KSB Amamix series Installation & Operating Manual
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KSB Amamix series Installation & Operating Manual

Submersible mixer. 60 hz
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Submersible Mixer
Amamix
60 Hz
Installation/Operating Manual
Mat. No.:
01065351

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Summary of Contents for KSB Amamix series

  • Page 1 Submersible Mixer Amamix 60 Hz Installation/Operating Manual Mat. No.: 01065351...
  • Page 2 All rights reserved. The 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 the manufacturer's express written consent. Subject to technical modification without prior notice. © KSB Aktiengesellschaft, Frankenthal 10.03.2016...

  • Page 3: Table Of Contents

    Contents Contents Glossary ............................5 General ............................6 Principles .................................6 Installation of partly completed machinery ....................6 Target group ..............................6 Other applicable documents ..........................6 Symbols ................................6 Safety ............................. 7 Key to safety symbols/markings ........................7 General ................................7 Intended use ..............................7 Personnel qualification and training ......................8 Consequences and risks caused by non-compliance with these operating instructions ......8 Safety awareness ............................8 Safety information for the operator/user .....................8...
  • Page 4 Contents Commissioning/Start-up/Shutdown ................... 24 Commissioning/start-up ..........................24 Operating limits ............................24 Shutdown/storage/preservation ........................27 Returning to service .............................28 Servicing/Maintenance ....................... 29 Safety regulations ............................29 Servicing/inspection ............................30 Drainage/disposal ............................33 Dismantling the submersible mixer ......................34 Reassembling the submersible mixer ......................36 Tightening torques ............................39 Spare parts stock ............................39 Trouble-shooting ........................

  • Page 5: Glossary

    Glossary Glossary Certificate of decontamination fluid the mixer is operated in, i.e. generally municipal or industrial waste water and A certificate of decontamination certifies that sludges. The fluid is described in greater detail the submersible mixer has been properly by means of the gas and solids content, the cleaned and decontaminated to eliminate any content and length of fibrous substances, its environmental and health hazards arising from...

  • Page 6: General

    The order number and order item number uniquely identify the submersible mixer and serve as identification for all further business processes. In the event of damage, contact your nearest KSB service center immediately to maintain the right to claim warranty. 1.2 Installation of partly completed machinery To install partly completed machinery supplied by KSB, refer to the sub-sections under Servicing/Maintenance.

  • Page 7: Safety

    2 Safety 2 Safety All the information contained in this section refers to hazardous situations. DANGER 2.1 Key to safety symbols/markings Table 3: Definition of safety symbols/markings Symbol Description DANGER DANGER This signal word indicates a high-risk hazard which, if not avoided, will result in death or serious injury.

  • Page 8: Personnel Qualification And Training

    2 Safety ▪ 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.

  • Page 9: Safety Information For Maintenance, Inspection And Installation Work

    2 Safety 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 authorized by the manufacturer. The use of other parts can invalidate any liability of the manufacturer for resulting damage.

  • Page 10: Transport/Temporary Storage/Disposal

    ▷ 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.

  • Page 11: Return To Supplier

    Always complete and enclose a certificate of decontamination when returning the submersible mixer. Always indicate any safety and decontamination measures taken. NOTE If required, a blank certificate of decontamination can be downloaded from the KSB web site at: www.ksb.com/certificate_of_decontamination 3.5 Disposal WARNING Fluids posing a health hazard Hazard to persons and the environment! ▷...
  • Page 12 3 Transport/Temporary Storage/Disposal Separate and sort the materials, e.g. by: - Metals - Plastics - Electronic waste - Greases and other lubricants Dispose of materials in accordance with local regulations or in another controlled manner. Amamix 12 of 54...

  • Page 13: Description

    ZN 3826 - M 19 Mat. No: 01080567 ZN 3826 - M 17 Fig. 1: Name plate (example) a) for standard submersible mixer, b) for explosion- proof submersible mixer Designation KSB order number Maximum fluid and ambient Enclosure temperature Motor type Rated power...

  • Page 14: Configuration And Function

    4 Description Propeller ▪ Self-cleaning (ECB) propeller Shaft seal ▪ Two bi-directional mechanical seals in tandem arrangement, with liquid reservoir Bearings ▪ Grease-packed rolling element bearings sealed for life Drive ▪ Three-phase asynchronous squirrel-cage motor Motors integrated in explosion-proof submersible mixers are supplied in a type of protection as defined in NEC 500: "Explosionproof for Class I, Division 1 Groups C and D, T3, hazardous (classified) locations".

  • Page 15: Scope Of Supply

    ▪ Separate name plate NOTE 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 mounting bracket.

  • Page 16: Installation At Site

    5 Installation at Site 5 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!

  • Page 17: Setting Up The Submersible Mixer

    ▷ Observe the information given in the general arrangement drawing. ▷ Installation in other positions is only permitted after prior consultation with and approval by KSB. Mount the submersible mixer on the applicable installation set as described in the separate "Installation parts/accessories" installation instructions.
  • Page 18 5 Installation at Site Set the overload protection device to the rated current specified on the name plate. 5.4.1.2 Level switch DANGER Dry-running of submersible mixer Explosion hazard! ▷ Never allow an explosion-proof submersible mixer to run dry. CAUTION Propeller not fully submerged Damage to the submersible mixer! ▷...
  • Page 19 5 Installation at Site 5.4.1.4 Sensors DANGER Operating an incompletely connected submersible mixer Explosion hazard! ▷ Never start up a submersible mixer with incompletely connected power cables or non-operational monitoring devices. The submersible mixer is equipped with sensors designed to prevent hazards and damage to the mixer.
  • Page 20 5 Installation at Site 5.4.1.6 Leakage inside the motor Fig. 4: a) Wiring of the electrode relay and b) Position of the electrode in the motor housing An electrode (B2) fitted inside the motor monitors the winding and connection space for leakage.
  • Page 21 5 Installation at Site ▪ Tripping current 0.5 to 3 mA (equivalent to a tripping resistance of 3 to 60 kΩ) 5.4.2 Electrical connection DANGER Electrical connection work by unqualified personnel Danger of death from electric shock! ▷ Always have the electrical connections installed by a trained electrician. ▷...

  • Page 22: Checking The Direction Of Rotation

    5 Installation at Site NOTE We recommend to use cable supports available as accessories for properly fastening the electrical cable at the tank edge. Run the power cable directly upwards without slack, and fasten. Remove the protective caps from the power cable immediately before connection.
  • Page 23 5 Installation at Site ✓ The submersible mixer is mounted on the installation set and located completely outside the fluid handled. If tank is filled: Mixer mounted on the guide rail and suspended from lifting gear. If tank is empty: Mixer mounted on the guide rail and in operating position. ✓...

  • Page 24: Commissioning/Start-Up/Shutdown

    6 Commissioning/Start-up/Shutdown 6 Commissioning/Start-up/Shutdown 6.1 Commissioning/start-up 6.1.1 Prerequisites for commissioning/start-up Before commissioning/start-up make sure that the following requirements are met: ▪ The submersible mixer has been correctly mounted on the installation set. ▪ The submersible mixer has been properly connected to the power supply and is equipped with all protection devices.
  • Page 25 6 Commissioning/Start-up/Shutdown 6.2.1 Frequency of starts CAUTION Re-starting while motor is still running down Damage to the submersible mixer! ▷ Do not re-start the submersible mixer before it has come to a standstill. ▷ Never start up a submersible mixer running in reverse rotation. To prevent high temperature increases in the motor and excessive loads on the motor, seal elements and bearings, the maximum number of start-ups shall not exceed 10 per hour and 5000 per year.
  • Page 26 6 Commissioning/Start-up/Shutdown The submersible mixer is operational when the fluid level is not lower than dimension W . This minimum level of the fluid handled must also be ensured during automatic operation. Fig. 7: Minimum level of fluid handled Table 6: Minimum level of fluid handled Ø...

  • Page 27: Shutdown/Storage/Preservation

    6 Commissioning/Start-up/Shutdown 6.2.4.4 Abrasive fluids Do not exceed the maximum permissible solids content specified in 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 commonly recommended for servicing and maintenance.

  • Page 28: Returning To Service

    6 Commissioning/Start-up/Shutdown 6.4 Returning to service For returning the submersible mixer to service adhere to the sections on commissioning/start-up and the operating limits. For returning the mixer 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.

  • Page 29: Servicing/Maintenance

    ▷ 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.

  • Page 30: Servicing/Inspection

    7 Servicing/Maintenance NOTE All maintenance, service and installation work can be carried out by KSB Service. Find your contact in the attached "Addresses" booklet or on the Internet under "www.ksb.com/contact". Never use force when dismantling and reassembling the submersible mixer.
  • Page 31 7 Servicing/Maintenance Replace any damaged components by original spare parts. DANGER Defective ground conductor Electric shock! ▷ Never switch on a submersible mixer with a defective ground conductor. 7.2.1.3 Checking the shackle/lifting rope ✓ Visual inspection The submersible mixer has been lifted out of the fluid handled and cleaned. Inspect the shackle/lifting rope and all fixing elements for visual damage.
  • Page 32 7 Servicing/Maintenance ▪ Thin-bodied paraffin oil No. 7174, made by Merck ▪ Equivalent brands of medical quality, non-toxic ▪ Water-glycol mixture WARNING Contamination of fluid handled by lubricant Hazard to persons and the environment! ▷ Using machine oil is only permitted if the oil can be disposed of properly. 7.2.1.5.2 Lubricant quantity Table 11: Lubricant quantity Size...

  • Page 33: Drainage/Disposal

    7 Servicing/Maintenance Remove screw plugs 903.01 and 903.02 with joint rings 411.01 and 411.02, and drain off the lubricant. Close screw plug 903.02 again, fitting a new joint ring 411.02. 7.2.1.5.4 Refilling the lubricant WARNING Lubricants posing a health hazard Hazard to persons and the environment! ▷...

  • Page 34: Dismantling The Submersible Mixer

    For dismantling and reassembly observe the general assembly drawing. (⇨ Section 9.1 Page 43) NOTE All maintenance, service and installation work can be carried out by KSB Service. Find your contact in the attached "Addresses" booklet or on the Internet under "www.ksb.com/contact".
  • Page 35 7 Servicing/Maintenance 7.4.2 Dismantling the propeller 23-9 914.05 550.02 914.01 550.01 Fig. 10: Dismantling the propeller ✓ The submersible mixer has been lifted out of the tank, cleaned and placed outside the tank as per operating instructions. Unscrew propeller screw 914.01 and disc 550.01. Screw a forcing screw into propeller 23-9 and pull off the propeller.

  • Page 36: Reassembling The Submersible Mixer

    7 Servicing/Maintenance ✓ The propeller has been removed. Undo circlip 932.04. Take out mechanical seal 433.02. Undo circlip 932.05. Take out casing cover 161. Take out mechanical seal 433.01. 7.4.4 Dismantling the motor section NOTE Special regulations apply to repair work on explosion-proof submersible mixers. Modification or alteration of the submersible mixers can affect explosion protection and is only permitted after consulting the manufacturer.
  • Page 37 Before reassembling the motor section, check that all joints relevant to explosion protection (flamepaths) are undamaged. Components with damaged flamepaths must be replaced. Only use original spare parts made by KSB for explosion-proof submersible mixers. The flamepaths are shown in the relevant drawings. (⇨ Section 9.2 Page 47)
  • Page 38 7 Servicing/Maintenance Clean the shaft, and touch up any score marks or scratches with a polishing cloth, if necessary. If score marks or scratches are still visible, replace shaft 210. Fit mechanical seal 433.01. Fit circlip 932.03. Fit casing cover 161. Fit circlip 932.05.

  • Page 39: Tightening Torques

    7 Servicing/Maintenance 7.5.5 Fitting the propeller 23-9 914.05 550.02 914.01 550.01 Fig. 14: Fitting the propeller Fit taper piece 721. Screw in socket head cap screw 914.05 and disc 550.02. Fit propeller 23-9. Fit screw 914.01 and disc 550.01. NOTE For Amamix 200G only carry out steps 3 - 4.
  • Page 40 7 Servicing/Maintenance Part No. Description Number of mixers (including stand-by mixers) 10 and Type more Rotor 23-9 Propeller 433.01 Mechanical seal, motor-side 433.02 Mechanical seal, propeller-side 321.01 Rolling element bearing, propeller-side 321.02 Rolling element bearing, motor- side Set of sealing 100% elements 7.7.2...
  • Page 41 7 Servicing/Maintenance E = spare part, R = replacement part, V = wear part; it is recommended to keep a stock of wear and replacement parts Amamix 41 of 54...

  • Page 42: Trouble-Shooting

    Motor is running on two phases only. Replace the defective fuse. Check the electrical cable connections. Motor winding or electrical cable are Replace with original KSB parts or contact KSB. defective X X Defective radial bearing in the motor Contact KSB.

  • Page 43: Related Documents

    9 Related Documents 9 Related Documents 9.1 General assembly drawing with list of components 9.1.1 Amamix 200 - Material variant C 914.05 903.01 433.02 550.02 412.06 411.01 433.01 59-31 412.04 81-51 81-39 901.01 23-9 932.03 932.02 59-17 914.03 321.02 901.02 5900 5900 914.01...
  • Page 44 9 Related Documents 9.1.2 Amamix 200 - Material variant G 433.02 433.01 412.05 59-17 412.04 914.03 23-9 903.01 23-9 411.01 932.03 932.02 932.01 81-51 81-39 901.02 59-31 5900 914.01 932.04 412.01 321.01 80-1 412.03 69-14 321.02 550.01 932.05 903.02 914.02 914.04 Fig.
  • Page 45 9 Related Documents 9.1.3 Amamix 300/400/600 - Material variant C 59-31 80-1 81-51 421.02 412.04 23-9 550.01 932.02 914.01 421.01 932.05 903.01 321.01 81-59 932.07 411.01 81-39 901.02 Amamix 901.01 600 C Amamix 300 C Amamix 600 C 412.01 903.02 321.02 412.02 932.04 412.04...
  • Page 46 9 Related Documents 9.1.4 Amamix 300/400/600 - Material variant G 903.01 23-9 421.01 411.01 932.02 81-59 932.07 932.05 321.01 59-31 80-1 81-51 421.02 412.04 81-39 901.02 901.01 Amamix 300 G 903.02 411.02 914.01 432.04 412.07 412.01 433.01 412.03 321.02 550.01 433.02 412.06 932.03...

  • Page 47: Flamepaths On Explosion-Proof Motors

    9 Related Documents 9.2 Flamepaths on explosion-proof motors 9.2.1 Flamepaths on explosion-proof motors - Variant C Fig. 19: Flamepaths on explosion-proof motors - Variant C Amamix 47 of 54...
  • Page 48 9 Related Documents 9.2.2 Flamepaths on explosion-proof motors - Variant G Fig. 20: Flamepaths on explosion-proof motors - Variant G Amamix 48 of 54...

  • Page 49: Wiring Diagrams

    9 Related Documents 9.3 Wiring diagrams 9.3.1 Motors: 1 4, 2 4, 0 6, 2 6 8 (7) Fig. 21: Wiring diagram Amamix 49 of 54...
  • Page 50 9 Related Documents 9.3.2 Motors: 3 8, 4 8, 4 12, 6 12, 8 12, 10 12 460 V / 60 Hz 575 V / 60 Hz 10 11 7 x . . . + 5 x 1.5 mm² 12 x . . . mm² 10 11 Fig.

  • Page 51: Forcing Screws

    9 Related Documents 9.4 Forcing screws Table 18: Forcing screws Size Forcing screw 8" [200] " “ 12" [300] M16 x 60 [118 mm] 20" [400] Ø “ [8 mm] “ 24" [600] " “ M20 x 95 [118 mm] “...

  • Page 52: Certificate Of Decontamination

    10 Certificate of Decontamination 10 Certificate of Decontamination Type ..........................Order number/ ..........................Order item number Delivery date ..........................Field of application: ....................................................Fluid handled Please check where applicable ⃞ ⃞ ⃞ ⃞ radioactive explosive corrosive toxic ⃞ ⃞ ⃞...

  • Page 53: Index

    Index Index Operating limits 7 Order number 6 Certificate of decontamination 52 Other applicable documents 6 Commissioning/start-up 24 Overload protection 18 Disposal 11 Partly completed machinery 6 Preservation 10 Electromagnetic compatibility 18 Explosion protection 16, 18, 19, 21, 22, 24, 25, 29 Return to supplier 11 Frequency inverter operation 18, 25 Safety awareness 8...
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