KSB Amamix direkt Installation instructions

Submersible Mixer
Amamix® direkt
Installation/Operating
Manual
Ident. number: 01057742
Goodnal STP ST041 Biological Treatment (KSB Amamix Direct Installation and Operation Manual) Vendor Manual
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Active 29/10/2013
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GDSTP-24130-MAN-0003_P1

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.
Subject to technical modification without prior notice.
© KSB Aktiengesellschaft Frankenthal 10.09.2010
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Contents
Glossary ................................................................................................ 5
1 General ................................................................................................ 6
1.1 Principles .......................................................................................................... 6
1.2 Installation of partly completed machinery .................................................. 6
1.3 Target group ................................................................................................... 6
1.4 Other applicable documents .......................................................................... 6
1.5 Symbols ............................................................................................................ 6
2 Safety ................................................................................................... 7
2.1 Key to safety symbols/markings ..................................................................... 7
2.2 General ............................................................................................................ 7
2.3 Intended use .................................................................................................... 7
2.4 Personnel qualification and training ............................................................. 8
2.5 Consequences and risks caused by non-compliance with these operating
instructions ...................................................................................................... 8
2.6 Safety awareness ............................................................................................. 8
2.7 Safety information for the operator/user ...................................................... 8
2.8 Safety information for maintenance, inspection and installation work ..... 9
2.9 Unauthorised modes of operation ................................................................. 9
2.10 Explosion protection ....................................................................................... 9
3 Transport/Temporary Storage/Disposal ........................................... 10
3.1 Transport ....................................................................................................... 10
3.2 Storage/Preservation ..................................................................................... 10
3.3 Return to supplier ......................................................................................... 11
3.4 Disposal .......................................................................................................... 11
4 Description ......................................................................................... 12
4.1 General description ....................................................................................... 12
4.2 Designation ................................................................................................... 12
4.3 Name plate .................................................................................................... 12
4.4 Design details ................................................................................................ 12
4.5 Configuration and function ......................................................................... 13
4.6 Scope of supply ............................................................................................. 13
4.7 Dimensions and weights ............................................................................... 14
5 Installation at Site ............................................................................. 15
5.1 Safety regulations ......................................................................................... 15
5.2 Checks to be carried out prior to installation ............................................. 15
5.3 Setting up the submersible mixer ................................................................ 16
5.4 Electrical connection ..................................................................................... 16
5.5 Checking the direction of rotation .............................................................. 21
Contents
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6 Commissioning/Start-up/Shutdown ................................................. 23
6.1 Commissioning/start-up ................................................................................ 23
6.2 Operating limits ............................................................................................ 23
6.3 Shutdown/storage/preservation ................................................................... 26
6.4 Returning to service ...................................................................................... 26
7 Servicing/Maintenance ...................................................................... 28
7.1 Safety regulations ......................................................................................... 28
7.2 Servicing/inspection ...................................................................................... 29
7.3 Drainage/disposal .......................................................................................... 32
7.4 Dismantling the submersible mixer ............................................................. 33
7.5 Reassembling the submersible mixer ........................................................... 35
7.6 Tightening torques ....................................................................................... 38
7.7 Spare parts stock ........................................................................................... 38
8 Trouble-shooting ............................................................................... 40
9 Related Documents ........................................................................... 41
9.1 General assembly drawing with list of components ................................... 41
9.2 Flamepaths on explosion-proof motors ....................................................... 45
9.3 Wiring diagrams ............................................................................................ 46
9.4 Forcing screws ............................................................................................... 47
10 EC Declaration of Conformity .......................................................... 48
11 Certificate of Decontamination ....................................................... 49
Index .................................................................................................. 50
Contents
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Glossary
Certificate of decontamination
A certificate of decontamination certifies that
the submersible mixer has been properly
cleaned and decontaminated to eliminate any
environmental and health hazards arising from
components in contact with the fluid handled.
Fluid
In accordance with the intended use of the
submersible mixer, the term "fluid" (also
referred to as the fluid handled) refers to the
fluid the mixer is operated in, i.e. generally
municipal or industrial waste water and
sludges. The fluid is described in greater detail
by means of the gas and solids content, the
content and length of fibrous substances, its
chemical composition and temperature.
Submersible mixer
Submersible mixers are mixing units with open
axial propeller hydraulics and a dry submersible
motor.
Glossary
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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.
The name plate indicates the type series and size, the main operating data, the order
number and the order item number. The order number and order item number
clearly identify the submersible mixer and serve as identification for all further
business processes.
In the event of damage, contact your nearest KSB service centre immediately to
maintain the right to claim under warranty.
1.2 Installation of partly completed machinery
To install partly completed machinery supplied by KSB, refer to the sub-sections
under Servicing/Maintenance.
1.3 Target group
This operating manual is aimed at the target group of trained and qualified specialist
technical personnel.
1.4 Other applicable documents
Table 1: Overview of other applicable documents
Document Contents
Data sheet Description of the technical data
General arrangement drawing/
outline drawing
Description of mating and installation dimensions
General assembly drawing1) Sectional drawing
Sub-supplier product literature1) Operating manuals and other product literature
of accessories and integrated machinery
components
Spare parts lists1) Description of spare parts
List of components1) Description of components
1.5 Symbols
Table 2: Symbols used in this manual
Symbol Description
✓Conditions which need to be fulfilled before proceeding with the
step-by-step instructions
⊳Safety instructions
⇨Result of an action
⇨Cross-references
1.
2.
Step-by-step instructions
Note
Recommendations and important information on how to handle
the product
1) If agreed to be included in the scope of supply
1 General
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2 Safety
All the information contained in this section refers to hazardous situations.
2.1 Key to safety symbols/markings
Table 3: Definition of safety symbols/markings
Symbol Description
!DANGER
DANGER
indicates a high-risk hazard which, if not avoided, will result in
death or serious injury.
!WARNING
WARNING
indicates a medium-risk hazard which, if not avoided, could result
in death or serious injury.
CAUTION
CAUTION
indicates a hazard which, if not avoided, could result in damage to
the machine and its functions.
Explosion protection symbol
identifies information about avoiding explosions in potentially
explosive atmospheres in accordance with EC Directive 94/9/EC
(ATEX).
General hazard symbol
in conjunction with one of the signal words indicates a hazard
which will or could result in death or serious injury.
Electrical hazard symbol
identifies information about protection against electrical voltage.
In conjunction with the signal word CAUTION, this symbol indicates
a hazard for the machine and its functions.
2.2 General
This manual contains general installation, operating and maintenance instructions
that must be observed to ensure safe operation of the submersible mixer and prevent
personal injury and damage to property.
The safety information in all sections of this manual must be complied with.
This manual must be read and completely understood by the responsible specialist
personnel/operators prior to installation and commissioning.
The contents of this manual must be available to the specialist personnel at the site
at all times.
Information attached directly to the submersible mixer must always be complied
with. This applies to, for example:
▪Arrow indicating the direction of rotation
▪Markings for connections
▪Name plate
The operator is responsible for ensuring compliance with all local regulations which
are not taken into account in this manual.
2.3 Intended use
The submersible mixer must only be operated within the operating limits described in
the other applicable documents.
▪Only operate submersible mixers which are in perfect technical condition.
▪Do not operate partially assembled submersible mixers.
!DANGER
2 Safety
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▪Only use the submersible mixer in the fluid described in the data sheet or
product literature.
▪Never operate the submersible mixer without fluid.
▪Observe the minimum fluid levels indicated in the data sheet or product
literature (to prevent overheating, bearing damage, cavitation damage, etc.).
▪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.
The responsibilities, competence and supervision of all personnel involved in
installation, operation, maintenance and inspection must be clearly defined by the
operator.
Deficits in knowledge must be rectified by sufficiently trained specialist personnel
training and instructing the personnel who will carry out the respective tasks. If
required, the operator can commission the manufacturer/supplier to train the
personnel.
Training on the submersible mixer must always be supervised by technical specialist
personnel.
2.5 Consequences and risks caused by non-compliance with these operating
instructions
▪Non-compliance with these operating instructions will lead to forfeiture of
warranty cover and of any and all rights to claims for damages.
▪Non-compliance can, for example, have the following consequences:
–Hazards to persons due to electrical, thermal, mechanical and chemical
effects and explosions
– Failure of important product functions
– Failure of prescribed maintenance and servicing practices
– Hazard to the environment due to hazardous substances
2.6 Safety awareness
In addition to the safety information contained in this manual and the intended use,
the following safety regulations shall be complied with:
▪Accident prevention, health and safety regulations
▪Explosion protection regulations
▪Safety regulations for handling hazardous substances
▪Applicable standards and laws
2.7 Safety information for the operator/user
▪Provide the personnel with protective equipment and make sure it is used.
▪Contain leakages so as to avoid any danger to persons and the environment.
Adhere to all relevant laws.
▪Eliminate all electrical hazards. (In this respect refer to the applicable national
safety regulations and/or regulations issued by the local energy supply
companies.)
2 Safety
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▪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.
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 authorised by the manufacturer. The use of
other parts can invalidate any liability of the manufacturer for resulting damage.
▪The operator ensures that all maintenance, inspection and installation work is
performed by authorised, qualified specialist personnel who are thoroughly
familiar with the manual.
▪Carry out work on the submersible mixer during standstill only.
▪The submersible mixer must have cooled down to ambient temperature.
▪When taking the mixer out of service always adhere to the procedure described
in the manual.
▪Decontaminate submersible mixers used in fluids posing a health hazard.
▪As soon as the work is completed, re-install and/or re-activate any safety-relevant
and protective devices. Before returning the product to service, observe all
instructions on commissioning.
2.9 Unauthorised modes of operation
Never operate the submersible mixer outside the limits stated in the data sheet and
in this manual.
The warranty relating to the operating reliability and safety of the submersible mixer
supplied is only valid if the mixer is used in accordance with its intended use.
2.10 Explosion protection
Always observe the information on explosion protection given in this section when
operating the submersible mixer in potentially explosive atmospheres.
Sections of the manual marked by the Ex symbol apply to explosion-proof
submersible mixers also when temporarily operated outside of potentially explosive
atmospheres.
Only submersible mixers marked as explosion-proof and identified as such in the data
sheet must be used in potentially explosive atmospheres.
Special conditions apply to the operation of explosion-proof submersible mixers to EC
Directive 94/9/EC (ATEX).
When operating explosion-proof mixers, especially adhere to the additional
requirements marked by the Ex symbol.
The explosion-proof status of the submersible mixer is only assured if the submersible
mixer is used in accordance with its intended use.
Never operate the submersible mixer outside the limits stated in the data sheet and
on the name plate.
Prevent impermissible modes of operation at all times.
Correct monitoring of the winding temperature is imperative.
2.10.1 Repair
Special regulations apply to repair work on explosion-proof submersible mixers.
Modifications or alterations of the submersible mixer may affect explosion protection
and are only permitted after consultation with the manufacturer.
Repair work at the flameproof joints must only be performed in accordance with the
manufacturer's instructions. Repair to the values in tables 1 and 2 of EN 60079-1 is
not permitted.
!DANGER
2 Safety
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3 Transport/Temporary Storage/Disposal
3.1 Transport
DANGER
Improper transport
Danger to life from falling parts!
Damage to the submersible mixer!
▷Use the attachment point provided (lifting lug or bail) for attaching lifting
accessories.
▷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.
▷Protect the power cable against damage.
▷Maintain adequate safety distance during lifting operations.
WARNING
Submersible mixer tipping over or rolling off
Risk of personal injury!
▷Secure the submersible mixer against tipping over or rolling off.
WARNING
Temporary storage on unsecured and uneven surfaces
Personal injury and damage to property!
▷Place the submersible mixer on level firm ground only.
▷Refer to the weights given in the data sheet/on the name plate.
Transport the submersible mixer as shown.
Transport with supporting clamp Transport with supporting strap Transport with lifting bail
3.2 Storage/Preservation
If commissioning is to take place some time after delivery, we recommend that the
following measures be taken for storage:
CAUTION
Improper storage
Damage to the power cables!
▷Support the power cables at the cable entry to prevent permanent deformation.
▷Only remove the protective caps from the power cables at the time of
installation.
3 Transport/Temporary Storage/Disposal
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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.
▪Store the submersible mixer under dry and vibration-free conditions, if possible
in its original packaging.
Table 4: Ambient conditions for storage
Ambient conditions Value
Relative humidity 5 % to 85 %
(non-condensing)
Ambient temperature - 20 ℃ to + 70°C
3.3 Return to supplier
1. Always flush and clean the submersible mixer, particularly if it has been used in
noxious, explosive, hot or other hazardous fluids.
2. If the submersible mixer has been used in fluids leaving residues which might
lead to corrosion when coming into contact with atmospheric humidity, or which
might ignite when coming into contact with oxygen, the submersible mixer must
also be neutralised and treated with anhydrous inert gas for drying purposes.
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
WARNING
Fluids posing a health hazard
Hazard to persons and the environment!
▷Submersible mixers used in fluids posing a health hazard must be
decontaminated.
▷Collect and properly dispose of flushing liquid and any liquid residues.
▷Wear safety clothing and a protective mask, if required.
▷Observe all legal regulations on the disposal of harmful substances.
1. Dismantle the submersible mixer.
Collect greases and lubricating liquids during dismantling.
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.
3 Transport/Temporary Storage/Disposal
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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.
4.2 Designation
Example: Amamix C 41 3 8 / 3 8 XD G
Table 5: Key to the designation
Code Description
Amamix Type series
C Propeller material, e.g. C = stainless steel
41 Nominal propeller diameter, e.g. 410 mm
3 Number of blades
8 Code for incidence angle of propeller
3 Motor size
8 Number of motor poles
XD Motor version
G Casing material, e.g. G = grey cast iron
4.3 Name plate
TYPE
No.
Q
P2
KSB Aktiengesellschaft
67227 Frankenthal
Mat. No: 01080556 ZN 3826 - M 12
TEMP. MAX.
WARNUNG - NICHT UNTER SPANNUNG ÖFFNEN
WANING - DO NOT OPEN WHEN ENERGIZED
AVERTISSEMENT - NE PAS OUVRIR SOUS TENSION
a) b)
°C kg
H
Motor IP 68 SUBM. MAX. 30 m CLASS F
3~ M.-No.
kW VHz cos φ
min-1
AIA/INS1
TYPE
No.
Q
P2
KSB Aktiengesellschaft
67227 Frankenthal
Mat. No: 01080566 ZN 3826 - M 16
TEMP. MAX.
WARNUNG - NICHT UNTER SPANNUNG ÖFFNEN
WANING - DO NOT OPEN WHEN ENERGIZED
AVERTISSEMENT - NE PAS OUVRIR SOUS TENSION
II2G Ex dc IIB T4
°C kg
H
Motor IP 68 SUBM. MAX. 30 m CLASS F
3~ M.-No.
kW VHz cos φ
min-1
AIA/INS1
0035 II2G Ex d IIB T4 PTB 02 ATEX 1055
1
2
3
10
11
5
4
6
7
8
9
13
14
15
12
16
17
18 20
19
AMAMIX C 4138 / 38 UDG
9971511000/000310
40 91
2010
DKM 112 MTX8
2,5
710 33 / 19 6,0
0,69
400/690 50
243823
AMAMIX C 4138 / 38 UDG
9971511000/000310
40 91
2010
DKM 112 MTX8
2,5
710 33 / 19 6,0
0,69
400/690 50
243823
Fig. 1: Name plate a) for explosion-proof model, B) for non-explosionproof model
1 Designation 2 KSB order and order item number
3 Max. fluid and ambient temperature 4 Enclosure
5 Motor type 6 Rated power
7 Rated speed 8 Rated voltage
9 Rated current 10 Year of construction
11 Total weight 12 Maximum immersion depth
13 Thermal class of winding insulation 14 Motor number
15 Power factor at design point 16 Rated frequency
17 Mode of operation 18 Starting current ratio
19 Marking for explosion-proof submersible mixers 20 ATEX marking for submersible motors
4.4 Design details
Design
▪Fully floodable submersible mixer
▪Horizontal installation
4 Description
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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 for explosion-proof submersible mixers are supplied in type of protection Ex d
IIB.
4.5 Configuration and function
123
456789 10
Fig. 2: Sectional drawing
1 Housing 2 Stator
3 Cable gland 4 Propeller
5 Mechanical seal 6 Rolling element bearing
7 Shaft 8 Temperature sensor
9 Leakage sensor 10 Guide bracket (accessory)
Submersible mixer with self-cleaning propeller (4) for mixing and keeping in
suspension municipal or industrial waste water and sludges.
Driven by the motor, the propeller (4) generates thrust for mixing the fluid handled.
The motor is monitored by means of temperature sensors (8) and leakage sensors (9).
The submersible mixer shaft (7) is equipped with two bi-rotational mechanical seals
(5) in tandem arrangement. A lubricant reservoir between the two mechanical seals
ensures cooling and lubrication.
The cable gland (3) is totally watertight.
4.6 Scope of supply
Depending on the model, the following items are included in the scope of supply:
▪Submersible mixer with supporting clamp
Design
Function
Sealing
4 Description
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▪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.
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.
▪Standard accessories sets 4, 6, 7 or 22
Installation parts/installation set (separate "Installation parts/accessories"
installation manual)
▪Guide bracket for stationary installation, accessories sets 7 and 22
▪Jet ring for Amamix 300, 400, 600
▪Pitch adapter
▪Cable fixing elements for properly routing the electrical cables inside the tank
▪Forcing screw
▪Lifting bail
▪Lifting hook
▪Lifting rope
▪Other accessories on request
4.7 Dimensions and weights
For dimensions and weights please refer to the general arrangement drawing/outline
drawing and data sheet of the submersible mixer.
Accessories
4 Description
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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!
▷Never start up the submersible mixer when there are persons inside the tank.
▷Disconnect or electrically disable the submersible mixer before entering the
tank.
WARNING
Hands, other body parts, or foreign objects in the propeller or propeller intake area
Risk of personal injury! Damage to the submersible mixer!
▷Never place your hands, other body parts or foreign objects into the propeller
or propeller intake area.
5.2 Checks to be carried out prior to installation
5.2.1 Checking the operating data
Before setting up the submersible mixer, verify that the name plate data matches the
data given in the purchase order and the system data.
5.2.2 Preparing the place of installation
WARNING
Installation on foundations which are unsecured and cannot support the load
Personal injury and damage to property!
▷Make sure the foundation concrete is of sufficient strength (min. C25/30 to
DIN 1045).
▷Only place the installation set on a foundation whose concrete has set firmly.
▷Refer to the weights given in the data sheet/on the name plate.
NOTE
In biogas installations, provide the possibility for visually monitoring and, if necessary,
adjusting the operating conditions of the submersible mixer (monitoring window).
NOTE
For servicing submersible mixers in biogas installations, access openings and
appropriate means of removal (lifting gear) must be provided so that the mixer can be
removed from the filled tank at any time. For this purpose, it is important to observe the
minimum removal dimensions for the submersible mixer as specified in the general
arrangement drawing/outline drawing and in the data sheet.
5 Installation at Site
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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.
5.2.3 Checking the lubricant level
903.01
411.01
Fig. 3: Checking the lubricant
The lubricant reservoirs are filled with an environmentally-friendly, non-toxic
lubricant at the factory.
✓The propeller has been removed. (⇨ Section 7.4.2 Page 34)
1. Position the submersible mixer as shown.
2. Undo screw plug 903.01 and joint ring 411.01.
⇨The lubricant level must reach the filler opening.
3. If the lubricant level is lower, top up lubricant through the filler opening until
the lubricant reservoir overflows.
4. Fit screw plug 903.01 and joint ring 411.01 again.
5. Fit the propeller. (⇨ Section 7.5.5 Page 37)
5.3 Setting up the submersible mixer
CAUTION
Incorrect installation position of submersible mixer
Damage by excessive stresses or strains!
▷Observe the data 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.
5.4 Electrical connection
5.4.1 Information for planning the control system
For the electrical connection of the submersible mixer observe the wiring diagrams
contained in the Annex.
The submersible mixer is supplied with a power cable and is wired for DOL starting.
Star-delta starting is possible with 8-pole and 12-pole motors.
NOTE
When laying a cable between the control system and the submersible mixer's connection
point, make sure to have a sufficient number of cores for the sensors! A minimum cable
cross-section of 1.5 mm² is required.
5 Installation at Site
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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.
2. Set the overload protection device to the rated current specified on the name
plate. (⇨ Section 4.3 Page 12)
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!
▷Never allow the liquid level to drop below the submersible mixer during mixer
operation (not even for short periods).
Automatic mixer operation in a tank requires the use of level control equipment.
Observe the specified minimum fluid level. (⇨ Section 6.2.2.1 Page 24)
5.4.1.3 Frequency inverter operation
The submersible mixer is suitable for frequency inverter operation as per IEC
60034-17.
DANGER
Operation outside the permitted frequency range
Explosion hazard!
▷Never operate an explosion-proof submersible mixer outside the specified
range.
DANGER
Incorrect setting of frequency inverter current limit
Explosion hazard!
▷Set the current limit to max. 1.2 times the rated current indicated on the name
plate.
When selecting a frequency inverter, check the following details:
▪Data provided by the manufacturer
▪Electrical data of the submersible mixer, particularly the rated current
Observe the following limits when operating the submersible mixer via frequency
inverter:
▪Only utilise up to 95 % of the motor power rating P2 indicated on the name
plate. (⇨ Section 4.3 Page 12)
▪Frequency range 25-50 Hz
Frequency inverter operation produces RFI emissions whose level varies depending on
the inverter used (type, interference suppression, make). To prevent the drive system,
consisting of a submersible motor and a frequency inverter, from exceeding the limits
stipulated in EN 50081 always observe the EMC information provided by the inverter
manufacturer. If the manufacturer recommends a shielded power cable, a
submersible mixer with shielded power cable must be used.
The submersible mixers generally meet the interference immunity requirements to
EN 50082. For monitoring the sensors installed, the operator must ensure sufficient
Selection
Operation
Electromagnetic
compatibility
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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. To monitor the leakage sensor inside the motor,
it is recommended to use a special relay available from KSB.
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.
Measuring transducers are required for analysing the sensor signals supplied. Suitable
devices for 230V~ can be supplied by KSB.
NOTE
Reliable and safe operation of the submersible mixer within the scope of our warranty is
only possible if the sensor signals are properly analysed as stipulated in the manual.
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. (⇨ Section 9.3 Page 46)
The individual sensors and the limit values to be set are described in the following
sections.
5.4.1.5 Motor temperature
DANGER
Insufficient cooling
Explosion hazard!
▷Never operate an explosion-proof submersible mixer without operational
temperature monitoring equipment.
▷For explosion-proof submersible mixers, use a thermistor tripping unit with
manual reset and ATEX approval for monitoring the temperature of explosion-
proof motors in "flameproof enclosure Ex d" type of protection.
CAUTION
Insufficient cooling
Damage to the submersible mixer!
▷Never operate a submersible mixer without operational temperature
monitoring equipment.
The motor is monitored by three series-connected PTC thermistors with terminals 10
and 11. They must be connected to a thermistor tripping unit with manual reset.
Tripping must result in the submersible mixer cutting out.
For explosion-proof submersible mixers use a thermistor tripping unit which is ATEX-
approved for monitoring the temperature of explosion-proof motors in "flameproof
enclosure" Ex d type of protection.
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5.4.1.6 Leakage inside the motor
PE
K 1
9
B2
B2
a) b)
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. This electrode must be connected to an electrode relay (core marked 9).
Tripping of the electrode relay must result in the submersible mixer cutting out.
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)
5.4.1.7 Leakage at the mechanical seal (optional)
K 1
9
PE
B2
B4
a) b)
B4 B2
Fig. 5: a) Wiring of the electrode relay and b) Position of the leakage sensor
Mixers with (optional) monitoring of mechanical seal leakage are fitted with an
electrode in the oil chamber in addition to the electrode (B2) monitoring leakage
inside the motor. Both electrodes are connected in parallel and must be monitored
by a single electrode relay.
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)
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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.
▷Observe regulations IEC 30364 (DIN VDE 0100) and, for explosion-proof models,
IEC 60079 (DIN VDE 0164).
WARNING
Incorrect connection to the mains
Damage to the mains network, short circuit!
▷Observe the technical specifications of the local energy supply companies.
CAUTION
Improper routing of power cable
Damage to the power cable!
▷Never move the power cable at temperatures below - 25 °C.
▷Never kink or crush the power cable.
▷Never suspend the submersible mixer by its power cable.
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.
For electrical connection observe the wiring diagrams (⇨ Section 9.3 Page 46) and
the information for planning the control system .
The submersible mixer is supplied with a power cable. Always connect all marked
cores.
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.
DANGER
Incorrect wiring
Explosion hazard!
▷The connection point of the cable ends must be located outside the potentially
explosive atmosphere or inside electrical equipment approved to equipment
category II2G.
CAUTION
Flow-induced motion and layers of floating sludge in biogas installations
Damage to the power cable!
▷Run the power cable upwards with as little slack as possible and protect, if
necessary.
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