cannot be held responsible for incorrect operation control Step 2 A Never touch the pump or the pipelines when pumping hot liquids or when sterilising Danger of burns Step 3 Danger of explosion A O Never run the pump with both the suction side and the pressure side blocked E mi O A a See the warning yo label 3007 0016 qu it 13 4 Operation Read the instructions carefully and pay special attention to the warnings Step 4 CAUTION The shaft seal must not run dry Do not all
26. steel Stationary seal ring SiC Stationary seal ring SiC o 12 o 1 O ring 1 O ring 13 0 1 Spring 1 Spring 14 o 1 Rotating seal ring SiC 2 Rotating seal ring SiC 15 o 1 O ring 2 O ring 40a 1 Seal housing 41 2 Screw for seal housing 42 2 Fittings 44 1 O ring for seal housing 50 1 O ring 51 1 Sec stationary seal ring 52 1 Drive ring 54 1 Basic 1 2 55 1 Diaphragm EPDM for Diaphragm valve from 2014 Service kits Denomination EPDM FPM FEP Service kit for single shaft seal O Service kit LKHUP 10 cee cece eect eee eee e eee e ee 9611922339 9611922338 9611922340 o Service kit LKHUP 20 sussesrsrrsrserrrsrerrerrerresr 9611922357 9611922356 9611922358 o Service kit LKHUP 25 35 usissssesesrererrrsererresee 9611922375 9611922374 9611922376 o Service kit LKHUP 40 ssussesissrersesresrrrrerrerrerr 9611922393 9611922392 9611922394 Service kit for double mechanical shaft Service kit LKHUP 10 cee cece cence ene teen ee 9611922345 9611922344 9611922346 Service kit LKHUP 20 ce eee e cence eee eee eee 9611922363 9611922362 9611922364 Service kit LKHUP 25 35 0oooocccnncccnnccnn cra 9611922381 9611922380 9611922382 Service kit LKHUP 40 oo cic cece eee ee ete eee eee 9611922399 9611922398 9611922400 Parts marked with Oe are included in the service kits Recommended spare parts Service kits Conversion kit single to double mechanical shaft seal Please order Do
27. trically connected by authorised personnel see the motor instructions CAUTION Alfa Laval cannot be held responsible for incorrect installation WARNING Alfa Laval recommends the installation of lockable repair breaker If the repair breaker is to be used as an emergency stop the colours of the repair breaker must be red and yellow CAUTION The pump does not prevent back flow when intentionally or unintentionally stopped If back flow can cause any hazardous situations precautions must be taken e g check valve to be installed in the system to prevent the problem described above Step 2 Ensure at least 0 5m 1 6 ft clearance around the pump S O A 3007 0006 Step 3 Check that the flow direction is correct O Outlet l Inlet f 3007 0007 al l ame 3 Installation Read the instructions carefully and pay special attention to the warnings Always check the pump before operation See pre use check in section 3 3 Pre use check pump with impeller screw Step 4 Remember seal rings 1 Ensure that the pipelines are routed correctly Y 2 Ensure that the connections are tight i 3007 0008 Few bends Correct Step 5 Avoid stress on the pump Pay special attention to Vibrations Thermal expansion of the tubes Excessive weldin
28. uble mechanical service kit pos 40a 41 42 900065 13 43 How to contact Alfa Laval Contact details for all countries are continually updated on our website Please visit www alfalaval com to access the information directly Alfa Laval Corporate AB This document and its contents is owned by Alfa Laval Corporate AB and protected by laws governing intellectual property and thereto related rights It is the responsibility of the user of this document to comply with all applicable intellectual property laws Without limiting any rights related to this document no part of this document may be copied reproduced or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise or for any purpose without the expressed permission of Alfa Laval Corporate AB Alfa Laval Corporate AB will enforce its rights related to this document to the fullest extent of the law including the seeking of criminal prosecution
29. uct wetted parts 7 2 LKH UltraPure Product wetted parts Option 54 N al a Q C Product wetted part 3007 0060 7 Parts list and service kits The drawing shows the LKH UltraPure pump sanitary version The items refer to the parts lists in the following sections 7 2 LKH UltraPure Product wetted parts Parts list Pos Qty Denomination 20 2 Nut 21 2 Washer 24 6 Cap nut 24a 6 Washer 25 1 Backplate compl Ra 0 8 1 Backplate compl Ra 0 5 1 Backplate compl Ra 0 5 electropolished 26 o 1 Pump casing O ring EPDM a 1 Pump casing O ring FPM Os 1 Pump casing O ring FEP 28 6 Bolt 29 1 Casing compl Tri clamp 1 Casing compl IS02037 1 Casing compl 1501127 36 1 mpeller screw Ra 0 8 mpeller screw Ra 0 5 mpeller screw Ra 0 5 electropolished 37 1 mpeller Ra 0 8 mpeller Ra 0 5 mpeller Ra 0 5 electropolished mpeller low ferrit 5 Ra 0 8 mpeller low ferrit 5 Ra 0 5 mpeller low ferrit 5 Ra 0 5 electropolished 38 ns 1 O ring impeller screw EPDM Ds 1 O ring impeller screw FPM Ds 1 O ring impeller screw FEP 39 40 7 Parts list and service kits The drawing shows the LKH UltraPure pump sanitary version The items refer to the parts lists in the following sections 7 2 LKH UltraPure Product wetted parts 7 3 LKH UltraPure Motor depended parts Option 54 N al a Q 3007 0060
30. water at ambient temperature and at 50 Hz Very often the noise level generated by the flow through the process system e g valves pipes tanks etc is much higher than that generated by the pump itself Therefore it is important to consider the noise level from the total system and take the necessary precautions with regard to personal safety if required 36 7 Parts list and service kits The drawing shows the LKH UltraPure pump sanitary version The items refer to the parts lists in the following sections 7 2 LKH UltraPure Product wetted parts 7 1 LKH UltraPure 10 20 25 35 40 EN g Q zit 5 o Cs 3007 0058 Double mechanical shaft seal 3007 0052_1 3007 0059 Single shaft seal Only used for 3 kW Fitting of legs 37 38 7 Parts list and service kits The drawing shows the LKH UltraPure pump sanitary version The items refer to the parts lists in the following sections 7 2 LKH UltraPure Prod
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