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Related Manuals for KSB Amaprop GDSTP-24130-MAN-0004 P1
Summary of Contents for KSB Amaprop GDSTP-24130-MAN-0004 P1
- Page 1 Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual Submersible Mixer Amaprop® GDSTP-24130-MAN-0004_P1 Installation/Operating Manual Ident. number: 01070280 Page 1 of 60 Q-Pulse Id VM386 Active 29/10/2013...
- Page 2 Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual Legal information/Copyright Installation/Operating Manual Amaprop® 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.
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Page 3: Table Of Contents
Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual Contents Contents Glossary ....................5 General ....................6 Principles ......................6 Installation of partly completed machinery ..........6 Target group ....................6 Other applicable documents ................6 Symbols ...................... - Page 4 Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual Contents Commissioning/Start-up/Shutdown ..........24 Commissioning/start-up ................24 Operating limits .................... 24 Shutdown/storage/preservation ..............28 Returning to service ..................29 Servicing/Maintenance ..............30 Safety regulations ..................30 Servicing/inspection ..................30 Drainage/disposal ..................
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Page 5: Glossary
Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 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... -
Page 6: General
Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 1 General 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. -
Page 7: Safety
Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 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... -
Page 8: Personnel Qualification And Training
Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 2 Safety ▪ Only use the submersible mixer in the fluid described in the data sheet or product literature. ▪ Never operate the submersible mixer without fluid. -
Page 9: Safety Information For Maintenance, Inspection And Installation Work
Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 2 Safety ▪ 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. -
Page 10: Transport/Temporary Storage/Disposal
▷ Never suspend the submersible mixer by its power cable. ▷ 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. -
Page 11: Storage/Preservation
3. 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 3.4 Disposal... - Page 12 Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 3 Transport/Temporary Storage/Disposal 2. Separate and sort the materials, e.g. by: - Metals - Plastics - Electronic waste - Greases and lubricating liquids 3. Dispose of materials in acc. with local regulations or in another controlled manner.
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Page 13: Description
Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 4 Description 4 Description 4.1 General description Submersible mixer with self-cleaning propeller for handling municipal or industrial waste water and sludges, as well as for use in biogas applications. -
Page 14: Configuration And Function
Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 4 Description P r o p e l l e r ▪ Self-cleaning (ECB) propeller S h a f t s e a l ▪ Two bi-directional mechanical seals in tandem arrangement, with liquid reservoir ▪... -
Page 15: Scope Of Supply
Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 4 Description Sealing The gear shaft (1) of the submersible mixer is equipped with two bi-rotational mechanical seals (6) in tandem arrangement. A lubricant reservoir between the two mechanical seals ensures cooling and lubrication. -
Page 16: Installation At Site
Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 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. - Page 17 Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 5 Installation at Site 5.2.3 Checking the lubricant level Lubricant check plug on gear unit Lubricant filler plug on gear unit 903.01 411.01 Fig. 4: Checking the lubricant (propeller not shown) The lubricant reservoirs are filled with an environmentally-friendly, non-toxic lubricant at the factory.
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Page 18: Setting Up The Submersible Mixer
Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 5 Installation at Site 3. Screw in the lubricant check plug of the gear unit and the lubricant filler plug, if applicable. 5.3 Setting up the submersible mixer... - Page 19 Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 5 Installation at Site NOTE Amaprop 1000 or 2500 mixers installed in biogas plants must be operated with frequency inverters! DANGER Operation outside the permitted frequency range Explosion hazard! ▷...
- Page 20 Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 5 Installation at Site All sensors are located inside the submersible mixer and are connected to the power cable. For information on wiring and core identification please refer to the wiring diagrams.
- Page 21 Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 5 Installation at Site The electrode relay (K1) must meet the following requirements: ▪ Sensor circuit 10 to 30V ~ ▪ Tripping current 0.5 to 3 mA (equivalent to a tripping resistance of 3 to 60 kΩ)
- Page 22 Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 5 Installation at Site CAUTION Motor overload Damage to the motor! ▷ Protect the motor by a thermal time-lag overload protection device in accordance with IEC 947 and local regulations.
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Page 23: Checking The Direction Of Rotation
Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 5 Installation at Site 5.5 Checking the direction of rotation WARNING Hands, other body parts, or foreign objects in the propeller or propeller intake area Risk of personal injury! Damage to the submersible mixer! ▷... -
Page 24: Commissioning/Start-Up/Shutdown
Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 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. - Page 25 Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 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.
- Page 26 Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 6 Commissioning/Start-up/Shutdown Fig. 8: Minimum level of fluid handled Table 6: Minimum level of fluid handled Ø D [mm] 1000 0.20 1200 1400 1600 1800 2000 2200...
- Page 27 Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 6 Commissioning/Start-up/Shutdown 6.2.2.2 Fluid temperature DANGER Fluid temperature Explosion hazard! ▷ Never operate the submersible mixer at fluid temperatures exceeding those specified in the data sheet or on the name plate.
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Page 28: Shutdown/Storage/Preservation
Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 6 Commissioning/Start-up/Shutdown 6.2.4 Frequency inverter operation DANGER Operation outside the permitted frequency range Explosion hazard! ▷ Never operate an explosion-proof submersible mixer outside the specified range. Frequency inverter operation of the submersible mixer is permitted in the frequency range from 25 to 50 Hz. -
Page 29: Returning To Service
Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 6 Commissioning/Start-up/Shutdown 6.4 Returning to service For returning the submersible mixer to service observe the sections on commissioning/start-up and the operating limits (⇨ Section 6.2 Page 24). -
Page 30: Servicing/Maintenance
A regular maintenance schedule will help avoid expensive repairs and contribute to trouble-free, reliable operation with a minimum of maintenance expenditure and work. 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 at www.ksb.com/ contact". - Page 31 Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 7 Servicing/Maintenance Maintenance interval Maintenance work Checking the sensors After 16,000 operating hours Lubricant change (⇨ Section 7.2.1.5 Page 32) Every five years General overhaul 7.2.1 Inspection work 7.2.1.1 Measuring the insulation resistance...
- Page 32 Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 7 Servicing/Maintenance 7.2.1.4 Checking the sensors CAUTION Excessive test voltage Damage to the sensors! ▷ Never test the sensors with voltages exceeding 30 V. The tests described below measure the resistance at the core ends of the power cable.
- Page 33 Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 7 Servicing/Maintenance Gear unit Table 12: Quantity of gear unit lubricant Variant Lubricant quantity SP 189 (shaft centreline height 158 mm) 2.0 l SP 190 (shaft centreline height 192 mm) 2.6 l...
- Page 34 Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 7 Servicing/Maintenance ✓ A suitable container for the leakage is on hand. ✓ The submersible mixer is placed horizontally on a level surface. 1. Place the container underneath screw plug 903.04.
- Page 35 Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 7 Servicing/Maintenance Lubricant drain plug on gear unit 903.02 411.02 Fig. 11: Draining the lubricant (propeller not shown) 1. Position the submersible mixer as shown. 2. Place a suitable vessel under the screw plugs.
- Page 36 Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 7 Servicing/Maintenance CAUTION Lubricant level too high Mechanical seal operation is impaired! ▷ Always place the submersible mixer in horizontal position (as shown) for filling in the lubricant.
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Page 37: Drainage/Disposal
Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 7 Servicing/Maintenance 8. Screw the lubricant check plug of the gear unit back in. 7.3 Drainage/disposal WARNING Fluids posing a health hazard Hazardous to persons and the environment! ▷... - Page 38 Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 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 at www.ksb.com/ contact".
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Page 39: Reassembling The Submersible Mixer
Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 7 Servicing/Maintenance ✓ The propeller has been removed. 1. Undo circlip 932.05. 2. Take out mechanical seal 433.02. 3. Undo circlip 932.03. 4. Take out seal cover 471. - Page 40 Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 7 Servicing/Maintenance 7.5.2 Reassembling the motor section DANGER Wrong screws/bolts Explosion hazard! ▷ Only use original screws/bolts on explosion-proof submersible mixers. NOTE Before reassembling the motor section, check that all joints relevant to explosion protection (flamepaths) are undamaged.
- Page 41 Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 7 Servicing/Maintenance 7.5.4 Leak testing After reassembly the mechanical seal area/lubricant reservoir must be tested for leakage. The lubricant filler opening is used for leak testing. Observe the following values for leak testing: ▪...
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Page 42: Tightening Torques
Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 7 Servicing/Maintenance ✓ The drive shaft of the gear unit is readily accessible. ✓ The protective caps have been removed from the shaft and the propeller-end mechanical seal. - Page 43 Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 7 Servicing/Maintenance ▪ Description ▪ Part No. ▪ Quantity of spare parts ▪ Shipping address ▪ Mode of dispatch (freight, mail, express freight, air freight) Refer to the general assembly drawing for part numbers and descriptions.
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Page 44: Trouble-Shooting
Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 8 Trouble-shooting 8 Trouble-shooting Submersible mixer does not generate flow Insufficient flow Excessive current/power consumption Vibrations and noise during mixer operation A B C D Possible cause... -
Page 45: Related Documents
Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 9 Related Documents 9 Related Documents 9.1 General assembly drawing with list of components 9.1.1 Amaprop 1000 571.01 920.02 23-9 411.01 903.01 81-51 914.05 914.05 412.05 932.03 550.03... - Page 46 Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 9 Related Documents 9.1.2 Amaprop 1200 - 2500; motors: 1 4, 2 4, 3 4, 4 4, 5 4 23-9 901.04 550.02 412.05 719-02 81-73 932.03 412.06 411.01...
- Page 47 Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 9 Related Documents 9.1.3 Amaprop 1200 - 2500; motor: 6 4 901.04 550.02 914.05 411.01 412.02 81-73 903.01 550.03 932.03 932.02 412.05 901.03 412.07 81-51 411.05 932.07 932.01...
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Page 48: Flamepaths On Explosion-Proof Motors
Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 9 Related Documents 9.2 Flamepaths on explosion-proof motors 9.2.1 Amaprop 1000 and Amaprop 2500 / 6 4 Fig. 21: Flamepaths on explosion-proof motors - Amaprop 1000 and Amaprop 2500 / 6 4 9.2.2 Amaprop 1200 - 2500;... -
Page 49: Wiring Diagrams
Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 9 Related Documents 9.3 Wiring diagrams 9.3.1 Motors: 1 4, 2 4, 3 4 8 (7) V1 W1 V2 W2 Fig. 23: Wiring diagram of motors 1 4, 2 4, 3 4 Amaprop®... - Page 50 Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 9 Related Documents 9.3.2 Motors: 4 4, 5 4, 6 4, 11 4, 16 4, 23 4 CAUTION Incorrect electrical connection Winding damage! ▷ Observe the wiring diagram and the direction of rotation. (⇨ Section 5.5 Page...
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Page 51: Forcing Screws
Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 9 Related Documents 9.4 Forcing screws Table 15: Forcing screws Size Forcing screw 1200, 1400, M20 x 315 1600, 1800, 1801 (315) Lock nut M20 1 x 45°... -
Page 52: General Arrangement Drawings
Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 9 Related Documents 9.5 General arrangement drawings G e n e r a l a r r a n g e m e n t d r a w i n g o f A m a p r o p 1 0 0 0 - V e r s i o n f o r... - Page 53 Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 9 Related Documents G e n e r a l a r r a n g e m e n t d r a w i n g o f A m a p r o p 1 0 0 0 - V e r s i o n f o r l e v e l -...
- Page 54 Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 9 Related Documents G e n e r a l a r r a n g e m e n t d r a w i n g o f A m a p r o p 1 2 0 0 - 2 5 0 0 F min 3 bzw.
- Page 55 Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 9 Related Documents A m a p r o p 1 6 0 0 - G e a r u n i t G - 4 0 0 V , 5 0 H z - Ø D = 1 6 0 0...
- Page 56 Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 9 Related Documents A m a p r o p 2 2 0 0 - G e a r u n i t G - 4 0 0 V , 5 0 H z - Ø D = 2 2 0 0...
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Page 57: Ec Declaration Of Conformity
Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 10 EC Declaration of Conformity 10 EC Declaration of Conformity Manufacturer: KSB Aktiengesellschaft Johann-Klein-Straße 9 67227 Frankenthal (Germany) The manufacturer herewith declares that the product: Amaline, Amamix, Amaprop KSB order number: .................... -
Page 58: Certificate Of Decontamination
Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual 11 Certificate of Decontamination 11 Certificate of Decontamination Type ..........................Order number/ ..........................Order item number Delivery date ..........................Field of application: ....................................................Fluid handled Please tick where applicable ⃞... -
Page 59: Index
Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual Index Index Certificate of decontamination 58 Operating limits 7 Commissioning/Start-up 24 Order number 6 Other applicable documents 6 Overload protection 18 Disposal 11 Partly completed machinery 6... - Page 60 Goodnal STP ST041 Biological Treatment (KSB Amaprop Installation and Operating Manual) Vendor Manual KSB Aktiengesellschaft P.O. Box 200743 • 06008 Halle (Saale) • Turmstraße 92 • 06110 Halle (Germany) Tel. +49 345 4826-0 • Fax +49 345 4826-4699 www.ksb.com Page 60 of 60...
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