Kasco Certisafe 2400c61 Manual

CertiSafe™Tank Mixer

Operation & Maintenance Manual

3020379

ANSI/UL 778: 2016

Ed.6+R:22Feb2017

CSA C22.2 #108: 2014 Ed.5

800 Deere Rd. Prescott, WI 54021 • 715-262-4488 • [email protected] • www.kascomarine.com

Document number 852110

CERTISAFE™ TANK MIXER MANUAL

852110 / 2021.1.1

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Contents

Safety First ��3

Mount & Control Panel Options��4

System Overview��5

System Specications ��5

Suggested Tools and Supplies ��6

Cable Installation Parts Included��6

Suggested Tank Penetration ��7

Unit Parts��9

Injection Nozzle Placement Recommendations �� 10

Maintenance Recommendations��11

Warranty �� 12

Non-Warranty Repairs�� 13

Repair Contact Form �� 14

Phone: 715-262-4488

Fax: 715-262-4487

www.kascomarine.com

[email protected]

Questions?

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IMPORTANT: PLEASE READ THIS MANUAL AND SAVE FOR FUTURE REFERENCE

SAFETY FIRST

• 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�

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CERTISAFE™ TANK MIXER MANUAL

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MOUNT & CONTROL PANEL OPTIONSMOUNT & CONTROL PANEL OPTIONS

Kasco offers 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�

Note: 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 struc-

tures 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�)

RM-100

Floor Mount

The RM-100 positions the mixer stably

on the tank oor and comes with a re-

trieval chain to safely lift the unit for ob-

servation 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�)

SM-100

Suspended Mount

Suspended from the tank roof, the

SM-100 uses a 60” stretcher bar to sup-

port the mixer in a raised position within

the tank� Two chains adjust the unit’s

elevation and facilitate safe removal for

observation and maintenance�

Control Panel Options

Standard CS-100, CS-200

• Motor contactor

• HOA, Manual or Automatic con-

trol through SCADA input

• Low water automatic shutoff

• 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

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CERTISAFE™ TANK MIXER MANUAL

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SYSTEM OVERVIEW

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� Effective mixing can be achieved in deeper tanks with mounting at or

above this depth�

NOTE: 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 SPECIFICATIONS

Model Voltage Phase Current

Draw

Amps Lock Rotor

Amps

Cord Gauge

50’ cord 100’ cord 200’ cord

2400C61 120 1 5�7 5�7 12 16 14 12

3400C61 120 1 7�0 7 18 16 14 12

3400HC61 240 1 3�5 3�5 9 14 14 12

4400C61 120 1 9�1 9�1 40 14 12 10

4400HC61 240 1 4�5 4�5 20 14 14 12

8400C61 240 1 9�0 9 40 14 12 12

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SUGGESTED TOOLS AND SUPPLIES

Electric or cordless drill

7/8” hole saw

(or 1-7/64” for 10 AWG cable)

Half-round metal le

Pan to catch shavings

Adjustable pliers

CABLE INSTALLATION PARTS INCLUDED

Description Item Qty. Part number 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

* Requires larger hole in tank roof (1-7/64”)

A

B

C

Eye bolt hardware

and installation instructions

included with mounting kits�

Fig. 1

Fig. 2

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CERTISAFE™ TANK MIXER MANUAL

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SUGGESTED TANK PENETRATION

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 diam-

eter, 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� Instruc-

tions 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.

Note:

• 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�

Ø 7/8” or 1-7/64”

Ø 3/8”

4”

Ø 7/8” or 1-7/64”

Ø 3/8”

4”

29”29”

Ø 3/8”

Floor Mount and Pipe Mount

Cord grip pass-through

7/8” or 1-7/64” hole located near the tank hatch�

Eye bolt pass-through

3/8” hole about 4” away from cord grip pass-

through�

Suspended Mount

Eye bolt pass-throughs

Two 3/8” holes located in line 29” to either side of

the tank hatch center point�

Cord grip pass-through

7/8” or 1-7/64” hole about 4” closer to the tank

hatch center point than one of the eye bolt pass-

throughs�

Fig. 3

Fig. 4

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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 7 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)�

C

Steel tank roof

A

Fig. 5

Steel tank roof

B

Fig. 6

Fig. 7

A

B

Fig. 8

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CERTISAFE™ TANK MIXER MANUAL

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Item Description Qty. Part number

A CertiSafe™ cage 1 993205

B Serrated screw 1 840543

C Serrated nut 1 840532

D Propeller 1 2400K

3400J

4400M

8400

UNIT PARTSUNIT PARTS

Fig. 9

Sealed motor unit

A

B

C

D

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CERTISAFE™ TANK MIXER MANUAL

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INJECTION NOZZLE PLACEMENT RECOMMENDATIONS

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 steal 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�

Chemical injection nozzle

Stainless steel hose clamps

Position nozzles below propeller

Fig. 10

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MAINTENANCE RECOMMENDATIONSMAINTENANCE RECOMMENDATIONS

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�

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?

1� With the power off, 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?

1� 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 continues to run, fault lies in the control panel or power

source�

• If the alternate GFCI continues to trip, fault lies in the unit or cord�

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 equip-

ment 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 effectively 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�

IMPORTANT: Disconnect electrical power prior to any maintenance or servicing!

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WARRANTY

Kasco offers 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 pack-

ages 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 appro-

priate 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�

Note: 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�

Shipping Address:

Kasco Marine, Inc�

800 Deere Rd�

Prescott, WI 54021

Attn: Repairs

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 recommenda-

tions 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 efcient service, please register the unit online at:

www�kascomarine�com/warranty-registration�

Once warranty coverage has been established, you may send the unit to Kasco for evaluation and repair�

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NON-WARRANTY REPAIRS

You can often repair failed equipment at a lower cost than re-

placement� 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�”

3020379

ANSI/UL 778: 2016

Ed.6+R:22Feb2017

CSA C22.2 #108: 2014 Ed.5

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�

Kasco Marine

800 Deere Road

Prescott, WI 54021

Contact Us

Phone: 715-262-4488

Fax: 715-262-4487

www.kascomarine.com

[email protected]

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REPAIR CONTACT FORM

• Kasco requires that all equipment sent for repair MUST be accompanied by this form and marked to Repairs attention�

• 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�

• Do not ship the mount or control panel with unit, unless otherwise instructed�

• A fee of $60 per hour will be assessed for cleaning excessively dirty units�

• Refer to the CertiSafe™ Tank Mixer Operation & Maintenance Manual for easy-to-follow troubleshooting tips to rule out site issues�

Note: Contact Information should be that of the person or company to contact for repair information�

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) Phone Email

Purchase order number

Additional notes

for repair technician:

Kasco Marine

800 Deere Road

Prescott, WI 54021

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Kasco CertiSafe 2400C61 Manual

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