KSB Amaprop GDSTP-24130-MAN-0004 P1 Installation & Operating Manual Download Page 1

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Submersible

ixer

Amaprop®

Installation/Operating

Manual

Ident. number:

01070280

Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual

Q-Pulse Id VM386

Active 29/10/2013

Page 1 of 60

GDSTP-24130-MAN-0004_P1

Summary of Contents for Amaprop GDSTP-24130-MAN-0004 P1

Page 1: ...p Installation Operating Manual Ident number 01070280 Goodnal STP ST041 Biological Treatment KSB Amaprop Installation and Operating Manual Vendor Manual Q Pulse Id VM386 Active 29 10 2013 Page 1 of 60...

Page 2: ...oduced edited or processed for any other purpose nor otherwise transmitted published or made available to a third party without KSB s express written consent Subject to technical modification without...

Page 3: ...peration 9 2 10 Explosion protection 9 3 Transport Temporary Storage Disposal 10 3 1 Transport 10 3 2 Storage Preservation 11 3 3 Return to supplier 11 3 4 Disposal 11 4 Description 13 4 1 General des...

Page 4: ...ixer 39 7 6 Tightening torques 42 7 7 Spare parts stock 42 8 Trouble shooting 44 9 Related Documents 45 9 1 General assembly drawing with list of components 45 9 2 Flamepaths on explosion proof motors...

Page 5: ...d handled refers to the fluid the mixer is operated in i e generally municipal or industrial waste water and sludges The fluid is described in greater detail by means of the gas and solids content the...

Page 6: ...l personnel 1 4 Other applicable documents Table 1 Overview of other applicable documents Document Contents Data sheet Description of the technical data General arrangement drawing outline drawing Des...

Page 7: ...installation operating and maintenance instructions that must be observed to ensure safe operation of the submersible mixer and prevent personal injury and damage to property The safety information i...

Page 8: ...specialist personnel 2 5 Consequences and risks caused by non compliance with these operating instructions Non compliance with these operating instructions will lead to forfeiture of warranty cover an...

Page 9: ...rdance with its intended use 2 10 Explosion protection Always observe the information on explosion protection given in this section when operating the submersible mixer in potentially explosive atmosp...

Page 10: ...ble Never use chains or lifting ropes included in KSB s scope of supply for lifting loads other than the KSB product supplied Safely attach lifting ropes or chains to the submersible mixer and crane T...

Page 11: ...ing residues which might lead to corrosion when coming into contact with atmospheric humidity or which might ignite when coming into contact with oxygen the submersible mixer must also be neutralised...

Page 12: ...liquids 3 Dispose of materials in acc with local regulations or in another controlled manner 3 Transport Temporary Storage Disposal 12 of 60 Amaprop Goodnal STP ST041 Biological Treatment KSB Amaprop...

Page 13: ...US TENSION II2G Ex dc IIB T4 C kg H Motor IP 68 SUBM MAX 30 m CLASS F 3 M No kW V Hz cos min 1 A IA IN S1 0035 II2G Ex d IIB T4 PTB 02 ATEX 1055 1 2 3 10 11 5 4 6 7 8 9 13 14 15 12 16 17 18 20 19 AMAP...

Page 14: ...in type of protection Ex d IIB 4 5 Configuration and function 2 3 4 5 6 7 8 1 Fig 3 Sectional drawing 1 Gear shaft 2 Housing 3 Stator 4 Cable gland 5 Propeller 6 Mechanical seal 7 Rolling element bear...

Page 15: ...A separate name plate is included in KSB s scope of supply This name plate must be attached in a clearly visible location outside the place of installation e g in the control cabinet or on the mounti...

Page 16: ...ort the load Personal injury and damage to property Make sure the foundation concrete is of sufficient strength min C20 25 to DIN 1045 Only place the installation set on a foundation whose concrete ha...

Page 17: ...filler opening until the lubricant reservoir overflows 4 Fit screw plug 903 01 and joint ring 411 01 again 1 Unscrew the lubricant check plug on the gear unit The lubricant level must reach the filler...

Page 18: ...e to have a sufficient number of cores for the sensors A minimum cable cross section of 1 5 mm is required 5 4 1 1 Overload protection 1 Protect the submersible mixer against overloading by a thermal...

Page 19: ...lded power cables a submersible mixer with shielded power cable must be used The submersible mixers generally meet the requirements on interference immunity stipulated by EN 50082 For monitoring the s...

Page 20: ...toring equipment The motor is monitored by three series connected PTC thermistors with terminals 10 and 11 Tripping must result in the submersible mixer cutting out Automatic re start is not permitted...

Page 21: ...nsor circuit 10 to 30V Tripping current 0 5 to 3 mA equivalent to a tripping resistance of 3 to 60 k 5 4 2 Connection to power supply DANGER Electrical connection work by unqualified personnel Danger...

Page 22: ...ith as little slack as possible and protect if necessary NOTE We recommend to use cable supports available as accessories for properly fastening the electrical cable at the tank edge 1 Run the power c...

Page 23: ...the submersible mixer into the fluid while checking the direction of rotation The submersible mixer is mounted on the installation set and positioned entirely outside the fluid The submersible mixer...

Page 24: ...ible operating range only CAUTION Excessive temperatures due to dry running or excessive fluid temperature Damage to the submersible mixer Never operate the submersible mixer outside the fluid Observe...

Page 25: ...Deposits accumulating on the housing surface entail the risk of insufficient cooling of the submersible mixer We recommend to check the housing surface regularly and remove severe dirt deposits 6 2 2...

Page 26: ...h2 Given Amaprop V 40 2500 44 Biogas application digestion substrate nMixer 40 rotations minute nmax 46 rotations minute Solution h2 40 46 x 0 50 m 0 38 m Wt 2 50 m 0 30 m 0 38 m 3 18 m Formula for c...

Page 27: ...t specified on the data sheet When the mixer is operated in fluids containing abrasive substances increased wear of the propeller and the shaft seal are to be expected In this case halve the intervals...

Page 28: ...Make sure that the submersible mixer cannot be started up accidentally The submersible mixer remains installed DANGER Persons entering the tank Electric shock Never start up the submersible mixer when...

Page 29: ...to service after storage also follow the instructions for maintenance inspection Section 7 2 Page 30 NOTE On submersible mixers older than 5 years we recommend replacing all elastomer seals 6 Commissi...

Page 30: ...osion proof submersible mixers Modification or alteration of the submersible mixers may affect explosion protection and is only permitted after consulting the manufacturer NOTE A regular maintenance s...

Page 31: ...defective and must be replaced NOTE If the insulation resistance values measured on the motor are too low the winding insulation is defective The submersible mixer must not be returned to service in t...

Page 32: ...reservoir is filled at the factory with an environmentally friendly non toxic lubricant of medical quality unless otherwise required by the customer The following lubricants can be used for lubricatin...

Page 33: ...rd Hazardous to persons and the environment Collect and properly dispose of flushing liquid and any liquid residues Wear safety clothing and a protective mask if required Observe all legal regulations...

Page 34: ...ings 411 03 04 again 7 2 1 5 4 Draining the lubricant WARNING Lubricants posing a health hazard Hazard to persons and the environment When draining the lubricant take appropriate measures to protect p...

Page 35: ...he screw plug 903 02 with joint ring 411 02 and drain off the lubricant 6 Close screw plug 903 02 again fitting a new joint ring 411 02 7 2 1 5 5 Filling in the lubricant WARNING Lubricants posing a h...

Page 36: ...bricant filler opening until the lubricant reservoir overflows 3 Close screw plug 903 01 again fitting a new joint ring 411 01 4 Unscrew the lubricant check plug on the gear unit 5 Unscrew the lubrica...

Page 37: ...isk of personal injury Always have repair and maintenance work performed by specially trained qualified personnel WARNING Submersible mixer started up inadvertently Risk of injury by moving parts Alwa...

Page 38: ...ns 1 Unscrew propeller screw 914 06 and disc 550 01 2 Screw a forcing screw into propeller 23 9 and pull off the propeller Section 9 4 Page 51 7 4 3 Removing the mechanical seals CAUTION Improper remo...

Page 39: ...are clearly marked for future reassembly 7 5 Reassembling the submersible mixer 7 5 1 General notes Safety regulations CAUTION Improper reassembly Damage to the submersible mixer Reassemble the subme...

Page 40: ...ive wrapping of the contact faces immediately before installation takes place Prevent any damage to the sealing surfaces or O rings 932 04 932 03 471 433 01 433 02 932 05 Fig 15 Installing the mechani...

Page 41: ...d joint ring 411 01 have been removed 1 Screw the testing device tightly into the lubricant filler opening 2 Carry out the leak test with the values specified above NOTE The pressure must not drop dur...

Page 42: ...834 Cable gland 1 1 2 2 2 3 40 R 818 Rotor with plug in pinion7 1 1 2 3 E 99 2 Installation kit for gear unit8 1 1 2 3 E 23 9 Propeller 1 1 1 2 2 3 30 E 433 01 Mechanical seal gear side 2 3 4 5 6 7 9...

Page 43: ...l express freight air freight Refer to the general assembly drawing for part numbers and descriptions 7 Servicing Maintenance Amaprop 43 of 60 Goodnal STP ST041 Biological Treatment KSB Amaprop Instal...

Page 44: ...ack of power supply Check electrical installation inform electric utility company X Motor winding or power cable are defective Replace with original KSB parts or contact KSB X Defective rolling elemen...

Page 45: ...using cover 321 Radial ball bearing 529 Bearing sleeve 818 Rotor 322 Radial roller bearing 550 Disc 834 Cable gland 411 Joint ring 571 Lifting bail 870 Gear unit 412 O ring 69 14 Leakage sensor 901 He...

Page 46: ...sc 818 Rotor 321 Radial ball bearing 571 Lifting bail 834 Cable gland 411 Joint ring 69 14 Leakage sensor 870 Gear unit 412 O ring 719 Sheathing 901 Hexagon head bolt 421 Lip seal 720 Special part 903...

Page 47: ...Bearing sleeve 818 Rotor 322 Radial roller bearing 550 Disc 82 5 Adapter 411 Joint ring 571 Lifting bail 834 Cable gland 412 O ring 69 14 Leakage sensor 870 Gear unit 421 Lip seal 719 Sheathing 901 H...

Page 48: ...Amaprop 2500 6 4 9 2 2 Amaprop 1200 2500 motors 1 4 2 4 3 4 4 4 5 4 1 2 3 Fig 22 Flamepaths on explosion proof motors Amaprop 1200 2500 motors 1 4 2 4 3 4 4 4 5 4 9 Related Documents 48 of 60 Amaprop...

Page 49: ...ge gn ye U V W 10 11 9 PE U V W 10 11 9 U1 V1 W1 U2 V2 W2 R1 R2 R3 B2 3 8 7 Fig 23 Wiring diagram of motors 1 4 2 4 3 4 9 Related Documents Amaprop 49 of 60 Goodnal STP ST041 Biological Treatment KSB...

Page 50: ...4 gn ge gn ye 6 6 5 5 2 2 1 1 3 3 10 1 11 2 7 3 9 4 8 5 U1 V1 W1 10 11 9 PE U2 V2 W2 Power cables Control cables 10 11 9 PE U1 V1 W1 U2 V2 W2 L1 L2 L3 L1 L2 L3 U1 V1 W1 U2 V2 W2 U1 V1 W1 U2 V2 W2 Fig...

Page 51: ...240 1 x 45 85 M20 12 118 R2 Lock nut M20 1000 2000 2200 2500 M20 x 425 325 315 230 240 1 x 45 85 M20 12 118 R2 Lock nut M20 9 Related Documents Amaprop 51 of 60 Goodnal STP ST041 Biological Treatment...

Page 52: ...bracket kg Dimensions mm S 166 1000 11 4 URG YRG 260 540 166 1000 16 4 WRG ZRG 273 520 174 1000 16 4 WRG ZRG 175 1000 16 4 URG YRG 181 1000 23 4 WRG ZRG 284 500 184 1000 16 4 URG YRG 273 520 184 1000...

Page 53: ...essories with swivelling option Size Weight incl guide bracket kg Dimensions mm S 166 1000 11 4 URG YRG 260 540 166 1000 16 4 WRG ZRG 273 520 174 1000 16 4 WRG ZRG 175 1000 16 4 URG YRG 181 1000 23 4...

Page 54: ...4 URG YRG 209 1248 310 1350 184 1177 approx 780 102 1200 4 4 URG YRG 209 109 1200 5 4 URG YRG 211 Amaprop 1400 Gear unit G 400 V 50 Hz D 1400 Table 19 Amaprop 1400 Size Weight incl guide bracket kg D...

Page 55: ...1801 Gear unit G 400 V 50 Hz D 1800 Table 22 Amaprop 1801 Size Weight incl guide bracket kg Dimensions mm A B C Emin Fmin G H L S 42 1801 1 4 URG YRG 169 1124 258 405 505 1225 143 approx 500 1053 app...

Page 56: ...1 4 URG YRG 186 1234 258 560 660 1265 143 approx 500 1163 approx 650 28 2500 2 4 URG YRG 189 30 2500 2 4 URG YRG 205 1275 310 1305 184 1204 approx 680 32 2500 2 4 URG YRG 205 35 2500 3 4 URG YRG 207 1...

Page 57: ...6 42 EC The manufacturer also declares that the following harmonised international standards were applied ISO 12100 1 A1 ISO 12100 2 A1 ISO 14121 1 EN 809 A1 EN 60034 1 EN 60034 5 A1 Halle 29 December...

Page 58: ...ng at your disposal No special safety precautions are required for further handling The following safety precautions are required for flushing fluids fluid residues and disposal We confirm that the ab...

Page 59: ...Lubricant Quality 32 O Operating limits 7 Order number 6 Other applicable documents 6 Overload protection 18 P Partly completed machinery 6 Preservation 11 R Return to supplier 11 S Safety awareness...

Page 60: ...aale Turmstra e 92 06110 Halle Germany Tel 49 345 4826 0 Fax 49 345 4826 4699 www ksb com 1592 89 5 10 Goodnal STP ST041 Biological Treatment KSB Amaprop Installation and Operating Manual Vendor Manua...

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