KSB Amamix direkt Installation instructions
Submersible Mixer
Amamix® direkt
Installation/Operating
Manual
Ident. number: 01057742
Goodnal STP ST041 Biological Treatment (KSB Amamix Direct Installation and Operation Manual) Vendor Manual
Q-Pulse Id VM385
Active 29/10/2013
Page 1 of 52
GDSTP-24130-MAN-0003_P1
Legal information/Copyright
Installation/Operating Manual Amamix® direkt
Original operating manual
KSB Aktiengesellschaft Halle
All rights reserved. Contents provided herein must neither be distributed, copied, reproduced, 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 prior notice.
© KSB Aktiengesellschaft Frankenthal 10.09.2010
Goodnal STP ST041 Biological Treatment (KSB Amamix Direct Installation and Operation Manual) Vendor Manual
Q-Pulse Id VM385
Active 29/10/2013
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Contents
Glossary ................................................................................................ 5
1 General ................................................................................................ 6
1.1 Principles .......................................................................................................... 6
1.2 Installation of partly completed machinery .................................................. 6
1.3 Target group ................................................................................................... 6
1.4 Other applicable documents .......................................................................... 6
1.5 Symbols ............................................................................................................ 6
2 Safety ................................................................................................... 7
2.1 Key to safety symbols/markings ..................................................................... 7
2.2 General ............................................................................................................ 7
2.3 Intended use .................................................................................................... 7
2.4 Personnel qualification and training ............................................................. 8
2.5 Consequences and risks caused by non-compliance with these operating
instructions ...................................................................................................... 8
2.6 Safety awareness ............................................................................................. 8
2.7 Safety information for the operator/user ...................................................... 8
2.8 Safety information for maintenance, inspection and installation work ..... 9
2.9 Unauthorised modes of operation ................................................................. 9
2.10 Explosion protection ....................................................................................... 9
3 Transport/Temporary Storage/Disposal ........................................... 10
3.1 Transport ....................................................................................................... 10
3.2 Storage/Preservation ..................................................................................... 10
3.3 Return to supplier ......................................................................................... 11
3.4 Disposal .......................................................................................................... 11
4 Description ......................................................................................... 12
4.1 General description ....................................................................................... 12
4.2 Designation ................................................................................................... 12
4.3 Name plate .................................................................................................... 12
4.4 Design details ................................................................................................ 12
4.5 Configuration and function ......................................................................... 13
4.6 Scope of supply ............................................................................................. 13
4.7 Dimensions and weights ............................................................................... 14
5 Installation at Site ............................................................................. 15
5.1 Safety regulations ......................................................................................... 15
5.2 Checks to be carried out prior to installation ............................................. 15
5.3 Setting up the submersible mixer ................................................................ 16
5.4 Electrical connection ..................................................................................... 16
5.5 Checking the direction of rotation .............................................................. 21
Contents
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6 Commissioning/Start-up/Shutdown ................................................. 23
6.1 Commissioning/start-up ................................................................................ 23
6.2 Operating limits ............................................................................................ 23
6.3 Shutdown/storage/preservation ................................................................... 26
6.4 Returning to service ...................................................................................... 26
7 Servicing/Maintenance ...................................................................... 28
7.1 Safety regulations ......................................................................................... 28
7.2 Servicing/inspection ...................................................................................... 29
7.3 Drainage/disposal .......................................................................................... 32
7.4 Dismantling the submersible mixer ............................................................. 33
7.5 Reassembling the submersible mixer ........................................................... 35
7.6 Tightening torques ....................................................................................... 38
7.7 Spare parts stock ........................................................................................... 38
8 Trouble-shooting ............................................................................... 40
9 Related Documents ........................................................................... 41
9.1 General assembly drawing with list of components ................................... 41
9.2 Flamepaths on explosion-proof motors ....................................................... 45
9.3 Wiring diagrams ............................................................................................ 46
9.4 Forcing screws ............................................................................................... 47
10 EC Declaration of Conformity .......................................................... 48
11 Certificate of Decontamination ....................................................... 49
Index .................................................................................................. 50
Contents
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Glossary
Certificate of decontamination
A certificate of decontamination certifies that
the submersible mixer has been properly
cleaned and decontaminated to eliminate any
environmental and health hazards arising from
components in contact with the fluid handled.
Fluid
In accordance with the intended use of the
submersible mixer, the term "fluid" (also
referred to as the fluid 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
content and length of fibrous substances, its
chemical composition and temperature.
Submersible mixer
Submersible mixers are mixing units with open
axial propeller hydraulics and a dry submersible
motor.
Glossary
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1 General
1.1 Principles
This manual is supplied as an integral part of the type series and variants indicated
on the front cover. It describes the proper and safe use of this equipment in all
phases of operation.
The name plate indicates the type series and size, the main operating data, the order
number and the order item number. The order number and order item number
clearly identify the submersible mixer and serve as identification for all further
business processes.
In the event of damage, contact your nearest KSB service centre immediately to
maintain the right to claim under warranty.
1.2 Installation of partly completed machinery
To install partly completed machinery supplied by KSB, refer to the sub-sections
under Servicing/Maintenance.
1.3 Target group
This operating manual is aimed at the target group of trained and qualified specialist
technical 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
Description of mating and installation dimensions
General assembly drawing1) Sectional drawing
Sub-supplier product literature1) Operating manuals and other product literature
of accessories and integrated machinery
components
Spare parts lists1) Description of spare parts
List of components1) Description of components
1.5 Symbols
Table 2: Symbols used in this manual
Symbol Description
✓Conditions which need to be fulfilled before proceeding with the
step-by-step instructions
⊳Safety instructions
⇨Result of an action
⇨Cross-references
1.
2.
Step-by-step instructions
Note
Recommendations and important information on how to handle
the product
1) If agreed to be included in the scope of supply
1 General
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2 Safety
All the information contained in this section refers to hazardous situations.
2.1 Key to safety symbols/markings
Table 3: Definition of safety symbols/markings
Symbol Description
!DANGER
DANGER
indicates a high-risk hazard which, if not avoided, will result in
death or serious injury.
!WARNING
WARNING
indicates a medium-risk hazard which, if not avoided, could result
in death or serious injury.
CAUTION
CAUTION
indicates a hazard which, if not avoided, could result in damage to
the machine and its functions.
Explosion protection symbol
identifies information about avoiding explosions in potentially
explosive atmospheres in accordance with EC Directive 94/9/EC
(ATEX).
General hazard symbol
in conjunction with one of the signal words indicates a hazard
which will or could result in death or serious injury.
Electrical hazard symbol
identifies information about protection against electrical voltage.
In conjunction with the signal word CAUTION, this symbol indicates
a hazard for the machine and its functions.
2.2 General
This manual contains general 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 in all sections of this manual must be complied with.
This manual must be read and completely understood by the responsible specialist
personnel/operators prior to installation and commissioning.
The contents of this manual must be available to the specialist personnel at the site
at all times.
Information attached directly to the submersible mixer must always be complied
with. This applies to, for example:
▪Arrow indicating the direction of rotation
▪Markings for connections
▪Name plate
The operator is responsible for ensuring compliance with all local regulations which
are not taken into account in this manual.
2.3 Intended use
The submersible mixer must only be operated within the operating limits described in
the other applicable documents.
▪Only operate submersible mixers which are in perfect technical condition.
▪Do not operate partially assembled submersible mixers.
!DANGER
2 Safety
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▪Only use the submersible mixer in the fluid described in the data sheet or
product literature.
▪Never operate the submersible mixer without fluid.
▪Observe the minimum fluid levels indicated in the data sheet or product
literature (to prevent overheating, bearing damage, cavitation damage, etc.).
▪Consult the manufacturer about any use or mode of operation not described in
the data sheet or product literature.
▪Never exceed the permissible operating limits (temperature, etc.) specified in the
data sheet or product literature.
▪Observe all safety information and instructions in this manual.
2.4 Personnel qualification and training
All personnel involved must be fully qualified to install, operate, maintain and
inspect the machinery this manual refers to.
The responsibilities, competence and supervision of all personnel involved in
installation, operation, maintenance and inspection must be clearly defined by the
operator.
Deficits in knowledge must be rectified by sufficiently trained specialist personnel
training and instructing the personnel who will carry out the respective tasks. If
required, the operator can commission the manufacturer/supplier to train the
personnel.
Training on the submersible mixer must always be supervised by technical 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 and of any and all rights to claims for damages.
▪Non-compliance can, for example, have the following consequences:
–Hazards to persons due to electrical, thermal, mechanical and chemical
effects and explosions
– Failure of important product functions
– Failure of prescribed maintenance and servicing practices
– Hazard to the environment due to hazardous substances
2.6 Safety awareness
In addition to the safety information contained in this manual and the intended use,
the following safety regulations shall be complied with:
▪Accident prevention, health and safety regulations
▪Explosion protection regulations
▪Safety regulations for handling hazardous substances
▪Applicable standards and laws
2.7 Safety information for the operator/user
▪Provide the personnel with protective equipment and make sure it is used.
▪Contain leakages so as to avoid any danger to persons and the environment.
Adhere to all relevant laws.
▪Eliminate all electrical hazards. (In this respect refer to the applicable national
safety regulations and/or regulations issued by the local energy supply
companies.)
2 Safety
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▪Take suitable precautions to prevent persons from coming near the propeller
when the submersible mixer is running.
▪It is strictly prohibited for any person to enter the tank while the submersible
mixer is running.
2.8 Safety information for maintenance, inspection and installation work
▪Modifications or alterations of the submersible mixer are only permitted with the
manufacturer's prior consent.
▪Use only original spare parts or parts authorised by the manufacturer. The use of
other parts can invalidate any liability of the manufacturer for resulting damage.
▪The operator ensures that all maintenance, inspection and installation work is
performed by authorised, qualified specialist personnel who are thoroughly
familiar with the manual.
▪Carry out work on the submersible mixer during standstill only.
▪The submersible mixer must have cooled down to ambient temperature.
▪When taking the mixer out of service always adhere to the procedure described
in the manual.
▪Decontaminate submersible mixers used in fluids posing a health hazard.
▪As soon as the work is completed, re-install and/or re-activate any safety-relevant
and protective devices. Before returning the product to service, observe all
instructions on commissioning.
2.9 Unauthorised modes of operation
Never operate the submersible mixer outside the limits stated in the data sheet and
in this manual.
The warranty relating to the operating reliability and safety of the submersible mixer
supplied is only valid if the mixer is used in accordance 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 atmospheres.
Sections of the manual marked by the Ex symbol apply to explosion-proof
submersible mixers also when temporarily operated outside of potentially explosive
atmospheres.
Only submersible mixers marked as explosion-proof and identified as such in the data
sheet must be used in potentially explosive atmospheres.
Special conditions apply to the operation of explosion-proof submersible mixers to EC
Directive 94/9/EC (ATEX).
When operating explosion-proof mixers, especially adhere to the additional
requirements marked by the Ex symbol.
The explosion-proof status of the submersible mixer is only assured if the submersible
mixer is used in accordance with its intended use.
Never operate the submersible mixer outside the limits stated in the data sheet and
on the name plate.
Prevent impermissible modes of operation at all times.
Correct monitoring of the winding temperature is imperative.
2.10.1 Repair
Special regulations apply to repair work on explosion-proof submersible mixers.
Modifications or alterations of the submersible mixer may affect explosion protection
and are only permitted after consultation with the manufacturer.
Repair work at the flameproof joints must only be performed in accordance with the
manufacturer's instructions. Repair to the values in tables 1 and 2 of EN 60079-1 is
not permitted.
!DANGER
2 Safety
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3 Transport/Temporary Storage/Disposal
3.1 Transport
DANGER
Improper transport
Danger to life from falling parts!
Damage to the submersible mixer!
▷Use the attachment point provided (lifting lug or bail) for attaching lifting
accessories.
▷Never suspend the submersible mixer by its power cable.
▷Never use the lifting ropes included in KSB's scope of supply for lifting loads
other than the KSB product supplied.
▷Safely attach lifting ropes to the submersible mixer and crane.
▷Protect the power cable against damage.
▷Maintain adequate safety distance during lifting operations.
WARNING
Submersible mixer tipping over or rolling off
Risk of personal injury!
▷Secure the submersible mixer against tipping over or rolling off.
WARNING
Temporary storage on unsecured and uneven surfaces
Personal injury and damage to property!
▷Place the submersible mixer on level firm ground only.
▷Refer to the weights given in the data sheet/on the name plate.
Transport the submersible mixer as shown.
Transport with supporting clamp Transport with supporting strap Transport with lifting bail
3.2 Storage/Preservation
If commissioning is to take place some time after delivery, we recommend that the
following measures be taken for storage:
CAUTION
Improper storage
Damage to the power cables!
▷Support the power cables at the cable entry to prevent permanent deformation.
▷Only remove the protective caps from the power cables at the time of
installation.
3 Transport/Temporary Storage/Disposal
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