Kasco CertiSafe 2400C61 Manual

CERTISAFE™ TANK MIXER MANUAL 1
800 Deere Rd. Prescott, WI 54021 | 715.262.4488 | [email protected] | kascomarine.com
CertiSafe™
TANK MIXER
Operation &
Maintenance
Manual
3020379
ANSI/UL 778: 2016
Ed.6+R:22Feb2017
CSA C22.2 #108: 2014 Ed.5
Document number 852110
Document version number 2022.1.0

CERTISAFE™ TANK MIXER MANUAL 1
715.262.4488
kascomarine.com | [email protected]
TABLE OF CONTENTS
QUESTIONS?
Safety First...............................................................................................................................2
Mount Options ........................................................................................................................3
Control Panel Options............................................................................................................3
System Overview ....................................................................................................................4
System Specications.............................................................................................................4
Suggested Tools and Supplies...............................................................................................5
Cable Installation Parts Included..........................................................................................5
Suggested Tank Penetration .................................................................................................6
Unit Parts .................................................................................................................................8
Injection Nozzle Placement ...................................................................................................9
Maintenance Recommendations........................................................................................10
Warranty ................................................................................................................................11
Non-warranty Repairs..........................................................................................................12
Repair Contact form .............................................................................................................13

CERTISAFE™ TANK MIXER MANUAL 2
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IMPORTANT: PLEASE READ THIS MANUAL AND SAVE FOR FUTURE REFERENCE
Moving Machinery
WARNINGS:
Shock Hazard
• Under NO circumstances should anyone enter the water with the mixer connected or in operation.
• Running the unit out of water will create a dangerous situation and damage the seals.
• NEVER lift the unit by the power cord. If you need to remove the mixer, use the installation or mount
apparatus.
• The unit must be connected to a GFCI-protected circuit.
• Comply with local and national wiring standards during any electrical service disconnect.
• Consult a qualied professional for electrical installation.
• Use all Personal Protective Equipment necessary for safe ingress, installation, and egress from the
work site.
• Refer to applicable national and local laws and standards to facilitate the safe installation of a
CertiSafe Tank Mixer. These may include but are not limited to OSHA, CCOHS, and other regulations
related to:
• Working over or near water
• Fall protection systems
• Falling object protection systems
• Electrical standards
• Illumination
• Ventilation
• Installation of CertiSafe™ Tank Mixers requires entry into environments that pose potential hazards,
such as those described in section 1910.146 of OSHA’s Occupational Safety and Health Standards for
Permit-required conned spaces. As such:
• Observe any applicable pre-entry measures required by the entry supervisor.
• Only those authorized via the permit system in place at the installation site should participate
in installation.
• Any authorized entrant should be accompanied by at least one authorized attendant to
monitor conditions inside and outside the permit spaces during installation.
• Prior to installation, be aware of all potential fall, trip, and atmospheric hazards in the permit
space, both before and after an entrance cover is removed.
SAFETY FIRST

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Kasco oers a variety of mounting options to best position a CertiSafe™ mixer in any tank environment,
all featuring durable stainless steel. There are also several optional control panels.
These mounting kits are designed for proper placement AND retrieval of CertiSafe™ mixers.
Once installed, ONLY remove mixers via the retrieval method specic to the mount.
PM-100
Pipe Mount
The PM-100 makes use of other
structures in the tank to position
the mixer. Use the upper mount
parts above the water line to
adjust the unit’s vertical position
and to swivel the lower mount
parts and the attached mixer.
(Pre-cut stainless steel pipe not
included.)
Standard CS-100, CS-200
• Motor contactor
• HOA, Manual or Automatic control through
SCADA input
• Low water automatic shuto
• UL 4X/3R enclosure
• 120V panel uses a 20A single pole
circuit breaker
• 240V panel uses a 30A single pole
circuit breaker
Advanced CS-150, CS-250
All standard features PLUS:
• Ground fault protection
• HOA, Hand and Auto position dry contacts
for SCADA
• Mixer fault dry contact for SCADA
• Mixer running dry contact for SCADA
• Larger 4X/3R enclosure
Advanced models are also available in stainless
steel (CS-150SS & CS-250SS)
RM-100
Floor Mount
The RM-100 positions the
mixer stably on the tank oor
and comes with a retrieval
chain to safely lift the unit for
observation and maintenance.
Protective feet on each of the
legs are designed to prevent
any damage to the tank. (Note:
minimum clearance is 24” for
square hatches, 25” for round
hatches.)
Suspended Mount
Suspended from the tank roof,
the SM-100 uses a 60” stretcher
bar to support the mixer in a
raised position within the tank.
Two chains adjust the unit’s
elevation and facilitate safe
removal for observation and
maintenance.
The ASM-100 accessory kit
includes an additional 60”
stretcher bar.
The SM-50 Suspended Mount
includes a 30” stretcher bar.
MOUNT OPTIONS
CONTROL PANEL OPTIONS

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Model Voltage Phase Amps
Locked
Rotor
Amps
Cord Gauge
50’ cord 100’ cord 200’ cord
2400C61 120 1 5.7 12 16 14 12
3400C61 120 1 7 18 16 14 12
3400H61 208-240 1 3.5 9 14 14 12
4400C61 120 1 9.1 40 14 12 10
4400HC61 208-240 1 4.5 20 14 14 12
8400C61 208-240 1 9.0 40 14 12 12
The Kasco CertiSafe™ Tank Mixer is part of a submerged active mixing system. It is intended for potable
water tanks (20,000 gallons and larger) to eliminate thermal stratication and ice formation, as well as
maintain residual disinfectant uniformity.
CertiSafe™ mixers are shipped prepared for use. The motor is equipped with thermal overload protection;
however, the mixing unit must be continuously submerged to ensure safe operation. It is important that
the installation provides appropriate voltage to the motor.
Operating the mixer continuously provides maximum water circulation in your tank. Optional system
controls are available from Kasco for mixer units (see page 4).
CertiSafe™ systems have a maximum operating depth of 50 feet. Eective mixing can be achieved in
deeper tanks with mounting at or above this depth.
This manual will cover the tank penetration process necessary to pass the power cable through
the tank roof during installation. Individual mount manuals contain information on additional tank
penetration and unit installation.
SYSTEM OVERVIEW
SYSTEM SPECIFICATIONS

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Description Item Qty. Part No. For use with
Cord AWG
Cord grip A 1
997210 14-16 AWG
997211 12 AWG
997212* 10 AWG
Cord grip nut B 1 997215 12-16 AWG
997216 10 AWG
Cable support C 1 997220 10 AWG
997221 12-16 AWG
SUGGESTED TOOLS AND SUPPLIES
CABLE INSTALLATION PARTS INCLUDED
Electric or
cordless drill
7/8” hole saw
(or 1-7/64” for 10
AWG cable)
* Requires larger hole in tank roof (1-7/64”)
Half-round
metal le
Pan to catch
shavings
Adjustable
pliers
Eye bolt hardware
and installation
instructions included
with mounting kits.
A
B
C

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Depending on the mount option you choose, two or three tank penetration holes will be required. The
rst is a either a 7/8” or 1-7/64” diameter hole, depending on the cord gauge. This is for the cord grip,
shipped with the CertiSafe™ Tank Mixer. Others are 3/8” in diameter (.281” for SM-50 Suspended Mount),
for eye bolts that hold the cable support and any chains included with the mount.
For reference, all tank penetration measurements are detailed below, followed by instructions for the
cord grip pass-through. Instructions and equipment for additional tank penetration are included with the
CertiSafe™ mounting kits.
To prevent galling, we recommend a moisture-cured, polyurethane compound sealant suitable for contact
with potable water and certied to meet the shrinkage for interior and exterior use. Refer to NSF/ANSI
Standard 61 for indirect additives.
• The maximum tank roof thickness accommodated by the tank penetration parts included is 1/8”.
• Suggested measurements are based on a 24” square access hatch.
SUGGESTED TANK PENETRATION
Ø 7/8”
29”29”
Ø 3/8”
Ø 3/8”
Ø 7/8”
15-20”
4”
Ø 3/8”
15-20”
Tank hatch
center point
SM-100
ASM-100
Ø 3/8”
4”
Ø .281”
Ø 7/8”
15”
4”
Ø .281”
15”
SM-50
Ø 7/8”
Ø 3/8”
4”
RM-100 & PM-100

CERTISAFE™ TANK MIXER MANUAL 7
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1. Drill a 7/8” hole (or 1-7/64” hole for 10 AWG cable) at the distance suggested for your mount.
See page 6 for details.
2. Deburr both sides of the hole. This is for the cord grip.
3. From the tank exterior, pass the cord grip (A) through the clearance hole, with the O-ring outside the
tank roof.
4. From the tank interior, t the cord grip nut (B) on the threads protruding into the tank.
5. Tighten the nut (B) until snug, being careful not to over-tighten.
6. Feed the power cable through the cable support (C).
• The cable support hangs on a connecting link suspended from an eye bolt. The connecting link
and eye bolt are included with CertiSafe™ mounting kits.
7. Continue to feed power cable through the cord grip (A) and out of the tank until all excess cord length
has been taken up, only leaving enough so that there is no strain on the cable.
8. Tighten the top nut on the cord grip to seal the power cable penetration.
9. Terminate the power cable into an exterior junction box (not supplied by Kasco).
SUGGESTED TANK PENETRATION (CONT.)
Steel tank roof
Steel tank roof
A
C
3 4
5
6
7
8
B

CERTISAFE™ TANK MIXER MANUAL 8
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Item Description Qty. Part No.
A CertiSafe™ cage 1 993205
B Serrated screw 1 840543
C Serrated nut 1 840532
D
2400K propeller 1 240170
3400J propeller 1 340125
4400M propeller 1 440430
8400 propeller 1 820505
UNIT PARTS
A
B
C
D
Sealed motor unit

CERTISAFE™ TANK MIXER MANUAL 9
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Once installed, its placement within the tank and powerful active mixing capabilities make
Kasco’s CertiSafe™ Tank Mixer an ideal anchor point for common third-party NSF-approved
chemical injection nozzles.
• For this purpose, we recommend that you x any nozzles (not supplied by Kasco) to the unit’s
cage, spaced as shown below.
• Use stainless steel hose clamps to secure the nozzle body to the cage, ensuring that the nozzle is
snug against the cage and that the tip is below the propeller.
• Shown here with two nozzles, solutions will be mixed together with the water pulled through
the propeller.
INJECTION NOZZLE PLACEMENT
Position nozzles
below propeller
Use stainless steel
hose clamps
Chemical injection
nozzle

CERTISAFE™ TANK MIXER MANUAL 10
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IMPORTANT: disconnect electrical power prior to any maintenance or servicing!
GFCI
GFCI (Ground Fault Circuit Interrupter) is a safety feature that can alert you to problems with the mixer.
It is important to test the GFCI upon installation, after each re-installation, and regularly thereafter
to ensure consistent operation. If you experience repeat interruptions, disconnect and remove the
equipment. Inspect the power cord and unit (mixer) for damage. If no damage is apparent, please contact
your Kasco distributor or representative for further instruction.
Observation
• Monitor the operating mixer for any reduction or variation in performance.
• Inspect the mixer annually and clean as needed to allow for heat dissipation and to verify that the
propeller is clean and free of nicks.
• Inspect the power cable annually for damage or abrasion and replace as necessary.
• Regularly clean all external rotating parts and examine them for wear.
• If you note a deciency in performance, remove the equipment from service and inspect for any
damage or failure. If you observe any canister leakage during annual inspection, send the mixer to
Kasco’s factory for service and repair.
Cleaning
The stainless-steel motor housing needs to be kept clean in order to allow heat to eectively dissipate.
Seal and Oil Replacement
• Replacing the seal and changing the oil every 3-5 years will add reliability and longevity to the mixer.
• Seal replacement and all other repair services should be performed by Kasco Marine.
Electrical Troubleshooting
• If a unit fails to operate, you can use a series of simple checks to determine the general cause.
• Once you’ve located the fault, please contact your distributor for information on how to proceed
with repair.
MAINTENANCE RECOMMENDATIONS
Is the GFCI Tripped?
1. If yes, reset the GFCI and check operation.
2. If the GFCI continues to trip, disconnect the unit in the panel and reset the GFCI.
• If the GFCI doesn’t trip, the fault lies in the unit or its cord.
• If the GFCI continues to trip, the fault lies in the control panel power source.
Is the cord damaged? With the power o, perform a visual inspection of the power cord. If there is visible
damage, contact your distributor for repair options.
What happens with an
alternate power source?
If the power cord and unit appear to be in good condition, safely plug it into an
alternate GFCI-protected power source.
• If the unit starts and runs, fault lies in the control panel or power source.
• If the alternate GFCI continues to trip, fault lies in the unit or cord.

CERTISAFE™ TANK MIXER MANUAL 11
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Kasco oers a standard 3-year warranty with the
following models:
• 2400C61
• 3400C61 / 3400HC61
• 4400C61 / 4400HC61
• 8400C61
At the time of purchase, a 5-year warranty is
available for packages including Advanced model
control panels.
Warranty must be purchased at the same time as
the mixer package. (Mixer package consists of the
mixer, mount, and control panel.)
Control panel MUST have GFCI protection.
Kasco® Marine, Inc. warrants this CertiSafe™
mixing system to be free from defects in material
or workmanship under appropriate use and
service. The Kasco Marine, Inc. obligation under
this warranty is limited to replacing or repairing,
without charge, proven defective part while within
the warranty period. Customer shall pay shipping
charges for returning the unit to Kasco.
THIS WARRANTY IS IN LIEU OF ANY OTHER
WARRANTIES, EXPRESSED OR IMPLIED. IN NO
EVENT WILL KASCO MARINE, INC. BE LIABLE FOR
ANY CONSEQUENTIAL DAMAGES.
Warranty is void if:
• The mixer is not maintained according to the
recommendations supplied in this manual.
• The mixer is returned for repair without the
power cord.
• The unit, control box, or power cord are altered
in any way from original shipment.
• The power cord is nicked or cut.
• The mixer is damaged by unauthorized service
Warranty Claim Procedure
Warranty period is established by the original
receipt. For ecient service, please register the unit
online at: kascomarine.com/warranty-registration.
Once warranty coverage has been established,
you may send the unit to Kasco for evaluation
and repair:
Kasco Marine, Inc.
800 Deere Rd.
Prescott, WI 54021
Attn: Repairs
Kasco only accepts complete assemblies for warranty repair. We must receive the power cord
and all other components with the motor as originally assembled. Kasco will bill the customer
to replace any missing parts necessary for repair. It is not necessary to return the control
panel, mount, or other parts with the motor assembly, unless specically requested by a Kasco
representative.
Please attach a repair form with the shipment. The repair form must include a name, physical
address (for return delivery of the repaired unit), daytime phone number, and an e-mail address
for correspondence regarding the warranty claim.
Any expedited shipping method for the return of the unit is at the customer’s expense. Kasco
Marine will return units repaired under warranty at our expense via ground freight within the
continental United States.
WARRANTY

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You can often repair failed equipment at a lower cost than replacement. Kasco Marine estimates repairs
at the request of the customer. This request should include a daytime phone number and e-mail address.
Estimate options are as follows:
• Kasco contacts the customer with a repair total after we evaluate the unit, but before we perform the
work quoted.
• Customer pre-approves repair of the unit if costs are below a stated dollar amount. Example: “Please
repair if total is under $150.00 before shipping charges.”
Kasco will recycle any unit we receive for estimate but which the customer declines to repair, unless the
customer species otherwise. If the customer would like the product returned, Kasco will return the unit
to the condition in which we received it, and we will ship it at the customer’s expense.
Billing
Contact Kasco to arrange payment for any non-warranty repairs. We will request payment information
upon customer approval of the estimate.
NON-WARRANTY REPAIRS
715.262.4488
Kasco Marine
800 Deere Road
Prescott, WI 54021
kascomarine.com | [email protected]
CONTACT US
3020379
ANSI/UL 778: 2016
Ed.6+R:22Feb2017
CSA C22.2 #108: 2014 Ed.5

®
Certified to
NSF/ANSI 61 & 372

CERTISAFE™ TANK MIXER MANUAL 13
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Company name
Contact name
First name Last name
Address
Street
City
State
ZIP code
Phone number
Primary Alternate
Email address
Preferred method of
contact (circle one) Phone Email
Purchase order
number
Additional product
information
Serial Number Cord Length
Information for Repair Technician
Was this unit used in a chemical treatment or wastewater
application? (circle one) Yes No
Additional notes
Kasco Marine
800 Deere Road
Prescott, WI 54021
Attn: Repairs
• Kasco requires that all equipment sent for repair MUST be
accompanied by this form and marked to Repairs attention.
• Unit should be cleaned before shipping.
• Kasco is NOT responsible for shipping damage accrued in
return shipment.
• It is the responsibility of the customer to ship and pay freight
to Kasco.
Note: Contact information should be that of the person or company to contact for repair information.
REPAIR CONTACT FORM