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GB 0416-C

ABS submersible aerator TA 152 to TA/TAK 2400

1 59

7 04

16 G

B 0

7.20

09

Installation and Operating Instructions

2 Installation and Operating InstructionsInstallation and Operating Instructions

TA 152 to TA/TAK 2400

GB 0416-CABS reserves the right to alter specifcations due to technical developments !

Installation and Operating Instructions

for submersible aeratorTA 152 (50/60 Hz) TA 901 (50/60 Hz) TA 2400 (50/60 Hz)

TA 302 (50/60 Hz) TA 1200 (50/60 Hz)

TA 602 (50/60 Hz) TA 1800 (50/60 Hz)

TAK 602 (50/60 Hz) TAK 1800 (50/60 Hz)

TAK 901 (50/60 Hz) TAK 2400 (50/60 Hz)

TAK 1200 (50/60 Hz)

Installation and Operating Instructions 3

TA 152 to TA/TAK 2400TA 152 to TA/TAK 2400TA 152 to TA/TAK 2400

GB 0416-C

Table of contents

1 General................................................................................................................................................... 6

1.1 Introduction ............................................................................................................................................. 6

1.2 Correct usage of the products................................................................................................................. 6

1.3 Application restrictions of the submersible aerators................................................................................ 6

1.4 Application areas for the submersible aerators ...................................................................................... 7

................................................................................................................................ 7

1.6 Technical data ......................................................................................................................................... 7

1.6.1 Technical data 400 V/50 Hz .................................................................................................................... 8

1.6.2 Technical data 460 V/60 Hz .................................................................................................................... 8

1.7 Dimensions ............................................................................................................................................. 9

1.8 Nameplate............................................................................................................................................. 10

2 Safety ................................................................................................................................................... 11

3 Transport and storage ........................................................................................................................ 11

3.1 Transport ............................................................................................................................................... 11

3.2 Transport securing devices ................................................................................................................... 11

3.2.1 Motor connection cable moisture protection ......................................................................................... 11

3.3 Storage of the units ............................................................................................................................... 12

4 Product description ............................................................................................................................ 13

4.1 Structural design ................................................................................................................................... 13

4.2 Motor monitoring system....................................................................................................................... 14

4.2.1 Temperature monitoring of the stator .................................................................................................... 14

4.2.2 DI-Electrode .......................................................................................................................................... 14

4.2.3 Temperature monitoring of the bearings (Option) ................................................................................. 14

4.2.4 Temperature indication.......................................................................................................................... 15

4.3 Operation with frequency inverters ....................................................................................................... 16

5 Installation ........................................................................................................................................... 17

5.1 Installation examples............................................................................................................................. 17

5.2 Installation of the ABS submersible aerator .......................................................................................... 18

5.2.1 Assembly of the channel extensions of the TAK range......................................................................... 18

5.3 Accessories........................................................................................................................................... 19

5.3.1 Hinged foot............................................................................................................................................ 19

5.3.2 Air pipe .................................................................................................................................................. 19

5.3.3 Silencer and weather cap...................................................................................................................... 20

5.3.4 Lifting rope/Hook eyelet ........................................................................................................................ 20

5.4 Tightening torque .................................................................................................................................. 22

5.5 Electrical connection .......................................................................................................................... 23

5.5.1 Standard connection diagrams, mains voltage 380 - 420 V at 50 Hz/460 V at 60 Hz .......................... 23

5.5.2 Lead designations ................................................................................................................................ 25

4 Installation and Operating Instructions


GB 0416-C

5.5.3 Checking direction of rotation................................................................................................................ 25

5.5.4 Changing direction of rotation .............................................................................................................. 26

5.5.5 Connection of the control circuit leads .................................................................................................. 26

5.5.6 Connection of the seal monitoring unit to the control panel .................................................................. 26

6 Commissioning ................................................................................................................................... 28

6.1 Starting frequency of the motors ........................................................................................................... 28

7 Maintenance ........................................................................................................................................ 29

7.1 General maintenance hints ................................................................................................................... 29

7.2 Maintenance hints if the submersible aerator is out of use for a considerable period ......................... 29

7.2.1 Before installation.................................................................................................................................. 29

7.2.2 After installation..................................................................................................................................... 29

......................................................................................................................................... 29

7.4 Removal of the submersible aerator .................................................................................................... 30


TA 152 to TA/TAK 2400TA 152 to TA/TAK 2400TA 152 to TA/TAK 2400

GB 0416-C



GB 0416-C

1 General

1.1 IntroductionThese Installation and Operating Instructions and the separate booklet Safety Hints contain basic instructions and safety hints which must be observed during transport, installation and commissioning. For this reason it is essential that they are read by the installing technician as well as by relevant skilled operators or users. They should also be always available where the unit is installed.

m highlighted with the general danger symbol.

cg This symbol indicates the danger of an explosion occurring.

ATTENTION Appears at safety hints, the non-observance of which could damage the unit or affect its functioning.

NOTE Used for important pieces of information.

1.2 Correct usage of the productsThe ABS products have been designed and built in accordance with the latest technology and taking into account the relevant safety regulations. However improper usage could cause a danger to life or limb of the user of a third party or cause damage or function impairment to the unit itself and other items of value.

The ABS units should only be used if they are in perfect technical condition taking into account all safety requirements and conscious of the need to avoid potentially dangers. The contents of the installation and operating instructions and the safety hints must be applied! Any other usage (abnormal usage) or usage

The manufacturer/supplier will not accept any responsibility for damage due to this. The risk is borne by the user. In case of doubt the entire scope of the planned application must be approved by ABS.

In the case of any faults arising, the ABS units should immediately be taken out of use and secured. The fault

1.3 Application restrictions of the submersible aeratorsThe submersible aerators are available in the standard version for 50 Hz and 60 Hz.

Limitations: Fluid temperature maximum 40 °C (104 °F)

Immersion depth is depending on the motor power, see chapter 1.6 technical data

g zones!



GB 0416-C

1.4 Application areas for the submersible aeratorsABS submersible aerators are generally used to transfer air from the environment into clean and wastewater and sewage.

Supplied with motors of the ME-series and in SX version the aerators can be applied as well in industrial applications.

Series (TAK = TA with channel extension)

Range

Material of the hydraulic partsAR = 1.4301 (wear parts without hard-chrom plating)CR = 1.4301 (wear parts hard-chrom plated)HR = 1.4571 (wear parts hard-chrom plated)

GX = 1.4581 (wear parts without hard-chrom plating)CX = 1.4581 (wear parts hard-chrom plated)

Motor

Number of poles in motor

Motor power [P2 x 10 in kW]

Motor designation (e.g. ME)

AAA BB CC UU VVV / W-XY.ZHydraulics

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X: Part of the manufacturing code for the motor size X gives the motor size

Y: Part of the manufacturing code for the motor size Y indicates the stator length. Selection here is between a motor frame size and number of poles 1 to n.

Z: Information on the motor, (frequency 60 Hz, SX = Motor in stainless steel).

NOTE The SX versions have an identical design to the motors of the ME-series. They only differ in the materials used and are also only available in a cooling jacket version.

1.6 Technical dataThe electrical data of the ABS submersible aerators TA/TAK depend on the operating point for which they have been designed. Independent from the operating point the following table contains the technical data of the motor.

The maximum noise level of all submersible aerators of the TA/TAK series under operating conditions i.e. in fully submerged position is always < 70db(A) (at 10 m/33 ft distance). The use of an ABS silencer will reduce the noise level to 55 db(A) at 10 m/33 ft distance.



GB 0416-C

1.6.1 Technical data 400 V/50 Hz

Hydraulics Motor

Type of start Rated motorpower* Rated current

(Mains voltage380 - 420 V)

[A]

Immersiondepth max.

[m]

Weight

Star/Delta

Direct P1

[kW]P2

[kW]TA

[kg]TAK[kg]

TA 152 M 30/4 3.95 3.0 7.0 3.0 80 -TA 152 M 40/4 5.00 4.0 8.9 5.0 95 -TA 302 M 60/4 7.22 6.0 12.5 4.0 120 -TA 302 M 90/4 10.08 9.0 19.4 6.0 130 -

TA/TAK 602 ME 110/4 12.4 11.0 23.2 4.0 225 295TA/TAK 602 ME 160/4 17.9 16.0 30.4 7.0 245 315TA/TAK 901 ME 185/4 20.2 18.5 33.3 4.5 415 475TA/TAK 901 ME 220/4 24.2 22.0 39.8 8.0 415 475TA/TAK 1200 ME 220/4 24.2 22.0 39.8 3.0 470 545TA/TAK 1200 ME 300/4 32.8 30.0 55.2 6.5 500 575TA/TAK 1200 ME 370/4 39.9 37.0 69.2 8.5 515 590TA/TAK 1800 ME 370/4 39.9 37.0 69.2 4.0 510 590TA/TAK 1800 ME 450/4 48.3 45.0 80.0 6.0 530 610TA/TAK 1800 ME 550/4 58.9 55.0 94.4 9.0 765 845TA/TAK 2400 ME 550/4 58.9 55.0 94.4 4.0 795 870

TA/TAK 2400 ME 750/4 81.0 75.0 128.0 7.5 915 990

*P1 = Power taken from mains; P2 = power at motor shaft, 10 m/33 ft cable with free cable ends are supplied as standard.

1.6.2 Technical data 460 V/60 Hz

Hydraulics Motor

Type of start Rated motorpower*

Rated current

[A]

Immersiondepth max.

[m]

Weight

Star/Delta

Direct P1

[kW]

P2

[kW]

TA

[kg]

TAK

[kg]

TA 152 M 46/4 5.58 4.6 8.6 2.5 95 -TA 152 M 75/4 8.9 7.5 13.1 5.0 105 -TA 302 M 90/4 11.2 9.0 16.0 4.5 120 -TA 302 ME 130/4 15.2 13.0 23.2 7.5 220 -

TA/TAK 602 ME 130/4 15.2 13.0 23.2 2.5 225 295TA/TAK 602 ME 185/4 21.1 18.5 29.4 4.5 245 315TA/TAK 602 ME 210/4 24.2 21.0 33.7 8.0 265 335TA/TAK 901 ME 210/4 23.9 21.0 35.4 2.5 415 475TA/TAK 901 ME 250/4 27.3 25.0 38.8 4.0 415 475TA/TAK 901 ME 350/4 37.8 35.0 54.7 8.0 445 505TA/TAK 1200 ME 350/4 37.8 35.0 54.7 4.5 500 575TA/TAK 1200 ME 430/4 46.6 43.0 68.7 6.0 515 590TA/TAK 1200 ME 520/4 55.5 52.0 80.7 8.0 535 610TA/TAK 1800 ME 520/4 55.5 52.0 80.7 4.0 530 610TA/TAK 1800 ME 630/4 67.4 63.0 96.1 8.0 765 845TA/TAK 2400 ME 630/4 67.4 63.0 96.1 4.5 795 870TA/TAK 2400 ME 860/4 91.9 86.0 128.0 7.5 915 990

*P1 = Power taken from mains; P2 = power at motor shaft, 10 m/33 ft cable with free cable ends are supplied as standard.



GB 0416-C

1.7 Dimensions

D*

F

E1

Ø E2

GH

Ø C

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*Flanges according to DIN 2633, PN 16

Type of aerator Ø C D Ø E1 (TA) Ø E2 (TAK) F G H

50H

z

TA 152 M 30/4 485 DN 80 581 - 169 242 629TA 152 M 40/4 485 DN 80 581 - 169 242 695TA 302 M 60/4 670 DN 80 790 - 178 347 687TA 302 M 90/4 670 DN 80 790 - 178 347 735TA/TAK 602 ME 110/4 714 DN 100 862 3533 180 397 981TA/TAK 602 ME 160/4 714 DN 100 862 3533 180 397 981TA/TAK 901 ME 185/4 840 DN 125 1065 3845 250 510 1399TA/TAK 901 ME 220/4 840 DN 125 1065 3845 250 510 1399TA/TAK 1200 ME 220/4 950 DN 150 1215 3930 245 595 1405TA/TAK 1200 ME 300/4 950 DN 150 1215 3930 245 595 1405TA/TAK 1200 ME 370/4 950 DN 150 1215 3930 245 595 1405TA/TAK 1800 ME 370/4 950 DN 150 1215 4135 245 595 1396TA/TAK 1800 ME 450/4 950 DN 150 1215 4135 245 595 1396TA/TAK 1800 ME 550/4 950 DN 150 1215 4135 245 595 1617TA/TAK 2400 ME 550/4 1050 DN 150 1345 4025 270 650 1625TA/TAK 2400 ME 750/4 1050 DN 150 1345 4025 270 650 1825

60H

z

TA 152 M 46/4 485 DN 80 581 - 169 242 695TA 152 M 75/4 485 DN 80 581 - 169 242 740TA 302 M 90/4 670 DN 80 790 - 178 347 687TA 302 ME 130/4 670 DN 80 790 - 180 347 1166TA/TAK 602 ME 130/4 714 DN 100 862 3533 180 397 1166TA/TAK 602 ME 185/4 714 DN 100 862 3533 180 397 1166TA/TAK 602 ME 210/4 714 DN 100 862 3533 180 397 1166TA/TAK 901 ME 210/4 840 DN 125 1065 3845 250 510 1399TA/TAK 901 ME 250/4 840 DN 125 1065 3845 250 510 1399TA/TAK 901 ME 350/4 840 DN 125 1065 3845 250 510 1399TA/TAK 1200 ME 350/4 950 DN 150 1215 3930 245 595 1405TA/TAK 1200 ME 430/4 950 DN 150 1215 3930 245 595 1405TA/TAK 1200 ME 520/4 950 DN 150 1215 3930 245 595 1405TA/TAK 1800 ME 520/4 950 DN 150 1215 4135 245 595 1396TA/TAK 1800 ME 630/4 950 DN 150 1215 4135 245 595 1617TA/TAK 2400 ME 630/4 1050 DN 150 1345 4025 270 650 1625TA/TAK 2400 ME 860/4 1050 DN 150 1345 4025 270 650 1825



GB 0416-C

1.8 NameplateWe recommend that you record the data from the original nameplate Figure 3 so that you can refer to the data at any time.

1

23 4

56

7

8 9 10 11

12 13 151416 17

18 19 202122

23 24 25

26 27

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Figure 5 Nameplate 42242500

Legend

9 Nominal current 23 Sound level

11 Nema Code Letter (only at 60 Hz, e.g. H) 25 Insulation class

NOTE In all communication please state type of the unit, item and serial number!



GB 0416-C

2 SafetySafety Hints. If

anything is not clear or you have any questions as to safety make certain to contact the manufacturer ABS.

3 Transport and storage

3.1 Transport

c The unit must never be raised by the power cable.

The submersible aerator is packed at the works for vertical transport.

a hoist. These connection points are dimensioned to support the aerator and accessories. If two connecting points are provided then both must be simultaneously connected to the lifting rope or chain.

m Take note of the entire weight of the unit incl. accessories. The hoist and chain must be adequately dimensioned for the weight of the unit and must comply with the current valid safety regulations.

m The unit should be protected from rolling over!

m The unit is prepared for transportation by placing it on an adequately strong, completely horizontal surface taking care that it cannot topple over.

m Do not stay or work in the swivel area of a suspended load!

m The lifting hook height must take into consideration the entire height of the unit as well as the length of the lifting chain!

3.2 Transport securing devices

3.2.1 Motor connection cable moisture protection

The motor connection cables are protected against the ingress of moisture along the cable by having the ends sealed at the works with protective covers.

ATTENTION These protective covers should only be removed immediately prior to connecting the units electrically.

prior to laying and connection of the power cable of the motor. Please note that the cable ends, even where

ATTENTION These protective covers only provide protection against water spray or similar and are not a water tight seal. The ends of the cables should not be immersed in water, otherwise moisture could enter the connection chamber of the motor.

NOTE If there is a possibility of water ingress then the cables should be secured so that the

ATTENTION Take care not to damage the cable or its insulation when doing this!



GB 0416-C

3.3 Storage of the units

direct sunlight, high humidity, aggressive dust emissions, mechanical damage, frost etc. The ABS original packaging with the relevant transport securing devices (where used) ensures optimum protection of the unit. If the units are exposed to temperatures under 0 °C/32 °F check that there is no water in the hydraulics, cooling system, or other spaces. In the case of heavy frosts, the units and cable should not be moved if possible. When storing under extreme conditions, e.g. in tropical or desert conditions suitable additional protective steps should be taken. We would be glad to advise you further

NOTE ABS units do not generally require any particular maintenance during storage. By rotating the shaft several times by hand, new lubricating oil or, depending on the version, a small amount of coolant (which also serves to cool or lubricate the mechanical seals) is applied to the sealing surfaces, thus ensuring perfect operation of the mechanical seals. The bearings supporting the motor shaft are maintenance-free.

In the case of extreme ambient temperatures below -20 °C/-4 °F (during transportation, storage or longer out of service periods), the coolant must be drained to prevent damage to the unit! In such cases, please contact your ABS dealer.



GB 0416-C

4 Product description

4.1 Structural design

20

4

19

22

21

17

13

14

16

15

18

5

6

2

1

3

7

8

9

10

11

12

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Legend1 Power and control cable with water tight cable inlet 12 Motor support and/or motor cams 2 Lifting hoop 13 Bushing3 Motor connection chamber 14 Channel ring4 Cable inlet 15 Flange air pipe5 Upper bearing of motor shaft 16 Hydraulic stator

7 Motor shaft with rotor 18 Seal monitor connection chamber (option)8 Lower bearing of motor shaft 19 Temperatur monitoring lower bearing (option)9 Seal monitor control chamber 20 Temperatur monitoring upper bearing (option)

10 Impeller 21 Mechanical seal (medium side)11 Collar disc 22 Mechanical seal (motor side)



GB 0416-C

4.2 Motor monitoring system

4.2.1 Temperature monitoring of the stator

Thermal limiters protect the stator from overheating in the case of asymmetric phase loading or voltage, continuous dry running or excessive temperatures in the medium itself.

The stator is equipped with three bimetallic thermal limiters which are connected in series.

4.2.2 DI-Electrode

The DI-electrodes carry out the seal monitoring function and signal the ingress of moisture into the motor by means of a special electronic device. (Option for Motor and connection chamber)

ATTENTION Thermistors or PT 100 devices must never be directly connected into the control or power system. They must always be connected to a suitable evaluation device.

Class F = 140° C/284° F. The temperature limiting switches may only be operated as

Operating voltage ...AC/...DC ...500 V ~/...101 V=

Rated voltage AC 250 V

Rated current 2.5 A

Rated current 1.6 A

max. switching current at IN 5.0 A

4.2.3 Temperature monitoring of the bearings (Option)

If bearing temperature monitoring is supplied, the standard versions of the pump possess a bimetallic thermal

motor to take place in plenty of time, e.g. where excessive bearing temperature due to wear occurs.

Switching temperature of motors of insulation class F :

Upper bearing = 140 °C/284 °F

lower bearing = 120 °C/248 °F

As an alternative temperature dependent resistors (thermistors,/PTC) with non-linear characteristics or PT 100

••



GB 0416-C

4.2.4 Temperature indication

A continuous indication of the temperature in the stator and the bearings is not possible using bimetallic thermal

characteristics into the stator and bearing blocks. This type of resistor has a linear characteristic, i.e. the resistance rise is proportional to the temperature rise.

Resistance

Temperature

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Function Temperature switch using the bimetallic principle, which opens at a rated temperature

Switching Taking care not to exceed the allowable switching current,

the control circuit

Resistance

Temperature

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Function Temperature dependent resistance (no switch) curve with stepwise behaviour

Switching Cannot be installed direct into the control circuit. Evaluation of the signal must be carried out by suitable electronic equipment

Resistance

Temperature

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Function Function temperature dependent resistance (no switch). The linear curve allows continuous measurement and indication of the temperature

Switching Cannot be installed direct into the control circuit. Evaluation of the signal must be carried out by suitable electronic equipment



GB 0416-C

4.3 Operation with frequency invertersThe stator design and the insulation grade of the motors from ABS means that they suitable for usage with fre-quency inverters. It is however essential that the following conditions are met when the motors are used with frequency inverters:

The guidelines for EMC (electromagnetic compatibility) are complied with.

The lowest frequency must be set so that an aeration still is ensured.

The maximum frequency must be set so the rated power of the motor is not exceeded.

wave. This means that motors losses and motor noise is reduced. Unfortunately these inverter output signals cause higher voltage spikes in the stator. Experience has shown that, depending on rated voltage and the length of the cable between the inverter and the motor, these voltage spikes can adversely affect the life of the

(see Figure 8)wave frequency, rated current of the inverter and maximum inverter output frequency.

critical area

non critical area

L = total length (from frequency inverter to motor)

10 50 100 150 L[m]

UN[V]

660

600

460

400380

230

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•••



GB 0416-C

5 Installation

m The safety hints in the previous sections must be observed!

5.1 Installation examples

1

2

7

8

6

4

3

5

5 304

16-0

003

Legend1 Hook eyelet 5 Electric cable2 Silencer 6 ABS submersible aerator3 Back-up wiring rope 7 Wiring rope4 Cable supporter 8 Air pipe



GB 0416-C

1

2

3

4

5

6

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Legend1 Silencer 4 Air pipe2 Cable junction box 5 Electric cable3 Floating raft 6 ABS submersible aerator

5.2 Installation of the ABS submersible aeratorThe submersible aerators of the TA series have been checked at the factory and are supplied fully assembled. In addition to that the separat cannel extensions of the TAK range have to be assembled at the user’s site.

tank. The submersible aerator is brought to the installation or operating position with the aid of a suitable hoist.

NOTE When installing the submersible aerator of the TA/TAK series in the tank the ABS recommendations as to positioning of the unit should be observed!

5.2.1 Assembly of the channel extensions of the TAK range

hex nuts.



GB 0416-C

1 2 3 0416

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3 Legend1 Washer2 Hex nut (to be secured with LOCTITE type 243)3 Channel extension

ATTENTION Observe the tightening torques for stainless steel screws (see chapter 5.4)!

5.3 Accessories

HINT The accessories described below are not supplied as part of the standard execution and must be separately ordered.

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Figure 14 Silencer Figure 15 Weather cap

5.3.1 Hinged foot

ABS submersible aerators with hinged feet (see Figure 12)with a swivel joint. The hinged feet are connected to the aerator by means of threaded rod, which is adjustable in height.

5.3.2 Air pipe

an air pipe (see Figure 13)over the surface even at the highest liquid level.



GB 0416-C

symmetrically arranged screws. The screw strength is up to DN 125 inclusive at M16. Beyond that M20 screws are used.

The screws should be inserted so that the nut points downwards when the pipe is in the installed position. Make certain to use washers under the nut. Screws of quality A2-70 (AISI 304) or better should be used. The screws should be tightened with the correct torque.


5.3.3 Silencer and weather cap

proof cap (see Figure 15)

If at the same time the suction noise of the submersible aerator is to reduced, then an adequately dimensioned

cap (see Figure 14).

5.3.4 Lifting rope/Hook eyelet

All lifting elements must be adequately dimensioned for the application with particular reference to the effects of fatigue or wear.

All lifting elements must be of stainless steel of quality 1.4301 (AISI 304) or better.

1

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GB 0416-C

A wire rope is placed between the crane hook eyelet and the upper location points on the top of the motor. The material and dimensions of the wire rope should be such that a safety factor of 5 times the required strength is ensured. In addition the rope should exhibit no fraying or twists.

the required number wire rope clamps (4 pcs.) at a suitable distance apart, which is at least twice the wire rope

immediately adjacent to the thimble. The semi-circular portion of the cable clamp must be at the untensioned section of the wire rope.


Motor with lifting hoop Motor with lifting eylet

Ø d

min. 2 x d

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Rope Ø d Ø 8 Ø 10

Motor 50 Hz/60 Hz TA 152 TA 302 TA 602 TA/TAK 901 TA/TAK 1200

TA/TAK 1800

TA/TAK 2400

available, is the air pipe itself. This could be the case in open tanks (without a load carrying bridge). In this case the submersible aerator is generally placed in position with the aid of a mobile crane.

location for the hook of the mobile crane and as a connecting point for the lifting wire rope which is later to be



GB 0416-C

The crane hook eyelet consists of a 2-piece pipe clamp, a swivel joint and an oval eyelet. The pipe clamp

capable of swinging upwards when the air pipe is installed in a vertical manner. The crane hook eyelet must be

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clamps

5.4 Tightening torque

® securing washers is correct as in Figure 19 and table for tightening torque!

Outer side of the 2 securing washers

Inner side of the 2 securing washers

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Tightening torque for ABS stainless steel screws A4-70:

Thread M6 M8 M10 M12 M16 M20 M24

Tightening torque 6.9 Nm 17 Nm 33 Nm 56 Nm 136 Nm 267 Nm 460 Nm

DN 80 DN 100 DN 125 DN 150Tightening torque in Nm 40 45 50 60



GB 0416-C

5.5 Electrical connection


Before commissioning an expert should check that one of the necessary electrical protective devices is available. Earthing, neutral, earth leakage circuit breakers, etc. must comply with the regulations of the local

with regard to cross-sectional area and maximum voltage drop. The voltage stated on the nameplate of the pump must correspond to that of the mains.

c The incoming power supply as well as the connection of the pump itself to the terminals on the control panel must comply with the circuit diagram of the control panel as well as the motor connection

The power supply cable must be protected by an adequately dimensioned slow-blow fuse corresponding to the rated power of the pump.

ATTTENTION The unit should only be operated with the overload relay and thermal sensors/limiters connected.

5.5.1 Standard connection diagrams, mains voltage 380 - 420 V at 50 Hz/460 V at 60 Hz

M3 ~

PE

F1

DI

W2

V2

W1

V1

U2 U1

F0

W1

U1

V1

0551

-003

1

50 HzM 30/4

M3 ~

PE

F1

DI

W2

V2

W1

V1

U2 U1

F0

V2

U2

W2

W1

U1

V1

0551

-003

2

50 Hz 60 HzM 40/4 M 46/4M 60/4 M 75/4M 90/4 M 90/4ME 110/4 ME 130/4



GB 0416-C

M3 ~

Cable 2

Cable 1

W2

U2

V2

W1

V1

U1

F0

F1

U2

V2

W2

W1

PE

V1

U1

Di

Di

PE

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0

50 Hz 60 HzME 160/4-32 ME 185/4ME 185/4-41 ME 210/4ME 220/4-41 ME 250/4

M3 ~W2 W1

V2

U2

V1

U1

Cable 2

Cable 1

W2

V2

U2

PE

V1

W1

U1

PE

F1

Di

F0

Cable 3

PE

0562

-003

1

50 Hz 60 HzME 185/4-41 ME 210/4ME 220/4-41 ME 250/4ME 300/4-42 ME 350/4-42ME 370/4-43 ME 430/4-43ME 450/4-44 ME 520/4-44ME 550/4-51 ME 630/4-51ME 750/4-52 ME 860/4-52

M3 ~W2 W1

V2

U2

V1

U1

Cable 2

Cable 1

W2

V2

U2

PE

V1

W1

U1

PE

DI connection chamber20

(X) cable core marking control cable

2221 DI motor chamber

DI oil chamber

switc

h of

f

13

12

11

10

PE

winding

switc

h of

f 41

lower bearing

upper bearing

45

43

44

42

Cable 3

40

tem

pera

ture

mea

sure

men

t

31

37

35

36

34

PTC PT10030

X 0562

-003

2

ATTENTION The cable leads are routed out of the motor. No switching takes place in the motor! Any switching required (use of bridges) must be carried out in the control panel.

NOTE Information on the type of starting can be obtained from the nameplate of the aerator.



GB 0416-C

5.5.2 Lead designations

Direct starting in star1 U1

46

3 2

5U2

W2 V2

W1 V1

0562

-003

3

L1 L2 L3 JoinNorth America 1 2 3 4 & 5 & 6

ABS/Germany U1 V1 W1 U2 & V2 & W2

Direct starting in delta1U1

4

6

325

U2

W2

V2

W1

V1

0562

-003

4

L1 L2 L3 -North America 1; 6 2; 4 3; 5 -

ABS/Germany U1; W2 V1; U2 W1; V2 -

5.5.3 Checking direction of rotation


m When checking the direction of rotation, the unit should be secured in such a manner that no danger

the hydraulic system!

cm When carrying out the direction of rotation check as well as when starting the unit pay attention to the

START REACTION. This can be very powerful.

STAR

TR

EA

CTI

ON RO

TOR

RE

AC

TION

0562

-003

5 ATTENTIONThe start reaction is

anti clockwise

NOTE If a number of aerators are connected to a single control panel then each unit must be individually checked.

ATTENTION The mains supply to the control panel should have a clockwise rotation. If the leads are connected in accordance with the circuit diagram and lead designations, the direction of rotation will be correct.

ATTENTIONThe direction of rotation is correct

if the imeller/propeller rotates in a clockwise manner when viewing

down from the top of the placed unit

ATTENTIONThe direction of rotation is correct

if the imeller/propeller rotates in a clockwise manner when viewing

down from the top of the placed unit



GB 0416-C

5.5.4 Changing direction of rotation


cIf the direction of rotation is incorrect then this is altered by changing over two phases of the power supply cable in the control panel. The direction of rotation should then be rechecked.

NOTE The direction of rotation measuring device monitors the direction of rotation of the mains supply or that of an emergency generator.

5.5.5 Connection of the control circuit leads


4224

0220

DI Öl- / ÜberwachungsraumDI Oil- / Separation chamber

DI Motorraum / Motor chamberDI Anschlußraum / Connection chamber

Lower bearingLager unten /

Upper bearing

WindingWicklung /

Lager oben /

Abs

chal

ten

/ Sw

itch

off

2122

20

13

11

12

10

PE

Type:

No:

Adern Kennzeichnung SteuerkabelCable core marking control cable

PTC

Abs

chal

ten

/ Sw

itch

off

43

4445

(X)

42

4140

Tem

pera

turm

essu

ng/

Tem

pera

t. m

easu

rem

ent

35

Oil chamberEx-DI Ölraum /

3736

34

31

PT10030

10K-10K- 22/2

22/1

Motorüberwachung / Motor monitoring

X05

62-0

036 Control circuit leads for

submersible aerators

10 = Common lead11 = Stator upper12 = Bearing upper13 = Bearing lower20 = DI-connection chamber21 = DI-Motor chamber22 = DI-Oil chamber

= PE (green/yellow)

NOTE The available connections can be obtained from the relevant connection diagram.

5.5.6 Connection of the seal monitoring unit to the control panel

The submersible aerators are supplied as standard with DI-probes for seal monitoring. In order to integrate this

this in accordance with the circuit diagrams below.

service. Please contact your ABS service centre.



GB 0416-C

X1

X2

Ele

ctro

de3

(DI)

PE

M2+

M1-

Bul

p 24

V 2

-5 W

MAINS 0562

-003

7

Ele

ctro

de3

(DI)

PE

6124

009

M2+

M1-

MAINS

1-8

15/18

10

11 9 13 12

14

0562

-003

8

Ele

ctro

de3

(DI)

PE

6124

007

6124

008

M2+

M1-

MAINS

6

15 11 10

7 8 9

Pum

p2

Pum

p3

0562

-003

9

110 V (Art.-Nr./Part No.: 6 124 0113) 115 V (Art.-Nr./Part No.: 6 124 0170)230 V (Art.-Nr./Part No.: 6 124 0114) 230 V (Art.-Nr./Part No.: 6 124 0171)400 V (Art.-Nr./Part No.: 6 124 0115) 460 V (Art.-Nr./Part No.: 6 124 0172)440 V (Art.-Nr./Part No.: 6 124 0116) 575 V (Art.-Nr./Part No.: 6 124 0173)

ATTENTION Maximum relay contact loading: 2 Ampere.



GB 0416-C

6 Commissioning


Before commissioning the aerator/plant should be checked and a functional test carried out. Particular attention should be paid to the following:

ATTENTION When starting or during every kind of operation it must be ensured that the unit is

Has the electrical connection been made in accordance with current regulations?

Have the thermal limiters/sensors been connected?

Is the motor protection switch correctly set?

Have the power supply cables been correctly installed?

Has the tank/basin been cleaned?

Is the direction of rotation correct including when driven by an emergency generator?

Has the hydraulics been checked that there are no foreign objects in the hydraulics?

Are the screens or sand traps necessary for correct operation of the plant in functional order?

Has the air line been properly secured? (wind loads)

Are the level controls functioning correctly?

6.1 Starting frequency of the motors

the works)

Motor power maximum starts per hour at interval in minutesup to 11 kW 10 6

> 11 kW 6 10

ATTENTION The allowable starting frequency for any starting devices should be obtained from manufacturer of these devices.

••••••••••••••



GB 0416-C

7 Maintenance


7.1 General maintenance hints

c Before commencing any maintenance work the unit should be completely disconnected from the

NOTE The maintenance hints given here are not designed for “do-it-yourself” repairs as special technical knowledge is required.

HINT A maintenance contract with our maintenance department will ensure you the best technical service under all cicumstances.

Lubricated-for-life ball bearings together with monitoring devices ensure optimum aeration reliability provided that the unit has been connected and operated in accordance with the operating instructions.

Should, nevertheless, a malfunction occur, do not improvise but ask your ABS customer service department for assistance.This applies particularly if the aerator is continually switched off by the current overload in the control panel, by the thermal sensors/limiters of the thermo-control system or by the seal monitoring system (DI).

ATTENTION The lifting tools like chains and shackles should be visually checked in regular intervals (approx. every 3-month) for wear and corrosion. These parts should be replaced if required!

The ABS service organisation would be pleased to advise you on any applications you may have and to assist you in solving your aerating problems.

NOTE The ABS warranty conditions are only valid provided that any repair work has been carried out in ABS approved workshops and where original ABS spare parts have been used.

7.2 Maintenance hints if the submersible aerator is out of use for a considerable period

NOTE If the aerators have remained idle for more than 12 months then we recommend that you ask ABS or an approved distributor for advice.

7.2.1 Before installation

The covers giving moisture protection of the cables should be only removed immediately before actual installation of the unit. After the removal of the transport securing devices and before connecting up the unit electrically the motor shaft should be rotated a number of times by turning the impeller or propeller by hand.

7.2.2 After installation

If, after installation of the submersible aerator, it remains out of use for prolonged periods then we recommend that the unit be run for a maximum of 1 minute every 3 months in order to check both its functioning and availability.




GB 0416-C

ATTENTION Only coolants released by the manufacturer should be used!

AVersion with cooling jacket

B Version without cooling jacket

1

212

0562

-004

0 Legend

2 Cooling liquid emptying

Glycol Frostox WS (Partnr.: 11030083)(TYFOROP Chemie GmbH)

Alternative coolant released by ABS:Propylenglycol Code 27(Houghton Deutschland GmbH)

DOWCAL 20-G HEAT TRANSFER FLUID(Dow Deutschland GmbH & Co. OHG)DOWCAL brand of - The Dow Chemical Company

Data is only valid for coolant used ex works. (Additional product information and safety data sheet are available on request).

m When dealing with Frostox WS the general protective measures for chemicals must be observed. The information and hints in the safety data sheets covering this must be observed!

Filling volumes (in liter)Motor ME4 TA/TAK 901, 1200, 1800

50 Hz 60 Hz with cooling jacket (only SX) without cooling jacketME 220/4-41 ME 250/4-41.60 38.3 8.0ME 300/4-42 ME 350/4-42.60 38.3 8.0ME 370/4-43 ME 430/4-43.60 33.8 8.0ME 450/4-44 ME 520/4-44.60 33.3 8.0

Motor ME5 TA/TAK 1800/240050 Hz 60 Hz with cooling jacket (only SX) without cooling jacketME 550/4-51 ME 630/4-51.60 43.0 15.0ME 750/4-52 ME 860/4-52.60 55.5 15.0

Coolant: 33% Glycole and 67% water; frost resistant up to -20 °C/-4 °F

7.4 Removal of the submersible aerator


c Before removal of the unit the motor connection cables at the control panel should be completely

inadvertently switched back on.

to the aerator.

Lift the aerator out of the tank/basin using the suitable hoist.

•••



GB 0416-C

I ABS Production Lohmar GmbH I Scheiderhöher Straße 30-38, D-53797 Lohmar, Germany II Tel. +49 22 46 900 0 I Fax +49 22 46 900 200 I www.absgroup.com I

GB 0416-C

abs submersible aerator ta 152 to ta/tak 2400 - …ppptl.co.nz/pdf/tatak.pdfabs submersible aerator...

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