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- Page 1 Goodnal STP ST041 Biological Treatment (KSB Amamix Direct Installation and Operation Manual) Vendor Manual Submersible Mixer Amamix® direkt GDSTP-24130-MAN-0003_P1 Installation/Operating Manual Ident. number: 01057742 Page 1 of 52 Q-Pulse Id VM385 Active 29/10/2013...
- Page 2 Goodnal STP ST041 Biological Treatment (KSB Amamix Direct Installation and Operation Manual) Vendor Manual 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.
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Page 3: Table Of Contents
Goodnal STP ST041 Biological Treatment (KSB Amamix Direct Installation and Operation 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 Amamix Direct Installation and Operation Manual) Vendor Manual Contents Commissioning/Start-up/Shutdown ..........23 Commissioning/start-up ................23 Operating limits .................... 23 Shutdown/storage/preservation ..............26 Returning to service ..................26 Servicing/Maintenance ..............28 Safety regulations ..................28 Servicing/inspection ..................
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Page 5: Glossary
Goodnal STP ST041 Biological Treatment (KSB Amamix Direct Installation and Operation 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 Amamix Direct Installation and Operation 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 Amamix Direct Installation and Operation 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 Amamix Direct Installation and Operation 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 Amamix Direct Installation and Operation 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 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
Goodnal STP ST041 Biological Treatment (KSB Amamix Direct Installation and Operation Manual) Vendor Manual 3 Transport/Temporary Storage/Disposal CAUTION Damage during storage by humidity, dirt or vermin Corrosion/contamination of the submersible mixer! ▷ For outdoor storage cover the (packed or unpacked) submersible mixer and accessories with waterproof material. -
Page 12: Description
Goodnal STP ST041 Biological Treatment (KSB Amamix Direct Installation and Operation 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 13: Configuration And Function
Goodnal STP ST041 Biological Treatment (KSB Amamix Direct Installation and Operation 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 B e a r i n g s ▪... -
Page 14: Dimensions And Weights
Goodnal STP ST041 Biological Treatment (KSB Amamix Direct Installation and Operation Manual) Vendor Manual 4 Description ▪ Support for power cable ▪ Two shackles (for hoisting tackle and cable support) ▪ Separate name plate NOTE A separate name plate is included in KSB's scope of supply. -
Page 15: Installation At Site
Goodnal STP ST041 Biological Treatment (KSB Amamix Direct Installation and Operation 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 16: Setting Up The Submersible Mixer
Goodnal STP ST041 Biological Treatment (KSB Amamix Direct Installation and Operation Manual) Vendor Manual 5 Installation at Site 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. - Page 17 Goodnal STP ST041 Biological Treatment (KSB Amamix Direct Installation and Operation Manual) Vendor Manual 5 Installation at Site 5.4.1.1 Overload protection 1. Protect the submersible mixer against overloading by a thermal time-lag overload protection device in accordance with IEC 947 and local regulations.
- Page 18 Goodnal STP ST041 Biological Treatment (KSB Amamix Direct Installation and Operation Manual) Vendor Manual 5 Installation at Site interference immunity by appropriately selecting and laying the cable in the plant. No modifications are required on the power cable of the submersible mixer. Suitable analysing devices must be selected.
- Page 19 Goodnal STP ST041 Biological Treatment (KSB Amamix Direct Installation and Operation Manual) Vendor Manual 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...
- Page 20 Goodnal STP ST041 Biological Treatment (KSB Amamix Direct Installation and Operation Manual) Vendor Manual 5 Installation at Site 5.4.2 Connection to power supply DANGER Electrical connection work by unqualified personnel Danger of death from electric shock! ▷ Always have the electrical connections installed by a trained electrician.
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Page 21: Checking The Direction Of Rotation
Goodnal STP ST041 Biological Treatment (KSB Amamix Direct Installation and Operation Manual) Vendor Manual 5 Installation at Site NOTE We recommend to use cable supports available as accessories for properly fastening the electrical cable at the tank edge. 1. Run the power cable directly upwards (if possible) without slack, and fasten. - Page 22 Goodnal STP ST041 Biological Treatment (KSB Amamix Direct Installation and Operation Manual) Vendor Manual 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.
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Page 23: Commissioning/Start-Up/Shutdown
Goodnal STP ST041 Biological Treatment (KSB Amamix Direct Installation and Operation 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 24 Goodnal STP ST041 Biological Treatment (KSB Amamix Direct Installation and Operation 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 25 Goodnal STP ST041 Biological Treatment (KSB Amamix Direct Installation and Operation 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 26: Shutdown/Storage/Preservation
Goodnal STP ST041 Biological Treatment (KSB Amamix Direct Installation and Operation Manual) Vendor Manual 6 Commissioning/Start-up/Shutdown Frequency inverter operation of the submersible mixer is permitted in the frequency range from 25 to 50 Hz. 6.3 Shutdown/storage/preservation 6.3.1 Measures to be taken for shutdown... - Page 27 Goodnal STP ST041 Biological Treatment (KSB Amamix Direct Installation and Operation Manual) Vendor Manual 6 Commissioning/Start-up/Shutdown NOTE On submersible mixers older than 5 years we recommend replacing all elastomer seals. Amamix® direkt 27 of 52 Page 27 of 52 Q-Pulse Id VM385...
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Page 28: 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 29: Servicing/Inspection
Goodnal STP ST041 Biological Treatment (KSB Amamix Direct Installation and Operation 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/... - Page 30 Goodnal STP ST041 Biological Treatment (KSB Amamix Direct Installation and Operation Manual) Vendor Manual 7 Servicing/Maintenance 2. Replace any damaged components by original spare parts. DANGER Defective earth conductor Electric shock! ▷ Never switch on a submersible mixer with a defective earth conductor.
- Page 31 Goodnal STP ST041 Biological Treatment (KSB Amamix Direct Installation and Operation Manual) Vendor Manual 7 Servicing/Maintenance WARNING Contamination of fluid handled by lubricant Hazardous to persons and the environment! ▷ Using machine oil is only permitted if the oil can be disposed of properly.
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Page 32: Drainage/Disposal
Goodnal STP ST041 Biological Treatment (KSB Amamix Direct Installation and Operation Manual) Vendor Manual 7 Servicing/Maintenance 7.2.1.5.4 Topping up the lubricant WARNING Lubricants posing a health hazard Hazard to persons and the environment! ▷ When filling in the lubricant take appropriate measures to protect persons and the environment. -
Page 33: Dismantling The Submersible Mixer
Goodnal STP ST041 Biological Treatment (KSB Amamix Direct Installation and Operation Manual) Vendor Manual 7 Servicing/Maintenance 7.4 Dismantling the submersible mixer 7.4.1 General information/Safety regulations WARNING Work on the submersible mixer by unqualified personnel Risk of personal injury! ▷ Always have repair and maintenance work performed by specially trained, qualified personnel. - Page 34 Goodnal STP ST041 Biological Treatment (KSB Amamix Direct Installation and Operation Manual) Vendor Manual 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.
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Page 35: Reassembling The Submersible Mixer
Goodnal STP ST041 Biological Treatment (KSB Amamix Direct Installation and Operation Manual) Vendor Manual 7 Servicing/Maintenance 1. Undo circlip 932.04. 2. Take out mechanical seal 433.02. 3. Undo circlip 932.05. 4. Take out casing cover 161. 5. Take out mechanical seal 433.01. - Page 36 Goodnal STP ST041 Biological Treatment (KSB Amamix Direct Installation and Operation 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 37 Goodnal STP ST041 Biological Treatment (KSB Amamix Direct Installation and Operation 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.
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Page 38: Tightening Torques
Goodnal STP ST041 Biological Treatment (KSB Amamix Direct Installation and Operation Manual) Vendor Manual 7 Servicing/Maintenance NOTE For Amamix 200G only carry out steps 3 - 4. 7.6 Tightening torques Table 11: Tightening torques Thread Torque [Nm] 7.7 Spare parts stock 7.7.1 Recommended spare parts stock for 2 years' operation to DIN 24296... - Page 39 Goodnal STP ST041 Biological Treatment (KSB Amamix Direct Installation and Operation Manual) Vendor Manual 7 Servicing/Maintenance ▪ 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 40: Trouble-Shooting
Goodnal STP ST041 Biological Treatment (KSB Amamix Direct Installation and Operation 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 41: Related Documents
Goodnal STP ST041 Biological Treatment (KSB Amamix Direct Installation and Operation Manual) Vendor Manual 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... - Page 42 Goodnal STP ST041 Biological Treatment (KSB Amamix Direct Installation and Operation Manual) Vendor Manual 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...
- Page 43 Goodnal STP ST041 Biological Treatment (KSB Amamix Direct Installation and Operation Manual) Vendor Manual 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...
- Page 44 Goodnal STP ST041 Biological Treatment (KSB Amamix Direct Installation and Operation Manual) Vendor Manual 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...
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Page 45: Flamepaths On Explosion-Proof Motors
Goodnal STP ST041 Biological Treatment (KSB Amamix Direct Installation and Operation Manual) Vendor Manual 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 9.2.2 Flamepaths on explosion-proof motors - Variant G Fig. -
Page 46: Wiring Diagrams
Goodnal STP ST041 Biological Treatment (KSB Amamix Direct Installation and Operation Manual) Vendor Manual 9 Related Documents 9.3 Wiring diagrams 9.3.1 Motors: 1 4, 2 4, 0 6, 2 6 8 (7) V1 W1 V2 W2 Fig. 21: Wiring diagram Amamix®... -
Page 47: Forcing Screws
Goodnal STP ST041 Biological Treatment (KSB Amamix Direct Installation and Operation Manual) Vendor Manual 9 Related Documents 9.3.2 Motors: 3 8, 4 8, 4 12, 6 12, 8 12, 10 12 U1 V1 W1 U2 V2 10 11 7 x . . . + 5 x 1.5 mm²... -
Page 48: Ec Declaration Of Conformity
Goodnal STP ST041 Biological Treatment (KSB Amamix Direct Installation and Operation Manual) Vendor Manual 10 EC Declaration of Conformity 10 EC Declaration of Conformity Manufacturer: KSB Aktiengesellschaft Johann-Klein-Straße 9 D-67227 Frankenthal, Germany The manufacturer herewith declares that the product: Amaline, Amamix, Amaprop KSB order number: .................... -
Page 49: Certificate Of Decontamination
Goodnal STP ST041 Biological Treatment (KSB Amamix Direct Installation and Operation 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 50: Index
Goodnal STP ST041 Biological Treatment (KSB Amamix Direct Installation and Operation Manual) Vendor Manual Index Index Certificate of decontamination 49 Operating limits 7 Commissioning/Start-up 23 Order number 6 Other applicable documents 6 Overload protection 17 Disposal 11 Partly completed machinery 6... - Page 51 Goodnal STP ST041 Biological Treatment (KSB Amamix Direct Installation and Operation Manual) Vendor Manual Page 51 of 52 Q-Pulse Id VM385 Active 29/10/2013...
- Page 52 Goodnal STP ST041 Biological Treatment (KSB Amamix Direct Installation and Operation 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...
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