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Installation at Site

5.1

Safety regulations

DANGER

Improper installation in potentially explosive atmospheres

Explosion hazard!

Damage to the submersible mixer!

▷

Comply with the applicable local explosion protection regulations.

▷

Observe the information given in the data sheet and on the name plate.

DANGER

Persons entering the tank

Electric shock!

▷

Never start up the submersible mixer when there are persons inside the tank.

WARNING

Hands, other body parts, or foreign objects in the propeller or propeller intake area

Risk of personal injury! Damage to the submersible mixer!

▷

Never place your hands, other body parts or foreign objects into the propeller
or propeller intake area.

5.2

Checks to be carried out prior to installation

5.2.1 Checking the operating data
Before setting up the submersible mixer, verify that the name plate data matches the
data given in the purchase order and the system data.

5.2.2 Preparing the place of installation

WARNING

Installation on foundations which are unsecured and cannot support 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 has set firmly.

▷

Refer to the weights given in the data sheet/ on the name plate.

NOTE

In biogas installations, provide the possibility for visually monitoring and, if necessary,

adjusting the operating conditions of the submersible mixer (monitoring window).

NOTE

For servicing submersible mixers in biogas installations, access openings and

appropriate means of removal (lifting gear) must be provided so that the mixer can be

removed from the filled tank at any time. For this purpose, it is important to observe the

minimum removal dimensions for the submersible mixer as specified in the general

arrangement drawing/outline drawing and in the data sheet.

1. Check structural requirements.

All structural work required must have been prepared in accordance with the
dimensions stated in the outline drawing/general arrangement drawing.

5 Installation at Site

16 of 60

Amaprop®

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

Q-Pulse Id VM386

Active 29/10/2013

Page 16 of 60

Содержание Amaprop GDSTP-24130-MAN-0004 P1

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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