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Giantmix FR1, FR3, FR4, FR5, FR6 Operating instructions

1. After correct installation and attaching the support e g upper control arm remove the transport securing device OO gt Check visually for damage to the sealing membrane If the sealing membrane is damaged contact SUMA 23 Giantmix FR operating instructions summa 9 Agitation CAUTION Damage to assets on the propeller agitator Danger of floating layer formation when filling or raising the fill level and adding solid substances in case of insufficient agitation If floating layers are present gt Carefully change the fill level to prevent twisting of the agitator pipe through strain by solid floating layers gt When raising the fill level let the propeller sink into the floating layer and relax the upper control arm gt When lowering the fill level slowly lower the propeller while the machine is running until the floating layer at the agitator pipe is worked in 9 1 Requirements Requirements for error free agitation Make sure that the agitator blade is always fully immersed in the substrate when agitating Make sure that the agitator is not damaged Make sure that the transport supports and the transport securing devices are removed Make sure that the agitator is not blocked by solid substance deposits Listen for unusual sounds and vibrations during operation e g caused by insufficient lubrication loose oovee0 parts damage to the motor transmission bearings or shafts vortices etc To preve
2. gt Make sure that the lifting equipment is suited for the weight stated on the type plate gt Do not lift the agitator on the motor only use attachment points see fig 1 Notice The following applies for both variants If the pipe is longer than 4 m attach counterweight in the rear on the transmission and align the agitator horizontally Storage gt To prevent the sealing surfaces from sticking together turn the propeller every 2 months gt Store the Giantmix FR at a temperature between 15 C 4 F and 40 C 104 F fig 1 Giantmix FR s attachment points 1 Attachment points 3 Wooden wedge as transport securing device 2 Transport securing device with ring eyelet Giantmix FR operating instructions 7 Installation 10 fig 3 Propeller agitator Giantmix FR with sealing plate standard design 1 Propeller 2 Agitator rotor 3 Sealing plate 30 6 7 8 4 Sealing membrane or rubber com 9 pression seal optional 5 Electric motor 10 Oil equalizing container Spur gearing two stage Upper control arm or toothed rod with winch optional Shaft tube support bracket with hinge installa tion Scraper 12 11 fig 3 Propeller agitator Giantmix FR with slewing ring and sealing frame 1 Propeller 2 Agitator rotor 3 Sealing frame and cover plate 4 Sealing membrane 5 Electric motor 6 Oil equalizing container wo on 10 11 12 Spur gearing two stage Power take off
3. optional Slewing ring and slewing bracket Upper control arm or toothed rod with winch optional Hinge installation Scraper 13 Giantmix FR operating instructions summa 8 Assembly DANGER Mortal danger through wrong assembly gt Observe all details concerning the properties of the biogas tank wall concrete quality wall thickness etc in the operating instructions of the biogas plant manufacturer gt Make sure that the biogas tank is empty or that the substrate has settled sufficiently and that the biogas tank is ventilated DANGER Mortal danger through explosion gt Make sure that there is no explosive gas air mix during the entire installation DANGER Mortal danger through improper conduct during installation deinstallation and repair work gt Make sure that assembly work is only performed by trained or qualified personnel gt Make sure that the Giantmix FR is not turned on if it is not properly and completely installed in the biogas tank opening if persons are located in the danger zone gt Make sure that there are no persons especially children and or animals present in the vicinity of the Giantmix FR during installation deinstallation and repair work gt Make sure that the Giantmix FR is not left unsupervised during installation deinstallation and repair work gt Use personal safety equipment E g safety belt safety rope gas indicator respiratory protection safety
4. 2x gt Make core drilling with min 60 cm and max 70 cm gt When using the standard design make sure that the boring is not larger than 70 cm Insufficient distance to the tie bolts with borings larger than 70 cm Optionally SUMA supplies larger sealing plates with 120 cm x 120 cm or 143 cm x 143 cm NOTICE For installation depths larger than 150 cm SUMA offers special sealing membranes upon request NOTICE Positioning the center of the opening in the gas range is possible Optimum agitation performance in hor izontal range at approx 50 cm below normal fill level With a second joint seal sealing membrane it is possible to place the center of the opening up to max 150 cm below normal fill level Giantmix FR operating instructions Opening with new tank construction Ho MAO fig 6 Opening in the wall of the biogas tank 1 Distance center of opening normal fill 4 Width of opening level 2 Fill level 5 Center of opening 3 Height of opening gt Place the center of opening below normal fill level covering 50cm to max 100 cm membrane 1x 100 cm to max 150 cm membrane 2x gt Make opening with min 60 cm x 60 cm and max 70 cm x 70 cm gt When using the standard design make sure that the opening is not larger than 70 cm x 70 cm There is no sufficient distance to the tie bolts with openings larger than 70 cm x 70 cm Optionally SUMA supplies larger sealing plates with 120 cm x 1
5. GmbH Silcherstra e 74 D 73642 Welzheim Managing Director 060_01 10 We declare that it is our sole responsibility that Three Phase Motors with type designation to which this declaration relates is in accordance with the provision of the following directives 94 9 EC and conform with the following standards EN 60079 0 2006 EN 60079 15 2005 EN 60034 Marking The designated product is intended for installation into to another machine Operation is prohibited until the final product complies with regulation 2006 42 EC This statement does not guarantee any characteristics regarding product liability Safety instructions stated in the production records must be adhered to d AN Product Manager ATB Antriebstechnik GmbH Technology in Motion Silcherstr 74 D 74642 Welzheim A in Motion Nous attestons sous notre seule responsabilit que Moteurs a courant tri phas des types codifi e N Y 280M se r f rant cette attestation correspondent aux dispositions des directives suivantes et sont conformes aux normes suivantes Marquage LE Le produit indiqu est pr vu pour tre int gr dans une machine La mise en service n est autoris e que lorsque la conformit du produit final selon la di rective 2006 42 CE a t v rifi e Cette d claration ne constitue pas une assurance des propri t s au sens de la responsabilit produit Les consignes de
6. and maintenance DANGER Mortal danger through improper conduct during installation deinstallation maintenance and repair work gt Make sure that inspection and maintenance work is only performed by trained or qualified personnel gt Make sure that the Giant Mixer FR is not turned on if it is not properly and completely installed in the biogas tank opening if persons are located in the danger zone gt Make sure that there are no persons especially children and or animals present in the vicinity of the Giant Mixer FR during maintenance and repair work gt Make sure that the Giant Mixer FR is not left unsupervised during maintenance and repair work gt Use personal safety equipment Safety belt safety rope gas indicator respiratory protection safety shoes protective gloves etc CAUTION Damage to the propeller agitator through bad maintenance gt Make sure that the transmission contains the proper oil quantity gt Make sure that the cooling of the motor and or the surfaces of transmission and motor are always clean gt Do not clean the electric motor directly with a water jet or high pressure gt Do not clean the axial face seal with high pressure 11 1 Prior to maintenance work Prior to starting maintenance work gt To deinstall the propeller agitator lower the fill level in the biogas tank sufficiently gt Make sure that the fill level in the biogas tank is below the installation o
7. be expected e g through ice and snow gt Perform additional protective measures if required gt To determine the service intervals install operating hour counters The electric motors with a rated voltage of 400 VA 690 VY are suited for a 6 pole start star delta up to max 15 kW as well as for a 3 pole start via soft start and or frequency converter gt With a 3 pole start use the jumpers U1 W2 V1 U2 W1 V2 for a delta connection fig 10 PM A U1 VI WI TA NM Q d fig 10 Terminal strip for 3 pole connection Operation with a frequency converter is admissible if e the frequency converter is suited for use with electric motors in explosive areas OR e if the electric motor is outside of an ex zone gt Ensure this in line with EN 60204 1 and EN ISO 13850 Safety devices acc to cat 1 13 12 12 46 fig 11 Terminal strip for version with power take off protection 1 U1 8 T2 max 2 5 V 2 V1 9 PIC 3 W1 10 PTC2 4 U2 11 Contact switch 1 5 V2 12 Contact switch 2 6 W2 13 PE 7 T1 max 2 5 V DANGER Danger of explosion through escape of biogas gt Ensure the perfect state and correct installation of the screwed cable connection 22 Giantmix FR operating instructions summa Connecting the motor gt Check whether the electric data of the propeller agitator and the control coincide gt Connect the feed cable to the motor in a right rotary field The connection diagram is located
8. be performed by done 1 2 Check for impermeability of pipelines and apparatuses in the vicinity of the worksite ENEE D Extinguishing and other safety measures a Provision of fire fighting water fire Extinguisher at the worksite seier u RETTENE EAO E A ER E E EA O A E E E O AN A E E O REG O ele ege E Ul Craftsman LI Member of the company U Supervisor LI Fireman d Removal of flammable substances vapors gasses or dust deposits ENEE U UU Marking of the worksite street tracks etc a By red flag 20 m on both sides of the worksite b By signs e g ignition work on pipe bridge Ooo Barrier diversion of tank trucks blockade fOr rail Gans saccesccuctssssaconcsaccesssavsaccascsussascaactecsaccescancsassabctnstadstactuciaacensdusvadsnbsasitad hast ustadavnccutsaschsatastadsbbeaniincutsdec acaoteaa Protecting the surrounding area from welding sparks a Covering neighbouring cables pipes b Affix protective wall protect roofing keep damp if applicable C Stop work in case of railway traffic EE d Keep a minimum distance of essere M FLOM tank wagons fuel depots CLC EEN C v r or seal pipe ducts grates light and canal shafts mean ann For work in and on containers apparatuses ditches pipelines on deinstalled facility parts in tight spaces etc additional measures on UUUUUU a Drive permit near aan Nonnen dated nn b Work Permit u a aaa Nor n
9. commissioning shall be forbidden until it has been determined that the final product confirms with the provisions of directive 2006 42 EC The declaration of conformity shall expire if it is not used as intended and if there is a design modification which was not acknowledged by us as the manufacturer This declaration does not provide assurance of properties concerning product liability issues Authorised representative of SUMA R hrtechnik GmbH Sulzberg 4th January 2011 for the compilation of all the Technical documentation Ce Ges Carsten G lker Dipl Ing Engineering graduate Paul Th rw chter Dipl Ing FH Managing director Erkl rung der EG Konformitat Nr Declaration of EC Conformity No Attestation de conformit CE No Wir erkl ren in alleiniger Ver antwortung dass Drehstrommotoren mit der Typenbezeichnung N Y 100L auf die sich diese Erkl rung bezieht den Bestimmungen den folgenden Richtlinien entsprechen und mit Normen bereinstimmen folgenden Kennzeichnung x ll 3G Ex nA Il T3 od T4 EN 60079 Das bezeichnete Produkt ist zum Einbau an in eine andere Maschine bestimmt Die Inbetriebnahme ist solange untersagt bis die Konformit t des Endproduktes mit der Richtlinie 2006 42 EG festgestellt ist Diese Erkl rung ist keine Zusicherung von Eigenschaften im Sinne der Produkthaftung Die Sicherheitshinweise der Produkt dokumentation sind zu beachten ATB Antriebstechnik
10. s curit rappel es dans la documentation du produit doi vent tre respect es Welzheim 04 Januar 2010 Ersetzt Replaces KE 060_08 09 KE 060_01 10
11. 20 cm or 143 cm x 143 cm NOTICE Reduce assembly and drilling time for anchor bolt holes The additionally required steel reinforcement concrete tanks is not within the anchor bolts 90 cm x 90 cm contribute but within or outside of it NOTICE For installation depths larger than 150 cm SUMA offers special sealing membranes on request NOTICE Positioning the center of the opening in the gas range is possible Optimum agitation performance in hor izontal range at approx 50 cm below normal fill level With a second joint seal sealing membrane it is possible to place the center of the opening up to max 150 cm below normal fill level 17 Giantmix FR operating instructions summa Clearance for the cladding and the insulation material 18 10 fig 7 Installation site for the standard sealing plate dimensions stated in cm Installation site gt Keep the sections of the biogas tank wall shown in fig 7 free from cladding and or insulation material gt Reserve at least 110 cm x 110 cm in the installation opening section for the standard sealing plate Reserve larger sections accordingly for larger sealing plates gt With the variant with a 30 sealing plate and a left oriented alignment agitation clockwise reserve the position labelled 30 fig 7 gt With the variant with a 30 sealing plate and a left oriented alignment agitation counter clockwise the dimensions are mirro
12. 92 131 0 Fax 49 0 83 76 92 131 19 E mail info suma de Internet www suma de All rights reserved 2010 Original version EC Declaration of Conformity Manufacturer SUMA R hrtechnik GmbH Martinszeller Str 21 DE 87477 Sulzberg Germany Product description Giantmix FR1 FR3 FRA FR5 FR6 Product Description The Giantmix FR propeller agitators are designed for the stirring of biological liquids such as liquid manure with renewable raw materials in agricultural biogas containers The agitator pipe with agitator blades is led through an installation opening in the container wall The installation opening is sealed so that is perma nently gas tight in technical terms through the attachment panel with a sealing membrane located on the agitator frame We hereby as the exclusive responsible party declare that the Giantmix FR model SUMA propeller agitators correspond with the provisions of the following directives in the currently valid draft respectively Explosion Protection Directive 94 9 EC Machinery Directive 2006 42 EC Applied harmonised standards EN ISO 12100 1 EN 13463 1 EN 13463 8 EN 60079 14 EN ISO 12100 2 EN 13463 5 EN 60079 0 EN 60079 15 The appliances are marked with the following information gt for the mechanical components C amp x Il 2G ck IA T1 gt for the electrical components dch Il 3G Ex nA II T3 If it is adjusted installed or joined with other machines devices or components then its
13. IL Dispose of the Giantmix FR as follows gt Dispose of the Giantmix FR in line with the valid local and or national regulations gt Dispose of the transmission oil and the sealing oil in line with the valid disposal regulations The operator is responsible for disposal Notice SUMA will dispose of the machine against a fee 15 Technical data 15 1 Type plate 10 The type plate of the Giantmix FR is attached to the pipe or the slewing bracket and lists the following details Giantmix Made in Germany Martinszeller Str 21 DE 87477 Sulzberg Type O Year built O Weight kg Serial No Tel 49 8376 92131 0 amp 1126 ck IIAT1 ee E Notice CE x 11 2G ck IIAT1 For electrical details and labels concerning electric explosion protection see the type plate of the electric motor 39 Giantmix FR operating instructions 15 2 Technical data Emut Giantmix type FR1 FR3 FR4 FR5 FR6 Motor size 160L 160M 160L 160L 180L Motor design IM B35 IM B35 IM B35 IM B35 IM B35 Motor flange H 350 mm H 350 mm H 350 mm 350 mm H 350 mm Motor shaft 42x110 mm 42x110 mm 42x110 mm 42x110 mm 42x110 mm Rated power 7 5 kW 11 kW 15 kW 18 5 kW 22 kW Rated voltage 400 VA 400 VA 400 VA 400 VA 400 VA Rated speed 730 rpm 1465 rpm 1470 rpm 1475 rpm 1475 rpm Frequency 50 Hz 50 Hz 50 Hz 50 Hz 50 Hz Rated curr
14. Long axis agitators Giantmix FRI FR3 FR4 FR5 FRG for biogas plants Operating instructions Original edition Subject to technical changes Version 2011 10 Giantmix FR operating instructions Inhaltsverzeichnis User guide 1 1 Warning notices 1 2 Further symbols 1 3 Accompanying documents see enclosures 1 4 Storage Safety 2 1 Symbols on the product 2 2 Safety notices 2 3 Product liability Intended use Improper usage Delivery scope 5 1 Standard design with sealing plate 5 2 Design with slewing ring and sealing frame 5 3 Accessories optional Transport and storage Installation Assembly 8 1 Design 8 2 Check the scraper 8 3 Operating and ambient conditions 8 4 Prior to installation 8 5 Installation material and aids 8 6 Prerequisites for installation in the biogas tank wall 8 7 Make an opening in the wall of the biogas tank 8 8 Attach the tie bolts 8 9 Installation in the biogas tank wall 8 10 Connecting the electricity supply 8 11 After installation Agitation 9 1 Requirements 9 2 Rotation direction of the propeller gt a oa a A 10 10 11 11 12 13 14 14 14 15 15 15 15 16 19 19 21 23 24 24 24 Giantmix FR operating instructions 10 11 12 13 14 15 16 17 18 19 9 3 Optimum agitation 9 4 Height adjustment of the agitator 9 5 Optional drive of the agitator with power take off 9 6 Setting the r
15. MA recommends transmission oils with a quality in acc with SAE 85W 140 API GL 5 Replacing shaft seal rings To ensure impermeability gt Have the shaft seal rings replaced after at most 8 000 operating hours by technicians trained by or quali fied by SUMA Motor 1 pe Transmission 2 pcs Replace axial face seal and bearing in the bearing housing DANGER Mortal danger through improper repair work gt Exclusively have axial face seals and bearings replaced by personnel trained or qualified by SUMA 34 Giantmix FR operating instructions summa Replacing the bearing For error free operation gt Have all bearing replaced prior to reaching their rated service life Lo by personnel trained or qualified by SUMA Service life Lan Motor bearing Transmission bearing Propeller bearing in hours h FR1 20 000 h 40 000 h 80 000 h 7 5 kW 195 U min FR3 20 000 h 90 000 h 40 000 h 11 kW 390 U min FR4 20 000 h 38 000 h 24 000 h 15 kW 390 U min FR5 20 000 h 24 000 h 14 000 h 18 5 kW 390 U min FR6 20 000 h 16 000 h 8 000 h 22 kW 390 U min CAUTION Reduction in bearing life due to drive by tractor option Due to the increased speed and power of the tractor reduces the lifetime of propeller bearing especially significant gt Replace propeller bearing after about 500 1000 tractor drive hours 35 Giantmix FR operating instructions Monitoring the impermeabi
16. ansmission Agitator shaft twisted off Check pipe for bending replace agitator shaft and if necessary agitator pipe Agitator blade scrapes on scraper Check propeller for damage and replace if necessary readjust scraper Motor or transmission too hot Insufficient ventilation Ensure sufficient cooling air supply Ventilator blades on the motor defect Replace ventilator blades Wrong oil level in the transmission Drain oil and fill in required quantity Bearing defect Check transmission and or motor Surfaces very dirty Clean surfaces Motor hums Two phase run Check fuses terminal box supply cables and motor connection Motor burnt out Motor protection switch wrongly connected or adjusted Replace motor and adjust protection properly Motor wrongly connected Replace motor and connect properly Water penetration through melting snow or condensation wrong cable screw connection e g too large badly closed terminal box Replace motor and provide suitable weather protection use matching cable screw connection close terminal box correctly 29 Giantmix FR operating instructions Error Gas or liquid emerges from the sealing membrane rubber compression seal optional Possible cause Sealing membrane damaged EHE Measure Replace sealing membrane Sealing membrane not properly installed C
17. as tank opening if persons are located in the danger zone gt Make sure that there are no persons especially children and or animals present in the vicinity of the Giantmix FR during installation deinstallation and repair work gt Make sure that the Giantmix FR is not left unsupervised during installation deinstallation and repair work gt Use personal safety equipment E g safety belt safety rope gas indicator respiratory protection safety shoes protective gloves hard hats etc 13 1 Prior to disassembly Observe the following prior to deinstalling the Giantmix FR gt Prior to deinstallation lower the fill level of the biogas tank sufficiently gt Make sure that the biogas tank is ventilated For more information see Safety notices on page 6 13 2 Disassembly 38 Deinstall the Giantmix FR as follows gt Turn the Giantmix FR off gt Separate the Giantmix FR from the electricity supply Disconnect the electric connections Install the transport securing device OO Disconnect the upper control arm and or toothed rod with the winch optional from the Giantmix FR Hang on the Giantmix FR see fig 1 on page 12 Detach the sealing plate of the Giantmix FR from the biogas tank wall Lift the Giantmix FR out with suitable lifting equipment Close the opening gas tight by screwing on the dummy cover accessory OO OO Giantmix FR operating instructions 14 Disposal Emut O
18. ase dated u aaa c Securing permit for electric operating materials None dated u ae UUUU a Prior tothe start of work report daily to B 1 2 3 eeh bh At theend of work report dally to B 12 3 4 ee UU a Ticked safety measures checked by name ee b Inspection of the worksite after termination of the work by name D Agreement with the responsibilities for the danger area Start of work reported OME vicssaccercssecsessnsscecsscorsins BALE acssacacceancasiegetassduccqsancetuvegetadatacaasecaegcnsasiadcasaasebucsyentcaiavzsCaneertes aszeadaneesausttecanastanienslauancadepacodieetnce Reie e or Ee Elo For B 2 measure C number For B 3 measure C number For B 4 measure C number le ASSUI EE Date Signature of operations manager 43 Giantmix FR operating instructions summa 19 Check list for commissioning NOTICE gl In accordance with the Equipment and Product Safety Act GPSG technical working materials machines facilities may first be commissioned after asserting the conformity with the Machine Guideline 2006 42 EC This means that the conformity with the Guideline 2006 42 EC must be asserted for commissioning technical working materials that are modified installed on site and or joined with external parts Operator Address Postcode place Telephone Machine Type no Date Pos Assessment guideline for commissio
19. between 40 and 75 methane and between 20 and 50 carbon dioxide as well as depending on the fermented material hydrogen sul phide as a trace gas in concentrations from 10 ppm up to max 1 mostly 0 01 0 4 Other trace gases may be different esters organic sulphur compounds alkylbenzenes and ammonia up to 30 ppm as well as hydrogen nitrogen and carbon monoxide and poss suspended substances Biogas must be marked Xn hazardous to health and R20 hazardous to health when inhaled as of con centrations of 200 ppm hydrogen sulphide Below this concentration there is no classification intended based on the hydrogen sulphide content Despite this gas mixtures containing hydrogen sulphide are still hazardous below the labelling requirement limits Irritation of the eyes and respiratory tract already occur with a content as low as 50 ppm hydrogen sulphide Severe poisoning that may lead to uncon sciousness and or death can be expected as of 700 ppm 0 07 Biogas has an ignition temperature of approx 700 C 595 C methane the lower explosion limit LEL is at approx 6 vol biogas 4 4 vol methane and the upper explosion limit UEL at approx 12 0 vol biogas 16 5 vol methane 17 1 Ternary diagram 100 4 0 10 20 30 40 50 60 70 80 90 100 Methane CH4 by vol fig 13 Ternary diagram for the explosion range methane air CO2 N2 mixtures According to Tabasaran Rettenberger UBA research repo
20. e Starting torques on page 32 Propeller agitator Strange noises vibra Daily Repair when required tions and Have defective parts replaced changes Damage Daily Repair when required Have defect parts replaced Dirt build up Monthly Wipe or suction off dirt Damage and corrosion At least 2 000 operating hours annually Repair when required Have defective parts replaced Sealing membrane Impermeability Daily Perform visual inspection Repair if necessary Sealing plate Retighten all nuts of anchor bolts 3 weeks after start up M12 retighten with 60 Nm M16 retighten with 110 Nm Oil equalizing con tainer Check oil level Daily Refill oil if necessary sealing oil in acc with ISO VG 68 See Monitoring the impermeability with the oil equalizing container on page 36 Control connections E check In line with BetrSichV Test in acc with DIN VDE 0702 and leads 6 months Clean also on the inside if required Remedy defects Electric motor E check In line with BetrSichV Test in acc with DIN VDE 0702 6 months Clean inside if necessary If damp inside remedy cause and dry Replace bearing 20 000 operating hours See Replacing the bearing on page 35 Seals Wear and tear 8 000 operating hours See Replacing shaft seal rings on page 34 Transmission Oil level and imperme Monthly See Errors and trouble shooting on
21. e BetrSichV gt Observe all rules of technology gt Observe all safety notices gt Provide and observe the national and regional regulations for accident protection and occupational safety gt Provide and observe environmental protection regulations gt Make sure that persons under the influence of alcohol drugs or medication do not transport set up commission operate and or repair the Giantmix FR gt Make sure that the operating personnel is at least 18 years old gt Make sure that the operating personnel is instructed at regular intervals on all questions concerning industrial safety and environmental protection gt Make sure that the operating personnel has read and observes the operating instructions gt Observe all warning and notice signs on the Giantmix FR gt Make sure that the warning and notice signs are attached and legible Prior to working in and on the biogas tank the agitator and the electric equipment gt Turn off the main switch and secure it against accidental re activation with a padlock gt Pull off the key and attach a corresponding warning sign gt Use personal safety equipment E g safety belt safety rope gas indicator respiratory protection safety shoes protective gloves etc gt Make sure that the Giantmix FR is not operated without the safety equipment and protective covers attached by the manufacturer or in the factory gt Have defects on the Giantmix FR repaired immediate
22. eakiness through crushing the inside sealing membrane gt Avoid maximum deflection of the agitator Leave 5 distance to maximum tilt gt Limit the end positions of the toothed rod with srew connections 9 5 Optional drive of the agitator with power take off 26 Depending on design the through drive of the power take off stub on the transmission features a protec tive device that allows alternative operation with power take off or electrically DANGER Danger of explosion through wrong drive gt Do not drive with power take off inside an ex zone gt Only perform power take off drive with protective equipment gt Make sure that the contact switch is connected and functioning Manual operation via power take off gt Make sure that there is no ex zone in the area of the connected cardan shaft and in the area of the drive motor tractor gt Make sure that the electric motor is completely de energized gt Make sure that the admissible rotation speed of max 750 rpm is not exceeded gt Make sure that the agitation process is supervised gt Installation disassembly of the cardan shaft only with deactivated power take off motor turned off ignition key pulled off gt Make sure that the cardan shaft is correctly installed and secured gt Protect the cardan shaft from revolving by connecting the chain gt Make sure that no persons are located in the area of the rotating power take off or cardan shaft whe
23. ent 18 0 AA 21 0 AA 27 8 AA 36 0 AA 42 0 AA Starting current Ian 4 6 6 9 8 2 8 2 7 6 Power factor cos 0 7 0 87 0 86 0 83 0 83 Thermal sensor PTC resistor PTC 160 C PTC 160 C PTC 160 C PTC 160 C PTC 160 C Substrate temperature lt 70 C lt 70 C lt a Om lt 70 C lt 70 C Substrate ph value 6 5 8 2 6 5 8 2 6 5 8 2 6 5 8 2 6 5 8 2 Immersion depth membrane 1x lt 1 0m lt 1 0m lt 1 0m lt 1 0m lt 1 0m Immersion depth membrane 2x lt 1 5m lt 1 5m lt 1 8 m lt 1 5m lt 1 5m Immersion depth rubber compression seal lt 6 m lt 6m lt 6m lt 6m lt 6m optional Immersion depth axial face seal lt 10m lt 10m lt 10m lt 10m lt 10m Transmission ratio 3 69 3 69 3 69 3 69 3 69 Sound pressure level Lp distance Im 72 dB A 72 dB A 72 dB A 72 dB A 74 dB A Protection type IP55 IP55 IP55 IP55 IP55 NOTICE O JL 40 For installation depths larger than 150 cm SUMA offers special sealing membranes on request Giantmix FR operating instructions 16 Maintenance log Date Operating hours Work performed Performed by stamp signature 41 Giantmix FR operating instructions summa 17 Biogas safety information Biogas characterisation Biogas is a colorless non water soluble sewage gas resulting from the anaerobic breakdown of biomass like e g manure sewage sludge or biowaste It generally contains
24. heck installation and tighten evenly Agitator pipe warped Align agitator pipe Oil equalizing container empty Axial face seal defect Oil inspection glass above fill level Clean axial face seal of the propeller from foreign substances if necessary have axial face seal replaced by SUMA or a retailer Transmission seal defect Have shaft seal to the transmission replaced Agitator pipe worn damaged Replace agitator pipe Oil equalizing container sud denly empty Agitator pipe bent Align agitator pipe replace if necessary Slip on shaft defect Replace slip on shaft Oil equalizing container full Oil equalizing container is mounted lower than topmost propeller operating position Mount oil equalizing container higher than topmost propeller operating position Oil in the oil equalizing con tainer contaminated Axial face seal defect Oil inspection glass below fill level Check whether the oil has a strange odour e g substrate if necessary have seal on pro peller replaced Oil old used up Fill in new oil Notice O JL not constitute a defect grounds for reclamation 30 Corrosion caused by electrochemical reactions e g different grounding potentials pH value of the sub strate concentration of hydrogen sulphide or microbial contamination e g bacteria algae fungus do Giantmix FR operating instructions summa 11 Inspection
25. igher than uppermost propeller operating position gt If necessary secure oil equalizing container with 3 m hose bracket and M12 tie bolts on biogas tank wall Giantmix FR operating instructions summa 8 10 Connecting the electricity supply DANGER Electric shock can cause fatal injuries gt Work on electrical equipment not covered in this operating manual may only be performed by an cer tified electrician gt Have the Giantmix FR professionally grounded by an certified electrician gt Make sure that the supply cable is securely installed to prevent tripping getting stuck damage jam ming detaching dropping etc e g below ground at a sufficient height on buildings and masts gt Make sure that the cable length is sufficient for tilting the propeller agitator gt Do not install the cable in the range of the drag bearing gt Make sure that the cable is sufficiently proportioned Notice Q Tl SUMA offers flexible connection cables 7x4 2x1 mm2 for max 15 kW FR4 or 4x10 4x1 mm for 18 5 and 22 kW FR5 and FR6 per running meter on demand Connecting the electricity For proper connection of the electricity observe the following gt Make sure that the electricity is connected by an expert in line with the valid safety and accident pre vention regulations gt Observe the corresponding installation and operating regulations e g cable diameters fuse protective conductor connection gt U
26. ime and frequency of use of the agitator depend on the consistency of the fermentation substrate Giantmix FR operating instructions summa Possible causes of inhomogeneous substrate e Wrong agitation position e No longer sufficient agitation capacity E g through worn propeller e Inadequate flow properties of the substrate caused by too much solid substance content TS For more information see Errors and trouble shooting on page 28 In case of deviations from normal operation e g increased temperatures loud noises strong vibrations gt Turn off the agitator gt Check the agitator for damage For more information see Errors and trouble shooting on page 28 Foreign objects in the agitation medium e g strings ropes plastic bands cause imbalance on the pro peller Consequences of an imbalance e Higher stress on the bearings e Material fatigue e Early failure of the floating ring seal 9 4 Height adjustment of the agitator Optimum agitation depth To set the optimum agitation depth gt Adjust the tilt height during operation gt Set the propeller to the optimum agitation depth Upper edge of the agitator blade approx 30 cm below the surface of the substrate Set the tilt Also see fig 2 and fig 3 for a description of the adjustment Loosen the counter nuts of the upper control arms gt Set the tilt of the propeller with the upper control arm 8 10 gt Secure the upper c
27. in the terminal box on the motor Ground the electric agitator To prevent different grounding potentials and equipotential bonding flows between the components of the operating material gt Ensure sufficient grounding of the propeller agitator equipotential bonding Connect the ground lead to the ground screw symbol of the sealing plate and or sealing frame NOTICE O JL SUMA recommends connecting the ground wire to the ground terminal in the switching cabinet Protect the electric agitator from lightning To prevent atmospheric discharge on the agitator gt Integrate the agitator into the lightning protection equipment on site in line with EN 60079 14 Check the rotation direction of the motor gt Observe the ventilation hood on the motor Rotation direction clockwise when looking on the ventilation hood Observe the red arrow on the motor hood gt Briefly turn on the motor on the plant control test operation 8 11 After installation gt Re tighten all screws and nuts on the device with a dynamometric key see Starting torques on page 32 gt Observe standardized turning moments per connection element gt Check the function of the motor protection and the contact switch in the power take off protection gt Check the proper installation of equipotential bonding between the biogas tank the agitator and the dis tribution Check the proper integration into the lightning protection on site
28. irection of propeller Check rotation direction see Rotation direc tion of the propeller on page 24 and if necessary change it 28 Giantmix FR operating instructions Error Propeller agitator runs unsteadily Possible cause Propeller damaged or deformed Emut Measure Replace propeller Check installation situation and remove foreign objects if necessary Foreign objects have wrapped around the propeller Remove foreign objects e g by briefly revers ing the rotation direction Corrosion on the propeller Determine cause for corrosion and remedy Unusual noises during oper Loose parts Re tighten all screws and nuts ation Damage to the agitator Contact SUMA customer service or retailer for assistance Deinstall agitator and have it checked if necessary Corrosion Stray current corrosion Ensure equipotential bonding Install reactive anode if necessary Repair or exchange damaged parts Electrochemical corrosion Contact corrosion Check concentration of foreign substances percolating juice copper sulphates etc Avoid foreign substances Install reactive anode if necessary Repair or exchange damaged parts Microbiological corrosion Check concentration for increased microor ganism content ensilage additives etc Repair or exchange damaged parts Knocking sounds on the agi tator Transmission bearing defect Check and service tr
29. ith nuts and disks 1 set Rubber sealing strips 4 pcs 900 x 80 x 6 1 set Drill bush 1 set see fig 3 on page 13 5 3 Accessories optional Ho Name Quantity Drill stencil 1 Dummy cover 980 98 cm x 98 cm 1 Protective hood for electric motor 1 Flexible connection cable 7x4 2x1 mm2 for max 15 kW FR4 per metre Flexible connection cable 4x10 4x1 mm for soft start or frequency converter operation FR5 and FR6 per metre Additional special accessories on request Notice SUMA delivers the Giantmix FR without a switch box gt Make sure that the safety and monitoring equipment e g emergency stop and start up control are installed on the biogas plant and in working condition 11 Giantmix FR operating instructions Citar 6 Transport and storage O JL 12 WARNING Danger of injury through improperly secured parts gt Use suitable lifting equipment e g digger crane etc gt Make sure that no persons are located beneath the load when lifting transporting and unloading low ering the Giantmix FR gt Always supervise the load while it is suspended gt Do not reach in beneath the propeller agitator when lifting and lowering gt Never reach into moving parts Transport gt Transport the Giantmix FR in a horizontal position gt Use suitable lifting equipment see weight on the type plate of the Giantmix FR
30. l equalizing container 1 2 3 4 when the oil has an operating temperature of approx 45 C 113 F Replace sealing membrane and or rubber compression seal optional 36 The sealing membrane made of EPDM 60 and or the rubber compression seal optional made of EPDM 70 are at least 8 years permanently impermeable for usual application in biogas plants To ensure impermeability gt Replace the sealing membrane and or rubber compression seal optional at latest after 8 years Giantmix FR operating instructions summa 12 Repair DANGER Mortal danger through improperly performed repair work gt Make sure that repair work is only performed by trained or qualified personnel gt Use personal safety equipment Safety belt safety rope gas indicator respiratory protection safety shoes protective gloves hard hat 12 1 Replacing the propeller The wear of the propeller depends on the operating time and the processed substrate Power consumption and or electricity consumption declines with wear SUMA recommends gt Prior to reaching the no load current load current load in non immersed state replace propeller gt Also replace the conical spring lock washers limes type conical spring washer Make sure that the installation surfaces are clean gt After replacing the propeller re adjust scraper gt Ensure that the distance x of the scraper is 3 mm see fig 4 on page 14 12 2 Replace slip on shaf
31. lease refer to the General Terms and Conditions or the contract documents for details on the warranty Giantmix FR operating instructions Citar 3 Intended use The biogas agitator Giantmix FR serves to mix renewable resources liquid manure and sewage sludge in concrete biogas tanks The Giantmix FR corresponds to device group II category 2G mechanical components and or 3G electric components in accordance with the Explosion Protection Directive 94 9 EC The Giantmix FR is approved for use in explosive environments in accordance with the Declaration of Conformity for zone 2 DANGER Mortal danger through explosion gt Use Giantmix FR exclusively in explosive areas of ex zones corresponding to the details on the type plate of the respective device Conditions for the proper use of the agitator gt Make sure that the conformity of the end product is warranted in line with the applicable directive after installation and or assembly with other components Ensure sufficiently dimensioned attachment of the agitator Make sure that the maximum pressure on the pipe duct sealing membrane is in the admissible range Make sure that the temperature of the substrate to be agitated does not exceed 70 C 158 F Make sure that the pH value of the substrate to be agitated is between 6 5 and 8 2 Make sure that all safety and monitoring equipment e g thermal sensor of the electric motor contact switch on the power take off a
32. lity with the oil equalizing container Do EHE The oil inspection glass on the side of the electric motor serves for visual assessment of the agitator s condition Depending on the installation situation it is possible to detect different statuses with possible error sources Error source Oil is contaminated with sub strate Oil inspection glass is above substrate level Oil inspection glass is below substrate level Axial face seal defect Agitator pipe defect Oil level drains quickly Agitator pipe bent Slip on shaft defect Agitator pipe bent Slip on shaft defect Oil level drains slowly Seal to transmission defect Axial face seal defect Slip on shaft defect Seal to transmission defect Slip on shaft defect Oil level fills slowly Bearing housing on propel ler side runs empty because oil equalizing container below the level of propeller operation position Oil milky dark Bubbles form through turning of the shaft Pipe material washed out Notice A milky color of the oil is no clear indicator of leaks Bonding of air humidity and or gas bubbles arising through the rotation of the shaft may turn the oil milky Required oil quantity sealing oil ISO VG 68 for refilling the agitator pipe e Agitator pipe 5 74 mm wall thickness approx 4 4 I m pipe length e Agitator pipe 4 00 mm wall thickness approx 4 9 Im pipe length Notice Fill oi
33. ly gt Do not modify or convert the Giantmix FR This will render the declaration of conformity null and void The operating permit expires Giantmix FR operating instructions summa In order to maintain the safety function and protection from explosion gt gt Exclusively replace parts with OEM parts with identical electric and mechanical data Check all safety equipment e g the sealing membranes attachments as well as electric connections and leads for perfect condition at regular intervals Danger of damage to the environment Make sure that lubricants or transmission oil do not flow into the ground the water or the sewage system Properly dispose of lubricant remnants waste oil and containers rags contaminated with these sub stances After de commissioning the Giantmix FR dispose of parts according to national regional and statutory regulations Observe the national regional and statutory regulations when disposing Danger through explosive and flammable atmosphere It is possible that poisonous flammable and explosive gases escape from the biogas tank Make sure that exclusively trained personnel performs installation and maintenance work on explosion proof machines in line with the Operational Safety Ordinance BetrSichV and the safety and mainte nance notices stated in operating instructions Prevent an explosive atmosphere around tank openings during maintenance w
34. n working with the cardan shaft Giantmix FR operating instructions summa 9 6 Setting the rotation angle Giantmix FR with slewing ring CAUTION Damage to the Giantmix FR through improper rotation gt To set the rotation angle of the Giantmix FR only turn it when not in motion CAUTION Giantmix FR with slewing ring and toothed rod with winch optional Leakiness through crushing the inside sealing membrane gt Avoid maximum deflection of the agitator Leave 5 distance to maximum tilt gt Rotate maximum to the limit screws M8 in the slewing ring fig 12 Setting the rotation angle Giantmix FR with slewing ring 1 Slewing bracket 4 Pivot nut 2 Locking screws 5 Slewing ring 3 Clamping jaws Adjusting the rotation angle gt Loosen two locking screws 2 gt If necessary loosen pivot nut 4 gt Turn the Giantmix FR in the desired direction gt Tighten the locking screws and pivot nut 27 Giantmix FR operating instructions 10 Errors and trouble shooting Notice JL Error No function For electrical details see type plate of the electric motor Possible cause Motor or transmission defect Measure Replace electric motor or transmission Motor protection switch has triggered Switch protective switch back to operating position Remedy the cause if necessary Control or electrical connection defect Repair control and or electricity connection Pr
35. nd non metal parts e g iron rods steel wire chains etc Long fibred and other clogging products 5 Delivery scope Notice O JL The delivery scope may deviate from the image on the title page 5 1 Standard design with sealing plate Name Quantity Complete biogas agitator including sealing plate 30 agitator tube gear 1 electric motor propeller sealing membrane or rubber compression seal optional hinge Attachment material sealing plate on tank wall 1 set tie bolt M12 x 130 galvanised complete with nuts and disks 27 pcs Upper control arm or toothed rack with winch optional wall mount tie 1 set bolt M12 x 130 3 pes galvanised complete with nuts and disks Rubber sealing strips 4 pcs 900 x 80 x 6 1 set Drill bush 1 set see fig 2 on page 13 10 Giantmix FR operating instructions 5 2 Design with slewing ring and sealing frame Name Emut Quantity 1 Complete biogas agitator incl slewing ring and sealing frame agitator tube gear electric motor propeller sealing membrane pivoting frame Attachment material sealing plate on tank wall tie bolt M12 x 130 galvanised complete with nuts and disks 1 set 30 pes Upper control arm 2 pcs wall mount 2 pcs tie bolts M12 x 130 6 pcs galvanised complete with nuts and disks 1 set Toothed rack with winch optional wall mount tie bolts M12 x 130 3 pes galvanised complete w
36. ning Yes Remark 1 Are all documents declaration of conformity operating instruc O tions complete available in the respective language and acces sible 2 Is the intended use possible according to the documents declara D tion of conformity operating instructions 3 Were all safety and installation instructions in the operating in O structions observed implemented 4 Installation was properly performed and checked oO torques seals attachments 5 Is there sufficient protection against mechanical hazards like D squashing shearing cutting catching drawing in hitting and friction 6 Is there sufficient protection against electric hazards like short D circuit overload error statuses touching live parts and electro static charge 7 Is there sufficient protection against noise vibrations heat and oO hazardous substances 8 Is safe proper and risk free operation handling possible if appli E cable in a test operation 9 Were all sources of ignition removed from and or avoided in the o range of the agitator Depending on the extent and the hazard potential of the technical facility an extensive assessment procedure may be re quired for commissioning Responsible for installation assembly Responsible for electric installations Responsible for commissioning 44 Datum Datum Datum SUMA R hrtechnik GmbH Martinszeller Str 21 DE 87477 Sulzberg Phone 49 0 83 76
37. nition Ventilate the biogas tank sufficiently prior to performing all installation and maintenance work Giantmix FR operating instructions summa 2 3 Product liability Liability exclusion SUMA will not assume any liability for damage to persons assets the environment and or breakdowns caused by non observance of the operating instructions The warranty does not cover unauthorised intervention or modification SUMA will assume no liability and warranty for damage to persons materials and or breakdown of the caused by the installation of replacement parts not approved by SUMA SUMA excludes warranty and liability claims for damage to persons assets and the environment caused by the following Unauthorised application of the Giantmix FR Improper transport installation deinstallation commissioning operation or maintenance of the Giantmix FR Non observance of the notices in the operating instructions concerning installation deinstallation commissioning operation and maintenance Operating the machine with defect safety and protection equipment improperly attached safety and protection equipment defect safety and protection equipment Unauthorised modifications of the motor e g drive ratios Insufficient monitoring of wear and tear parts Improperly performed repair work Foreign object damage e g through insertion of solid objects in the biogas tank that are not suited for the biogas process P
38. nt the risk of fire make sure that the transmission and motor are clean OO To prevent damage to the agitator do not change the rotation direction of the propeller during opera tion Check the oil level in the transmission daily and correct this if necessary Make sure that the sealing membranes are not damaged and tight Make sure that oil equalizing container mounted higher than topmost propeller operating position Make sure that the attachment parts are not damaged Make sure that the supply leads are not damaged OO OO OO Make sure that no one is performing any maintenance and repair work 9 2 Rotation direction of the propeller The Giantmix FR is designed for operation in one rotation direction by default In normal operation the propeller rotates counter clockwise seen from the motor To free the propeller from vortices briefly reverse the rotation direction of the standard propeller To prevent damage caused by increased load charges and strong vibrations gt Make sure that the rotation speed is reversed for at most 2 minutes 9 3 Optimum agitation 24 The composition of the substrate to be agitated varies For this reason it is not possible to make a bind ing statement concerning optimum agitation The degree of effectiveness of the agitator is increased by supporting the wheel effect of the agitator The wheel effect results with the rotary motion of the sub strate in clockwise direction The running t
39. ontrol arm with counter nuts gt Make sure that no more than 120 mm of thread are twisted out at the upper control arm The propeller agitator Giantmix FR with slewing ring is equipped with two upper control arms CAUTION Leakiness through defect rubber compression seal optional gt Do not adjust the tilt of the agitator gt The upper control arm serves for support only CAUTION Emptying of the bearing housing due to incorrect position of the oil equalizing container gt Ensure that oil equalizing container mounted higher than topmost propeller operating position gt If necessary secure oil equalizing container with 3 m hose bracket and M12 tie bolts on biogas tank wall gt Make sure that agitator is working not only in the uppermost stirring positions sometimes also oper ated horizontally Otherwise there is a risk that the bearings of the propepeller side run dry 25 Giantmix FR operating instructions summa MAO Option toothed rod with winch gt Put the agitator into the desired position with the winch gt Make sure that the agitator pipe does not contact the opening of the biogas tank gt Make sure that the inner sealing membrane is not crushed against the sealing plate opening NOTICE The top edge of the agitator blade should have a minimum distance of approx 30 cm from the substrate surface during operation CAUTION Giantmix FR with slewing ring and toothed rod with winch optional L
40. oothed rod into position e g center Draw in the position of the wall mount on the biogas tank wall below or above the agitator Drill holes 12 and clean Insert M12 tie bolts and screw on wall mount Attach upper control arm and or toothed rod with winch between wall mount and agitator Remove transport securing device see fig 1 on page 12 Check attachment and sealing of the attachment plate OO O Dog 8 Screw connections on the sealing frame version with slewing ring WARNING Danger of injury through improperly secured parts gt Lift agitator with suitable lifting device e g digger crane etc and corresponding load suspension device see fig 1 on page 12 gt Make sure that no persons are located beneath the load when lifting transporting and letting down the Giantmix FR gt Remove transport supports prior to lifting into the biogas tank gt Always supervise the load while it is suspended gt Do not reach in beneath the propeller agitator when lifting and lowering gt Never reach into moving parts CAUTION Damage to assets in case of improper installation gt Carefully insert the agitator into the biogas tank wall gt Prevent contact of the agitator blade with the floor the wall of the biogas tank and the ceiling of the biogas tank CAUTION Emptying of the bearing housing due to incorrect position of the oil equalizing container gt Ensure that oil equalizing container mounted h
41. opeller blocked Loosen blockade by reversing the rotation direction Propeller fallen or loose Remove agitator determine the cause and repair it check propeller and agitator for damage and replace propeller or agitator if necessary One or several phases without voltage Check voltage supply TMS triggering device or contact switch have triggered Perform a reset on the TMS triggering device remedy cause if necessary Insufficient agitation power Propeller worn out Wear is signalled by reduced power consump tion Replace propeller if necessary Agitation time too short with excessively long breaks Increase agitation intervals Dry substance content in the substrate is too high Check the substrate quantity composition and solid substance share and dilute if necessary or reduce addition of solid substances Electric motor overloaded Dry substance content in the substrate is too high Check the substrate quantity composition and solid substance share and dilute if necessary or reduce addition of solid substances Agitator pipe bent Replace agitator pipe Transmission defect Check transmission Voltage too low during operation Check connection cable diameter and length of the voltage supply Foreign objects have wrapped around the propeller Remove foreign objects e g by briefly revers ing the rotation direction False rotation d
42. ork Work that influences explosion protection may exclusively be performed by trained or qualified person nel Make sure that the permit for work in explosive areas is completed prior to any work on the Giantmix FR and signed by the person in charge If the work is not performed by SUMA Make sure that all work is performed and approved by trained and certified personnel exclusively Make sure that the trained personnel issues a written confirmation and or attaches their test seal on the machine Keep the confirmation in the operator s explosion prevention documentation and present this upon demand Higher risk of explosion It is possible that gas escapes when opening or removing the Giantmix FR gt gt gt gt Keep all ignition sources e g open flames hot heat sources tools emitting sparks non explosion proof electric devices away from the explosive zones ex zones Exclusively use spark free tools Make sure that the used tool e g power drill driller core drill chisel is a special spark free tool Make sure that welding burning and spark emitting work is not performed inside the ex zones To prevent the risk of fire make sure that the transmission and motor are clean surface In the range of the biogas plant gt Observe the regulations for biogas plants gt Do not smoke gt gt gt Do not use any open sources of fire Do not use any mobile phones or other source of ig
43. otation angle Giantmix FR with slewing ring Errors and trouble shooting Inspection and maintenance 11 1 Prior to maintenance work 11 2 Maintenance log 11 3 Starting torques 11 4 Maintenance plan 11 5 Wear related maintenance Repair 12 1 Replacing the propeller 12 2 Replace slip on shaft drive shaft 12 3 Replace bearings 12 4 Replacing the transmission 12 5 Replacing the motor Disassembly 13 1 Prior to disassembly 13 2 Disassembly Disposal Technical data 15 1 Type plate 15 2 Technical data Maintenance log Biogas safety information 17 1 Ternary diagram Permit for work in explosive areas Check list for commissioning 24 25 26 27 28 31 31 31 32 33 34 37 37 37 37 37 37 38 38 38 39 39 39 40 41 42 42 43 44 Giantmix FR operating instructions User guide wesch D 1 1 Warning notices Degree of warning notices The following signal words distinguish the warning notices according to the type of danger e Caution Warning of damage to assets e Warning Warning of injuries to the body e Danger Warning of mortal danger Structure of the warning notices SIGNAL WORD Type and source of danger gt Measures to prevent danger Used pictograms Danger of explosion May cause death or injury Danger of damage to assets or the environment IP e gt Giantmix FR operating instructions Citar 1 2 Further s
44. page 28 ability spots damp with oil Housing temperature Monthly Oil change Every 2 000 operating See Changing the transmission oil on hours at least every 2 page 34 years Replace bearing Ssee Replacing the bearing on page 35 Enter value in line with table Propeller bearing Replace bearing Ssee Replacing the bearing on page 35 Enter value in line with table Propeller Damage On demand Replace propeller if necessary Wear and tear Power consumption agitation capacity Replace propeller if necessary 33 Giantmix FR operating instructions summa 11 5 Wear related maintenance All moving parts wear out Wear depends on e Running period e Degree of strain e Operating conditions The following statements are recommendations only because the operating conditions vary greatly Increased material wear off or local corrosion may occur in rare cases with fixedly installed devices Possible causes e Ground currents shift in potential faulty grounding e Electrochemical reactions Higher acidification with coferments and biowaste Changing the transmission oil gt Change the transmission oil after the following periods Transmission oil change every 2 000 operating hours at least every two years Change transmission oil as follows gt Drain the old oil right after stopping the transmission machine still warm gt Refill at least 3 2 litres of transmission oil SU
45. pening It is not necessary to completely empty the tank gt Make sure that the biogas tank is aired if possible If this is not possible fitters require the corresponding equipment e g respiratory protection gt Fill out the permit for work in explosive areas and have this signed by the person in charge 11 2 Maintenance log gt Make sure that the performed inspection and maintenance work is completely documented form see Maintenance log on page 41 31 Giantmix FR operating instructions summa 11 3 Starting torques 32 gt To ensure secure screw connections tighten the screws at most with the maximum admissible start ing torque Calculation of the starting torques with an average friction coefficient of H 0 14 Addi tional lubrication L1 0 10 changes the friction coefficient substantially so that the starting torques are reduced Maximum admissible starting torques Screw M8 M10 M12 M14 M16 M20 M24 Grade A2 A4 70 u 0 10 16 32 55 88 134 262 451 u 0 14 20 40 69 111 171 334 574 Grade 8 8 galvanised u 0 10 21 43 73 117 180 363 625 u 0 14 27 54 93 148 230 464 798 Giantmix FR operating instructions 11 4 Maintenance plan Component Screw connections Check for activity Re tighten all screws and nuts Controlling 3 operating hours after commissioning then monthly visual inspection Emut Working material remark Externally visible screw connections Se
46. r inverted gt With the variant with slewing ring reserve the positions labelled DK for the strutting gt With the variant toothed rod with winch Attach the retainer in the desired position below or above the opening after installing the agitator NOTICE By increasing the distance 72 cm of the tilt angle can be increased to stir up Caution oil reservoir mount then higher the level of the upper agitator operating position on biogas tank wall Giantmix FR operating instructions summa 8 8 Attach the tie bolts 8 9 OO OO OO OO OO OO OO Center the drill stencil and or sealing plate Draw hole 1 see fig 8 screw attachment diagram Drill hole 12 at least 140 mm deep Make sure that the holes are drilled straight Clean the hole to ensure the load bearing capacity of the tie bolts blow out Hammer the tie bolt in with a plastic hammer and let it protrude approx 35 mm out of the wall Align the drill stencil and or agitator with the sealing plate horizontally and draw hole 2 Drill hole 2 Clean the boring and insert the tie bolt Attach the drill stencil and or sealing plate with disks and nuts Drill the remaining holes straight and clean Insert all tie bolts up to 35 mm Drill the holes for the upper control arm wall mount see fig 7 on page 18 Clean the concrete until it is dust free NOTICE O JL It is possible to insert the tie bolt after attaching the sealing plate Installation in
47. re connected and functioning gt Make sure that the agitator blade is completely covered with substrate for operation OO OO O gt Observe the inspection and maintenance intervals gt Observe the safety permission prohibition warning and operating instructions If changing the installation site or the operating situation of the Giantmix FR gt Check the ex zones and compare with the ex protection type of the Giantmix FR Giantmix FR operating instructions summa 4 Improper usage DANGER Mortal danger through explosion With a Giantmix FR featuring an optional drive with a cardan shaft gt Do not operate with the power take off if power take off or drive motor tractor are located in an explosive area see Agitation on page 24 Improper use of the agitator with e Operation via the cardan shaft without protective equipment see operating instructions of the cardan shaft e Operation in an inadmissible Ex zone Use other than that described in the chapter Intended use is not permitted The operator of the Giant mix FR is responsible for all damage caused by improper use In order to ensure safe operation and prevent damage to the Giantmix FR gt Make sure that the substrate to be agitated does not contain the following goods foreign substances or foreign objects Slaughterhouse waste bones etc Bulky sharp edged solid substances square timber wooden boards branches etc Metal a
48. rt 12 1982 no 10302207 part 1 Biogas is lighter than air and forms an explosive atmosphere together with air In the presence of ignition sources like hot surfaces open fires mechanically electrically induced sparks electrostatic discharge and lightening a higher risk of explosion is to be expected Biogas generates dangerous gasses when heated burned e g carbon monoxide sulphur dioxide sulphur trioxide formaldehyde The material stability strongly depends on the content of trace gasses e g hydrogen sulphide Hydrogen sulphide attacks most metals and polymers depending on the concentration temperature and humidity Stain less steels grade 1 4301 AISI 304 are somewhat resistant and stainless steels grade 1 4571 316 as well as polymers like PE PTFE PP or polyisobutylene are quite resistant 42 18 Permit for work in explosive areas Check the applicable boxes Delete where not applicable Permit for welding burning and other work causing sparks for drilling grinding impact and breaking work for application of non explosion protected devices A Client Construction Teli Foreman Worksite and type of work hrs for the time Construction Permit TFOM ege For workshop company Foreman B Hazardous locations in the area Worksite constructions machines etc Person in charge Construction Telephone 1 2 3 A C Safety measures to
49. se suitable screw material that matches the used connection cables gt Seal off unused screw fittings and or cable ducts in the terminal box properly gt Only use approved screw fittings in explosive sections For safe agitation gt Protect the motor from being overloaded and against overheating gt Make sure that the motor is completely without power in case of triggering Suitable combinations Motor protection switch with phase failure protection Temperature monitoring with the PTC thermal sensor integrated in the motor CAUTION Damage to assets through wrong triggering equipment The electric motor is equipped with thermistors PTC resistor with max 2 5 V testing voltage for addi tional motor protection with thermical machine protection TMS gt For application of the Giantmix FR in ATEX only use PTC triggering devices approved in acc with 94 9 EC SUMA supplies suitable devices on request gt In order to protect the motor make sure that a PTC triggering device is installed The variant with power take off protection has a contact switch in the power take off protection gt Make sure that the contact switch is connected and functioning gt To save additional scoring logic it is possible to connect the contact switch in series with the thermal sensors see fig 11 on page 22 The motors are protected against dust and water jets 21 Giantmix FR operating instructions summa If heavier strain is to
50. shoes protective gloves etc 8 1 Design The propeller agitator Giantmix FR is designed for installation from the outside It is not necessary to climb into the biogas tank 8 2 Check the scraper fig 4 Scraper distance Check scraper distance gt Make sure that the distance x of the scraper is 3 mm 14 Giantmix FR operating instructions summa 8 3 Operating and ambient conditions Operating and ambient conditions for Giantmix FR e Installation height lt 1000 m above sea level e Relative air humidity of the cooling air max 90 at 25 C 77 F e Ambient temperature from 15 C 5 F to 40 C 104 F gt Keep air intake and blowout of the motor unobstructed gt Prevent contamination through insects maggots or corrosion through hazardous substances like hydro gen sulphide chlorine ammonia ozone and nitrous oxides 8 4 Prior to installation Observe the following prior to installing the Giantmix FR gt Prior to retrospective installation lower the fill level of the biogas tank sufficiently gt Make sure that the biogas tank is ventilated For more information see Safety notices on page 6 8 5 Installation material and aids Name Quantity Drill stencil recommended 1 Tie bolt with nuts and disks 1 set Rubber sealing strips 4 pcs 900 x 80 x 6 1 set Sikaflex TS provided by the customer if necessary to compensate gaps and unevenness 8 6 Prerequisites for installa
51. t drive shaft SUMA recommends to have the slip on shaft replaced by the manufacturer or a specialist company 12 3 Replace bearings DANGER Improper repair work may be fatal gt Only have axial face seals replaced by personnel trained or qualified by SUMA Replacing the bearing housing gt Install bearing housing incl new flange seal gt Seal both flange surfaces with a sealing compound e g Hylomar M during installation gt Secure all screws with medium strength screw locking compound e g Loctite 242 gt Tighten all screws with the correct starting torque see Starting torques on page 32 12 4 Replacing the transmission SUMA recommends to have the transmission replaced by the manufacturer or a specialist company 12 5 Replacing the motor SUMA recommends to have the motor replaced by the manufacturer or a specialist company 37 Giantmix FR operating instructions summa 13 Disassembly DANGER Mortal danger through explosion gt Make sure that there is no explosive gas air mix during the entire deinstallation gt Make sure that the opening is closed to prevent increased oxygen intake DANGER Mortal danger through improper conduct during installation deinstallation and repair work gt Make sure that disassembly work is only performed by trained or qualified personnel gt Make sure that the Giantmix FR is not turned on if it is not properly and completely installed in the biog
52. the biogas tank wall fig 8 Screw attachment diagram Attachment of the sealing plate gt OO OO OO OO O Attach the supplied rubber sealing strips with one sided adhesive layer on the sealing plate in line with the boring Avoid gap on the bordering Seal gaps and dents in the concrete wall additionally with Sikaflex TS Attach Giantmix FR see fig 1 on page 12 and lift observe horizontal position Remove transport supports front and back Do not remove transport securing device secures the installation Lift the Giantmix FR with lifting equipment into the biogas tank opening Carefully place the sealing plate and or frame on tie bolts Make sure that the sealing membrane is not damaged Version with slewing ring see fig 9 on page 20 Loosen 8 screw connections per agitator side 2 on top 2 on bottom on the sealing frame 19 Giantmix FR operating instructions summa gt Tighten disks and nuts crosswise with 60 Nm see fig 8 Starting on the top screw the plate on alter nately from the inside to the outside so that the domed plate can be pulled evenly to the wall gt Version with slewing ring Tighten 8 screw connections on the sealing frame see Starting torques on page 32 Screw tight the wall mount for the upper control arm with disks and nuts with 60 Nm gt Option toothed rod with winch Attach the toothed rod with winch completely to the Giantmix FR incl support Turn the t
53. tion in the biogas tank wall Observe the following prerequisites for installation gt Make sure that the static and dynamic design of the biogas tank is suited for inclusion of the agitator gt Prior to installing ducts and making drill holes check the wall of the biogas tank for tensioning and heating elements steel reinforcements and similar gt To ensure perfect impermeability and stability of the attachment make sure that the wall of the biogas tank is sufficiently level only a few hollow places and dents are admissible 15 Giantmix FR operating instructions summa 8 7 Make an opening in the wall of the biogas tank CAUTION Change of static through core drilling gt Prior to retrospective drilling of core drill holes check the static of the biogas tank or have it checked For mere height adjustment SUMA recommends a round opening boring fig 5 For lateral adjustment via slewing ring SUMA recommends a square opening fig 6 A square opening allows you to use the full lateral slewing range With the slewing ring version the lat eral slewing range is 25 left right respectively Retrospective installation Ho fig 5 Opening in the wall of the biogas tank 1 Distance center of opening normal fill 3 Core drilling level 2 Fill level 4 Center of opening gt Place the center of opening below normal fill level covering 50cm to max 100 cm membrane 1x 100 cm to max 150 cm membrane
54. ymbols Notices Notice JL Notice on the proper handling of the device Handling instructions Layout of the handling instructions gt Handling instruction Statement of result if necessary Lists Structure of non numbered lists e List level 1 List level 2 Structure of numbered lists 1 List level 1 2 List level 1 2 1 List level 2 2 2 List level 2 1 3 Accompanying documents see enclosures Observe the following documents for safe and reliable operation e Handling instructions for the electric motor e Handling instructions for the cardan shaft optional e Ex zone plan of the respective biogas plant to be prepared by the operator 1 4 Storage gt Keep operating instructions including the accompanying documents near the propeller mixer Giantmix FR operating instructions summa 2 Safety 2 1 Symbols on the product The following safety and health protection notices are located on the sealing plate BGV A8 DIN 4844 Warning of explosive atmosphere 2 2 Safety notices Safety notices serve to prevent injury to persons and damage to the Giantmix FR and the environment The following applies for the operating personnel gt Read and observe all safety notices Danger of injury To prevent risks of injury gt Observe the accident prevention regulations for agricultural biogas plants gt Observe the accident prevention regulations of the Operational Safety Ordinanc

Giantmix FR1, FR3, FR4, FR5, FR6 Operating instructions

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