Technical Manual: For Installation, Operation and Maintenance of

Bei der Lehmkuhle 4
D-21279 Hollenstedt
Tel: +49-(0)4165-2211-0
Fax: +49-(0)4165-2211-25
E-Mail: service@HamannAG.com
www.HamannAG.com
Technical Manual
for installation, operation and maintenance of
Sewage Treatment Plant
Serial No.: 10283
Plant type: SuperMini PLUS
Date of issue: 02.10.12
Content
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I. Introduction
Plant components list
P&ID (Flow Diagram)
Important Information
Basic rules and regulations about storage, installation and commissioning of sew-
age treatment plants and their components.
II. Installation-, Operating- and Maintenance Instructions
Important information about installing the plant on board, functional description of
the plant and important safety, operating and maintenance instructions
III. Electrical Plans
Electrical circuit diagram
Print date: 02.10.2012
009855
Sewage Treatment Plant (set)
Super Mini PLUS 230 V
Part No.:
Description: 763 RMNr.:
67002011 Commission:
HAMANN AG
This list includes the main plant components with their part number and reference code.
Quantity Part No. Description Reference code
010303
000690
004371
004171
000446
009705
000445
000451
Level transmitter TK-308-RPE 1,00 pcs A-1-CL-003
1,00 pcs
1,00 pcs
1,00 pcs
1,00 pcs
1,00 pcs
1,00 pcs
1,00 pcs
Ball valve D40 / d50 A-1-X-004
Ball valve, 2-way 546 PVC-U DN20 (lockable) A-1-X-043
Flow rate limiter DMB-13,0 A-1-A-033
Ball valve, 3-way with electric actuator 2124C11AAAV A-1-V-007
Centrifugal pump aggregate FP-100-1GRD 230/400V
Capacitive limit switch KG-211R
Dosing Pump F-PK 2,2
A-1-ZP-005
A-1-P-023
A-1-CL-021
A-1-V-041 000446 Ball valve, 3-way with electric actuator 2124C11AAAV 1,00 pcs
010036 1,00 pcs Canister with screwed top PE 010 A-1-B-022
Components list Super Mini PLUS
005397 1,00 pcs Overflow valve CV SAP-S_024/230 A-1-H-101
To be mounted separately according to Piping and Instrumentation diagram:
Mounted at Treatment Tank:
Quantity Part No. Description
Quantity Part No. Description
Mounted at Dosing Station:
012519 1,00 pcs A-1-ZP-100 Centrifugal pump, self priming SAP-S 230 50Hz
004192 1,00 pcs A-1-P-032 Membrane/Diaphragm pump SWP 5902-24V DC
010104 1,00 pcs A-1-F-031 Water strainer 1160 (0,4mm)
003233 1,00 pcs A-1-P-042 Membrane/Diaphragm pump M 230V RG-G 1-1/2"
1 of 1 Page
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HAMANN AG
Bei der Lehmkuhle 4, D-21279 Hollenstedt, Tel: +49-(0)4165-2211-0, Fax: +49-(0)4165-2211-25
eMail: Service@HamannAG.com
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9
IMPORTANT INFORMATION
about storage, installation and commissioning of sewage treatment plants and their components.
Non-observance can lead to damages and malfunctioning as well as the loss of warranty.
STORAGE:
Each component of the sewage treatment plant has certain requirements regarding their storage, handling and
inspection. The following instructions are to be observed:
Storage requirements before and after installation:
Protected or enclosed dry areas or rooms, 5 ... 25C, optimal temperature is +15C, not in close proximity to
heat emitting or ozone generating sources or substances.
No ultraviolet light, no pollution materials such as dust or small particles coming from welding, sand blasting or
etc. No moisture or condensation on the elastomer is permitted.
No storage in close proximity to solvents, petrol, lubricants, acids, disinfectants or other chemicals.
The plants and their tanks must be stored completely empty, up until final commissioning.
Elastomer products and plastics:
(Stator, joint sleeves, splash rings, shaft seals, o-rings, hoses and adapters, mechanical seals, etc.)
Properly stored elastomer products in enclosed or protected areas will maintain their original quality over exten-
ded periods of time. The original quality can be effected through oxygen, ozone, heat, light, moisture, solvents
or storage under pressure, stress or strain.
All elastomer products are not covered through warranty because of aging or extended storage periods.
Pump's stator
For plants, which are to be in storage for long extended periods of time between delivery and final commissioning,
the stator should be disassembled from the pumps and be stored in a dry place. The regulations and instructions
in accordance with the corresponding component's maintenance and operating instructions for disassembly and
re-assembly of the pump's stator must be observed. Stators, which are to be in storage for more than 3 years must
be properly inspected and controlled before use (because of possible material fissure).
INSTALLATION:
The instructions and regulations contained in HAMANN AG's Technical Manual for Installation, Operation and
Maintenance must be observed. Specific Installation Instructions are contained in the above mentioned Tech-
nical Manual. These Installation Instructions can be provided separately.
During the installation of separately delivered components such as Transfer Pumps, Sludge Pumps or Dry Run-
ning Protection Pumps, the correct execution of the connection piping in accordance with the corresponding com-
ponent's maintenance and operating instructions must be observed. HAMANN AG should be consulted for
specialised installations.
Avoidable mistakes by the installation:
On the tanks and the piping of the plant systems, extra welding is not permitted and may not be undertaken,
otherwise the inner coating of the tank will be damaged.
For ships having CuNiFe piping, the piping of the sewage treatment system must be suitably isolated.
The construction of the sewage treatment systems may not be modified or changed without prior consultation.
Without consultation, no extra component that was not delivered through HAMANN AG may be connected to
the sewage treatment system.
The power supply of the electrical power grid may not deviate from the contract specifications of the sewage
treatment system.
The pumping characteristics of the pumps (i.e. self-priming or not self-priming) must be observed when instal-
ling the piping system. Corresponding free flow is be assured.
COMMISSIONING:
Prior to commissioning HAMANN AG must be consulted. The regulations and instructions in the Technical Manual
must be observed. It is recommended that the commissioning be completed by a service technician from
HAMANN AG. The safety regulations and instructions (Safety Data Sheets) are to be observed.
Avoidable mistakes by the commissioning:
The power supply (also those connected to land based power grids) grid may not deviate from the contract
specifications of the sewage treatment system.
Pumps which are not self-priming may not be allowed to run dry. Free flow in the piping system is to be assu-
red. Dry running protection equipment must be de-aerated.
Bei der Lehmkuhle 4
D-21279 Hollenstedt - Germany
Tel: +49-(0)4165 / 2211-0
E-Mail: Service@HamannAG.com
BG 0007 e 1 (92)
Operating- and Maintenance Instruction
This instruction includes important safety information and instructions for commission-
ing, operation and maintenance of the sewage treatment plant. It is essential therefore, that
the responsible specialist refers to it before starting any work at the plant as well as prior
to commissioning. Furthermore, this instruction must always be available on site.
With reservation of technical modification
Sewage Treatment Plant
Type: SuperMini PLUS
Sewage Treatment Plant SuperMini PLUS 3 (92)
CONTENT
GENERAL INFORMATION ABOUT THIS DOCUMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ASSIGNMENT OF INFORMATION IN THIS DOCUMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INTENDED USE AND OPERATORS RESPONSIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
VERSION OF THIS DOCUMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
STRUCTURE OF A ORDER-SPECIFIC TECHNICAL MANUAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DEPOSITORY OF OPERATING AND MAINTENANCE INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
LABELLING OF ADVICE AND SAFETY ADVICE IN THIS DOCUMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ACCENTUATION AND NOTATION OF SPECIFIC TEXT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
REFERENCE CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
LABELLING OF SAFETY ADVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
PERSONNEL QUALIFICATIONS AND TRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DANGERS RESULTING FROM FAILURE TO OBSERVE SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . 9
SAFETY-CONSCIOUS WORKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SAFETY INSTRUCTIONS FOR THE USER/MACHINE OPERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SAFETY INSTRUCTIONS FOR MAINTENANCE, INSPECTION AND ASSEMBLY WORK . . . . . . . . . . . . . . . 10
UNAUTHORIZED MODIFICATIONS, MANUFACTURING OF REPLACEMENT PARTS . . . . . . . . . . . . . . . . . 10
IMPERMISSIBLE MODES OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SYSTEM DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
LAYOUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
TREATMENT TANK (ASSEMBLY GROUP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DOSING STATION, CHLORINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
STANDARD PIPING AND INSTRUMENTATION DIAGRAM (P&ID) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
LEGEND FOR PIPING AND INSTRUMENTATION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
PROCESS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
TRANSPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
MOUNTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
PIPING CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
DIMENSIONAL DRAWINGS OF THE PLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
CONNECTION OF INVERTER (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
OPERATING/CONTROL ELEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
SWITCH CABINET AND MULTI FUNCTION DISPLAY (MFD) [6A1] . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
MANUAL OPERATED VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
COMMISSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
PREPARATION AND FIRST COMMISSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
STANDARD OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
FAULT MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
CHANGING PARAMETER AND MANUAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
OVERVIEW OF MFD MENU STRUCTURE (VERSION 01.03.2012) . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
MONITORING OF TREATED SEWAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
SAFETY INFORMATION - CALCIUM HYPOCHLORITE GRANULAR AND
SODIUM HYPOCHLORITE SOLUTION 12-14%. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
OPERATING SUPPLY ITEM SODIUM HYPOCHLORITE (CHLORINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
MEASURING OF FREE CHLORINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
COMPONENTS OF THE PLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
TREATMENT TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
MACERATOR PUMP (A-1-ZP-005) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3-WAY VALVE, CIRCULATION/DISCHARGE (A-1-V-007)
3-WAY VALVE SLUDGE (A-1-V-041) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
FLOW RATE LIMITER, PROCESS WATER (A-1-A-033) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
LEVEL TRANSMITTER, TREATMENT TANK (A-1-CL-003) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
SHUT OFF VALVE, INLET MACERATOR PUMP (A-1-X-004) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
SHUT OFF VALVE, CLEANING OUTLET (A-1-X-043) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
OVERFLOW VALVE (A-1-H-101) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
SHOCK DAMPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
DOSING STATION, CHLORINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
DOSING PUMP, CHLORINE (A-1-P-023) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
CHLORINE SENSOR (A-1-CL-021) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
EXTERNAL AND SEPARATELY MOUNTED COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
TRANSFER-MACERATOR PUMP (A-1-ZP-100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
PROCESS WATER PUMP (A-1-P-032) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
SOLENOID VALVE, PROCESS WATER (A-1-V-034) (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
PROCESS WATER STRAINER (A-1-F-031) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
SLUDGE PUMP (A-1-P-042) (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
LEVEL SWITCH, HOLDING TANK (A-1-CL-102) (OPTION)
LEVEL SWITCH, SLUDGE TANK (A-1-CL-103) (OPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
SHOCK DAMPER (USCG OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
SWITCH CABINET WITH MULTI FUNCTION DISPLAY (MFD) [6A1] . . . . . . . . . . . . . . . . . . . . . . . . 87
CLEANING AND MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
PERIODICITY PLAN FOR NORMAL CONTINUOUS OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
WINTER LAY-UP AND DECOMMISSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
TANK CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
SPARE PARTS ORDERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
General information about this document
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ONLY FOR PLANTS WITH US COAST GUARD CERTIFICATE
EPA Standards and USCG Certified MSD as per 33 CFR 159.57 (17)
Note:
The EPA standards state that in freshwater lakes, freshwater reservoirs or other
freshwater impoundments whose inlets or outlets are such as to prevent the ingress
or egress by vessel traffic subject to this regulation, or in rivers not capable of navi-
gation by interstate vessel traffic subject to this regulation, marine sanitation devices
certified by the U.S. Coast Guard installed on all vessels shall be designed and op-
erated to prevent the overboard discharge of sewage, treated or untreated, or of any
waste derived from sewage.
The EPA standards further state that this shall not be construed to prohibit the car-
riage of Coast Guard-certified flow-through treatment devices which have been se-
cured so as to prevent such discharges.
They also state that waters where a Coast Guard-certified marine sanitation device
permitting discharge is allowed include coastal waters and estuaries, the Great
Lakes and interconnected waterways, freshwater lakes and impoundments accessi-
ble through locks, and other flowing waters that are navigable interstate by vessels
subject to this regulation (40 CFR 140.3).
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1. GENERAL INFORMATION ABOUT THIS DOCUMENT
1.1 ASSIGNMENT OF INFORMATION IN THIS DOCUMENT
The information in this document refers to Sewage Treatment Plant of type
SuperMini PLUS according to:
General certificate drawing
02-001-00004-0-11000-0
Detail Drawing for Treatment Tank (assembly group) with drawing number
Detail Drawing for Dosing Station (assembly group) with drawing number
02-000-00008-0-01000
Control unit with MFD Software version
01.03.2012
Electrical diagram with drawing number
This document contains information for installation personnel, operator/maintainer
and for service personnel.
In addition to this document the appended documents for all components of the Sew-
age Treatment Plant have to be observed!
Personnel charged with installation, operation, maintenance, inspection and assem-
bly must be in possession of the appropriate qualifications. Please also refer also to
section "Personnel qualifications and training" on page 9.
1.2 INTENDED USE AND OPERATORS RESPONSIBILITY
The Sewage Treatment Plant may only be operated on sea going vessels for treat-
ment of sewage within range of performance that is described in this document. See
section "Plant capacity/design" on page 18 and 2. "Safety" on page 9.
The Sewage Treatment Plant may only be used together with auxiliary equipment
that is recommended and admitted by HAMANN AG.
For security reason the Sewage Treatment Plant may not be reconstructed or mod-
ified. If any modification of the system is required HAMANN AG has to be consulted.
The operator/operating company is bound to report all changes that will effect the
good condition and safety of the system immediately. This applies in particular re-
garding an asserting of warranty and warranty claims.
The Sewage Treatment Plant is manufactured state-of-the-art and is safe to operate.
It may be installed, taken into operation and function properly when it is ensured that
all information and recommendations in this document are taken into consideration.
A sign or label should be available in the toilets, which informs about not to
flush objects such as cigarettes, fruit peel, razor blades, bottles, cotton swabs,
condoms, sanitary napkins or tampons etc. (including those described as
compostable) down the toilet.
02-001-00025-0-01000-0 for 230 V IMO standard version
S2008-11094 / SMP230 Series 1 for 230 V AC operation
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1.3 VERSION OF THIS DOCUMENT
File name with version information:
SM_PLUS_e10.fm
Release date: 27.9.2012
File name with version and release date are given at the inner side of each page of
this document.
1.4 STRUCTURE OF A ORDER-SPECIFIC TECHNICAL MANUAL
The complete order-specific Technical Manual consists of:
Cover page
Table of content
Plant components list
Piping- and Instrumentation Diagram (P&ID)
Info sheet "Important Information about storage, installation and commissioning
of Sewage Treatment Plants and their components
Dimensional drawing of the plant
Operating and Maintenance Instruction (this document)
Documentation of optional components, if applicable
Electrical diagrams
1.5 DEPOSITORY OF OPERATING AND MAINTENANCE INSTRUCTIONS
The Operating and Maintenance Instruction is delivered as paper hardcopy by indi-
vidual shipment. It must always be available on site.
This document is also available as PDF file by E-mail. If you may need it, please con-
tact HAMANN AG.
A paper hardcopy of the electrical diagrams can be found inside of the switch cabinet.
1.6 SAFETY INFORMATION
Section 2. "Safety" on page 9 and all other safety advise given in this document must
be observed.
1.7 LABELLING OF ADVICE AND SAFETY ADVICE IN THIS DOCUMENT
Important safety advice. Non-observance of safety instructions could lead to danger
of life or limb:
Warnings regarding electric power equipment. Non-observance of safety instructions
could lead to danger of life or limb:
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Safety instructions whose non-observance could jeopardize the system/machine
and its functions:
Important additional information to ensure optimal function and maximum perfor-
mance:
1.8 ACCENTUATION AND NOTATION OF SPECIFIC TEXT
Designations out of the electrical diagram in square brackets.
Example: [7K1]
Switches/switch positions and signal lamps on and inside of switch cabinets in
capital letters.
Example: MAI N SWI TCH OFF
Text displays on Multi Function Display (MFD).
Example: >CHLOR. SHORTAGE<
Reference code out of the Piping and Instrumentation Diagram (P&ID) in brack-
ets.
Example: Transfer-macerator pump (A-1-ZP-100)
1.9 REFERENCE CODE
The reference code is a unique identification for all main components of the
Sewage Treatment Plant.
Please also refer to sections:
3.5 "Legend for Piping and Instrumentation Diagram" on page 15
3.4 "Standard Piping and Instrumentation diagram (P&ID)" on page 14
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2. SAFETY
This document provides basic information about operation and maintenance of the
plant and its components and must be read by the mechanical fitter and by the tech-
nical personnel/operator, responsible for the plant prior to assembly and commis-
sioning It should be kept at the operating site of the device or near the plant at all
times.
Compliance is required not only with the General Safety Instructions given in this
section but also with the detailed instructions given under appendix and all other
chapters/sections.
2.1 LABELLING OF SAFETY ADVICE
See section "Labelling of advice and safety advice in this document" on page 7.
2.2 PERSONNEL QUALIFICATIONS AND TRAINING
Personnel charged with operation, maintenance, inspection and assembly must be
in possession of the appropriate qualifications. The company operating the machine
must define exact areas of responsibility, accountabilities and personnel supervision
schemes.
Personnel lacking the required skills and knowledge must receive training and in-
struction. If necessary, the operating company may commission the manufacturer or
supplier to conduct training courses.
Furthermore, the operating company must ensure that the personnel fully under-
stand the contents of the operating instructions.
2.3 DANGERS RESULTING FROM FAILURE TO OBSERVE SAFETY INSTRUCTIONS
Failure to comply with safety Instructions may lead to danger of life or limb as well as
environmental hazards or system/device malfunctions. Non-observance of Safety In-
structions may invalidate the right of claim to damages. Some examples of danger
resulting from failure to comply are as follows:
Failure of important machine/plant functions
Failure to follow prescribed methods of service and maintenance
Danger to life and limb due to electrical, mechanical or chemical influences
Danger to the environment due to leakage of hazardous substances
2.4 SAFETY-CONSCIOUS WORKING
Always comply with the safety instructions listed in this document, the existing na-
tional accident prevention regulations and any operating and safety rules relative to
a ship's internal work.
2.5 SAFETY INSTRUCTIONS FOR THE USER/MACHINE OPERATOR
Any potentially hazardous hot or cold machine parts must be provided with pro-
tection against accidental contact.
Protective guards for moving parts (e.g. coupling) must never be removed while
the system is in operation.
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Leakage's (e.g. in the shaft seal) of hazardous conveying liquids (e.g. toxic)
must be drained in such a way that no danger arises for persons or the environ-
ment. Always observe the relevant statutory requirements.
The risk of exposure to electrical power must be eliminated. For details see the
electrical installation regulations of your classification society and/or national
regulations.
When handling or storing materials labelled as hazardous, always follow appro-
priate precautionary methods, handling techniques and regulatory information,
and use appropriate protective clothing such as gloves or safety glasses.
In cases of emergency, such as for first aid measures, medical help, exposure
control, accidental release or fire consult the Material Safety Data Sheets of
used substances delivered by the manufacturer.
2.6 SAFETY INSTRUCTIONS FOR MAINTENANCE, INSPECTION AND ASSEMBLY WORK
The operator must ensure that all tasks relative to maintenance, inspection and as-
sembly are carried out by authorized and qualified personnel who have studied the
operating instructions closely and become sufficiently familiar with the machine.
As a basic rule, the machine must be brought to a standstill before work is carried
out; and the risk of exposure to electrical power must be eliminated. Always comply
with the de-commissioning procedures described in this document.
Any pumps or assemblies conveying media that are detrimental to health must be
decontaminated.
Immediately following completion of work, all safety and protective devices must be
replaced to their proper position and, where applicable, re-activated. Before re-start-
ing, observe the points listed under section "Commissioning" on page 30.
2.7 UNAUTHORIZED MODIFICATIONS, MANUFACTURING OF REPLACEMENT PARTS
Conversions or modifications of or for the machine are permissible only after consul-
tation with HAMANN AG. Original manufacturer replacement parts and manufactur-
er-approved accessories enhance the operational safety of the machine.
Using unauthorized parts may lead to the nullification of the manufacturer's li-
ability of any resultant damages.
2.8 IMPERMISSIBLE MODES OF OPERATION
The operational safety of system and its devices are under warranty only when being
operated as defined in the operating instruction. Never allow the specified threshold
values to be exceeded. See section "Technical data" on page 17.
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3. SYSTEM DESCRIPTION
3.1 LAYOUT
Figure 1: Principle diagram
The Sewage Treatment Plant consists of the following assembly groups and compo-
nents:
STANDARD COMPONENTS (MANDATORY FOR OPERATION)
Treatment tank (assembly group)
Dosing station, Chlorine (assembly group)
Transfer-macerator pump (A-1-ZP-100)
Process water pump (A-1-P-032) or
Solenoid valve, process water (A-1-V-034)
Process water strainer (A-1-F-031)
OPTIONAL COMPONENTS
If sludge draining by gravity is not possible:
Sludge Pump (A-1-P-042)
If ships sludge tank and/or sewage holding tank are not equipped with appropri-
ate level control devices:
Level switch, holding tank (A-1-CL-102)
Level switch, sludge tank (A-1-CL-103)
USCG wire cable isolator set (for US Coast Guard certified plants)
Bearing/support elements designed as 2+2 pieces wire cable isolators.
To be mounted instead of standard bearing-/support elements.
Treatment tank
Vent line
Chlorine
Sludge
Process water
Seawater
Chlorine dosing station
Process water pump
(A-1-P-032)
Transfer-macerator
pump (A-1-ZP-100)
Container, chlorine
(A-1-B-022)
Dosing pump, chlorine
(A-1-P-023)
Sludge Pump
(A-1-P-042)
to ships sludge tank or
separate compartment in
ships holding tank
Raw sewage from
ships holding tank
Treated sewage
over board
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3.2 TREATMENT TANK (ASSEMBLY GROUP)
Figure 2: View from front/right
Figure 3: View from front/left
3-way valve, circulation/
discharge (A-1-V-007)
Freshwater flushing
connection (A-1-R-058)
Clearing tank
(A-1-B-044)
Outlet sludge
(A-1-R-062)
Macerator pump
(A-1-ZP-005)
Shut off valve, inlet
macerator pump
(A-1-X-004)
Outlet discharge over
board (A-1-R-051)
Inlet sewage
(A-1-R-057)
Overflow valve
(A-1-H-101)
Terminal box
Bearing/support elements
Vent, treatment tank
(A-1-R-053)
Process water inlet
(A-1-R-052)
Connection chlorine
vent (A-1-R-055)
Level transmitter, treatment
tank (A-1-CL-003)
Chlorine injection
(A-1-R-054)
Shut off valve,
cleaning outlet
(A-1-X-043)
Whirlcontainer
(A-1-B-006)
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3.3 DOSING STATION, CHLORINE
Figure 4: Chlorine dosing station
All assembly groups and components have to be installed and connected according
to "Standard Piping and Instrumentation diagram (P&ID)" on page 14 and section "In-
stallation" on page 19.
Switch cabinet is mounted separately. See also section "Electrical connections" on
page 25 and separate electrical diagram.
Vent chlorine tank (A-1-R-060),
to be connected to Connection
chlorine vent (A-1-R-055)
Dosing pump, chlo-
rine (A-1-P-023)
Chlorine sensor
(A-1-CL-021)
Container, chlorine
(A-1-B-022)
Outlet of Dosing
pump, chlorine (A-1-
P-023), to be con-
nected to Chlorine in-
jection (A-1-R-054)
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3.4 STANDARD PIPING AND INSTRUMENTATION DIAGRAM (P&ID)
Note: The order-specific P&ID see introduction of the manual.
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3.5 LEGEND FOR PIPING AND INSTRUMENTATION DIAGRAM
*) Separately mounted components
Reference
code
Designation
A-1-A-033 Flow rate limiter, process water (A-1-A-033)
A-1-B-001 Sedimentation chamber (A-1-B-001)
A-1-B-002 Reaction & discharge chamber (A-1-B-002)
A-1-B-006 Whirlcontainer (A-1-B-006)
A-1-B-022 Container, chlorine (A-1-B-022)
A-1-B-044 Clearing tank (A-1-B-044)
A-1-CL-003 Level transmitter, treatment tank (A-1-CL-003)
A-1-CL-021 Chlorine sensor (A-1-CL-021)
A-1-CL-102 Level switch, holding tank (A-1-CL-102) (option) *)
A-1-CL-103 Level switch, sludge tank (A-1-CL-103) (option) *)
A-1-F-031 Process water strainer (A-1-F-031) *)
A-1-H-101 Overflow valve (A-1-H-101)
A-1-P-023 Dosing pump, chlorine (A-1-P-023)
A-1-P-032 Process water pump (A-1-P-032) *)
A-1-P-042 Sludge Pump (A-1-P-042) (option) *)
A-1-P-200 Transfer pump, grey water tank (A-1-P-200) (option) *)
A-1-R-051 Outlet discharge over board (A-1-R-051)
A-1-R-052 Process water inlet (A-1-R-052)
A-1-R-053 Vent, treatment tank (A-1-R-053)
A-1-R-054 Chlorine injection (A-1-R-054)
A-1-R-055 Connection chlorine vent (A-1-R-055)
A-1-R-056 Vent connection for clearing tank (A-1-R-056)
A-1-R-057 Inlet sewage (A-1-R-057)
A-1-R-058 Freshwater flushing connection (A-1-R-058)
A-1-R-059 Outlet sludge treatment tank (A-1-R-059)
A-1-R-060 Vent chlorine tank (A-1-R-060)
A-1-R-061 Outlet, chlorine tank (A-1-R-061)
A-1-R-062 Outlet sludge (A-1-R-062)
A-1-R-063 Outlet refeeding pipe (A-1-R-063)
A-1-R-064 Outlet sewage (A-1-R-064)
A-1-R-065 Inlet sewage (A-1-R-065)
A-1-V-007 3-way valve, circulation/discharge (A-1-V-007)
A-1-V-034 Solenoid valve, process water (A-1-V-034) (option) *)
A-1-V-041 3-way valve sludge (A-1-V-041)
A-1-X-004 Shut off valve, inlet macerator pump (A-1-X-004)
A-1-X-043 Shut off valve, cleaning outlet (A-1-X-043)
A-1-ZP-005 Macerator pump (A-1-ZP-005)
A-1-ZP-100 Transfer-macerator pump (A-1-ZP-100) *
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3.6 PROCESS DESCRIPTION
From a separate holding tank, sewage will be discharged via Transfer-macerator
pump (A-1-ZP-100) into the Sedimentation chamber (A-1-B-001) of the treatment
tank. The sewage flows into the first area of the Sedimentation chamber (A-1-B-001)
where constituents will be separated, and onward to a second area, where light
weighted constituents will be separated and only a small amount of suspended solids
will flow into the Reaction & discharge chamber (A-1-B-002).
After a defined volume of sewage enters the Reaction & discharge chamber (A-1-B-
002) and a specific level L2 has been reached and recognized by the Level transmit-
ter, treatment tank (A-1-CL-003), the following processes will be initiated:
The Process water pump (A-1-P-032) starts (or Solenoid valve, process water
(A-1-V-034) opens) and transfers process water into the treatment tank until fill-
ing level L4 is reached. This ensures that oxygen rich process water (sea water)
enters into the treatment process, encouraging oxidation.
The Dosing pump, chlorine (A-1-P-023) starts and a sodium hypochlorite solu-
tion is dosed for about 3 seconds (factory preset) into the Reaction & discharge
chamber (A-1-B-002).
After the Process water pump (A-1-P-032) has started (or the process water
valve has opened), the Macerator pump (A-1-ZP-005) will also start, ensuring
circulation inside of the treatment tank. Solid matters will be macerated, along
with being mixed and aerated. Extra turbulence is introduced through the Whirl-
container (A-1-B-006).
Via the 3-way valve, circulation/discharge (A-1-V-007), the sewage will circulate
while process water is flowing into the tank.
When level L4 is reached, the Process water pump (A-1-P-032) will stop. The
Macerator pump (A-1-ZP-005) will stay in operation and the 3-way valve, circula-
tion/discharge (A-1-V-007) switches over automatically so that treated sewage
can be discharged over board.
Any sediment (about 0.5 Liter) that has been collected inside of the Sedimenta-
tion chamber (A-1-B-001) will be discharged/drained automatically - normally
after every 5th treatment cycle (factory preset) - via 3-way valve sludge (A-1-V-
041). If sludge draining by gravity is not possible, an optional Sludge Pump (A-1-
P-042) has to be installed.
The sludge may then be collected in a separate sludge tank, a container or a
separate compartment in a ship's holding tank. It must then be disposed of
according to applicable regulations such as IMO resolution MEPC.159(55) or
disposed to a facility onshore.
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3.7 TECHNICAL DATA
ELECTRICAL DATA
*) order specific operation-/supply voltage can be seen on type plate of the plant and
in the electrical diagram.
WEIGHTS AND DIMENSIONS
TYPE PLATE
The type plate is positioned on the Switch cabinet. A corresponding type plate is
mounted on the Terminal box at the treatment tank (assembly group).
Figure 5: Type plate and optional type plate in case of USCG certification (below)
positioned at switch cabinet
Operation-/supply voltage*
with optional inverter
230V AC 10%
24V DC 10%
Electrical power requirement 1.5 kW
Protection class IP55
Weights Weight Dimensions (WxHxD)
IMO Standard
~ 72 kg
~ 918 x 730 x 560 mm
USCG version with shock dampers
~ 918 x 754 x 560 mm
Dosing station, chlorine (assembly group) ~ 10.5 kg ~ 421 x 510 x 321 mm
Switch cabinet ~ 21 kg ~ 400 x 500 x 210 mm
Hamann AG
Bei der Lehmkuhle 4, 21279 Hollenstedt, Germany
Model: Super Mini Plus
Serial no.:
Date of manufacture:
This unit is IMO certified according to MEPC. 159(55).
Issued on 01.09.2008 by
See- Berufsgenossenschaft, Hamburg
Designed hydraulic loading 2,118 m/d
(grey and black water)
Designed organic loading 1,28 kg/d (BSB)

U.S. Coast Guard Certification No.159.015/6009/0 U.S. Coast Guard Certification No.159.015/6009/0
for Type II uninspected vessels for Type II uninspected vessels
0801 -
U.S. Coast Guard Certification No.........................
for Type II, uninspected vessels.
Capacity: 1850 LPD (black water)
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AMBIENT CONDITIONS
The plant is designed for operation:
in shipping routes with seawater, freshwater and brackwater
at a max. ambient temperature of 50 C (+122 F) and 90% relative humidity
Roll- and pitch angle up to 22.5
The SUPER MINI PLUS plant may not be used in flammable and explosive at-
mosphere and areas!
PLANT CAPACITY/DESIGN
The sewage treatment plant is intended to treat 2118 Liters of grey and black water
per day having 1.28 kg BOD5 and max. 660 mg/ liter TSS.
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4. INSTALLATION
4.1 TRANSPORT
The treatment tank assembly group has to be lifted directly at the tank body. Trans-
port has to be done with appropriate lifting tool/carrying strap respectively with 2 per-
sons by hand. Take care that the attached components will not get damaged during
transport!
Transport of the treatment tank assembly group has to be done standing upright pref-
erably on a transportable pallet.
The treatment tank assembly group and the Chlorine Dosing Station must not
be lifted with lifting tools/carrying straps fixed at the attached plant compo-
nents!
4.2 MOUNTING
The treatment tank assembly group has to be mounted horizontally onto appropriate
frames/panels or baseplates.
It must be regard to a low vibration mounting ( 0.5g).
For noise reduction purposes the plant is equipped with Bearing/support elements.
Compression/shear mounts for IMO Standard version
Wire cable isolators for USCG version (delivered as loose parts and to be
mounted by the customer)
Due the fact, that the plant is mounted on elastic elements, we highly recom-
mend to use vibration dampers (compensators) for all piping and components
connections to the plant, because of extremely vibrations will be caused
through heavy manoeuvre at board during passage.
Figure 6: Plant with mounted wire cable isolators for USCG version
Any kind of welding at the tank of the sewage treatment plant will cause dam-
age to the coating inside of the tank!
If the ship's piping is made of CuNiFe, the sewage treatment plant's piping will
have to be properly isolated.
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In order to permit ready access to all parts requiring service, at least 400 mm of
space (distance "A") is recommended above the plant as well as in front and on both
sides.
The chlorine dosing station can be mounted in upright position onto appropriate
frames/panels or baseplates.
The switch cabinet has to be wall-mounted.
4.3 PIPING CONNECTIONS
The reference code in brackets () refers to drawing " Standard Piping and In-
strumentation diagram (P&ID)" on page 14 and table " Legend for Piping and
Instrumentation Diagram" on page 15.
INLET SEWAGE (A-1-R-065)
R 2" i (inside/female thread) DIN 2999, inlet of Transfer-macerator pump (A-1-
ZP-100)
OUTLET SEWAGE (A-1-R-064)
R 1" i (inside/female thread) DIN 2999, outlet of Transfer-macerator pump (A-1-
ZP-100)
INLET SEWAGE (A-1-R-057)
R 1" o (outside/male thread) DIN 2999, inlet of Overflow valve (A-1-H-101)
Feed line from Transfer-macerator pump (A-1-ZP-100) to Overflow valve (A-1-H-
101) according to "Standard Piping and Instrumentation diagram (P&ID)" on page
14.
A
A
A
A
A = min. 400 mm
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To avoid back-flow (and caused by this, a uncontrolled/unintentional filling of the
treatment tank) it is recommended to design the piping that either rises above the
seawater level or the plant's tank top (according to which point is positioned higher)
and/or to install check valves in accordance to section "Standard Piping and Instru-
mentation diagram (P&ID)" on page 14.
OUTLET REFEEDING PIPE (A-1-R-063)
R 1" i (inside/female thread) DIN 2999, outlet Transfer-macerator pump (A-1-ZP-
100)
The size of refeeding pipe must be 1". The pipe is connected from Outlet refeeding
pipe (A-1-R-063) to ship's holding tank, see "Standard Piping and Instrumentation di-
agram (P&ID)" on page 14.
This refeeding pipe provides a quick bleeding of Transfer-macerator pump (A-1-ZP-
100) and ensures a better lighting.
Besides this a better mixing of sewage in holding tank is obtained and therefore scal-
ing is avoided.
FRESHWATER FLUSHING CONNECTION (A-1-R-058)
R 3/4" o (outside/male thread) DIN 2999
In order to flush out the tank with freshwater or seawater (e.g. before maintenance
or infrequent usage). No permanent connection is to be made to a fresh water or po-
table water system.
OUTLET SLUDGE (A-1-R-062)
R 3/4" i (inside/female thread) DIN 2999
OUTLET DISCHARGE OVER BOARD (A-1-R-051)
R 3/4" i (inside/female thread) DIN 2999
For the discharge piping layout the total distance must be in accordance to table of
pump characteristic on page 51.
A sample cock (R ") must be installed about at a minimum of 2 m from Outlet dis-
charge over board (A-1-R-051) of the plant in order to check the chlorine concentra-
tion and the chlorine concentration level that is being discharged.
PROCESS WATER INLET (A-1-R-052)
R 1/2" o (outside/male thread) DIN 2999
The Process water inlet (A-1-R-052) has to be connected to the ships seawater sup-
ply.
Process water is supplied at Process water inlet (A-1-R-052) via Process water
strainer (A-1-F-031) and Process water pump (A-1-P-032).
To avoid a uncontrolled/unintentional emptying of the tank via process water line, a
check valve has to be installed between the outlet of the Process water pump (A-1-
P-032) and Process water inlet (A-1-R-052) of the plant. Alternatively a Solenoid
valve, process water (A-1-V-034) may be used instead of a pump. Water supply
pressure has to be between 1.5 and 5 bar.
To avoid a uncontrolled/unintentional filling of the tank via process water line, the pip-
ing maybe has to be designed with a piping loop above seawater level. See also sec-
tion "Standard Piping and Instrumentation diagram (P&ID)" on page 14.
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For maintenance purposes, e.g. cleaning of filter or pump, appropriate shutoff valves
have to be installed at inlet of Process water strainer (A-1-F-031) and outlet of Pro-
cess water pump (A-1-P-032).
VENT CHLORINE TANK (A-1-R-060)
CONNECTION CHLORINE VENT (A-1-R-055)
6 mm hose connection
Because of produced chlorine gas, a hose leading from Vent chlorine tank (A-1-R-
060) to Connection chlorine vent (A-1-R-055) has to be installed.
Only the hoses delivered with the plant should be used for installation.
DOSING PUMP, CHLORINE (A-1-P-023)
CHLORINE INJECTION (A-1-R-054)
6 mm hose connection
The outlet of Dosing pump, chlorine (A-1-P-023) has to be connected to the Chlorine
injection (A-1-R-054) at the treatment tank.
The position of the outlet of the Dosing pump, chlorine (A-1-P-023) should be posi-
tioned lower than the position of the Chlorine injection (A-1-R-054) in order to avoid
gravity feed.
Only the hoses delivered with the plant should be used for installation.
VENT, TREATMENT TANK (A-1-R-053)
R 1 " o (outside/male thread) DIN 2999
The vent connection of the treatment tank has to be connected to the ships funnel.
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4.4 DIMENSIONAL DRAWINGS OF THE PLANT
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Figure 7: Dimensions of the plant
20
5
3
0
1
8
0
355
0
5
1
5
7
3
0
0
5
0
5
180
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4.5 ELECTRICAL CONNECTIONS
The power supply must correspond with voltage and frequency given in the or-
der confirmation and the Technical Data!
All power supply lines for switch cabinet and separate components must be
designed sufficiently regarding fuses and wire cross section!
In the electric diagram detailed specified connection cables are to observe
strictly!
All electrical connections must be in accordance with the electrical diagram (see
electrical diagram in the technical manual) and in accordance with national rules/reg-
ulations.
Main power supply for SuperMini PLUS Sewage Treatment Plant has to be connect-
ed to the switch cabinet. The switch cabinet has to be mounted at the desired posi-
tion.
The following separate components have to be connected by the customer according
to Figure 8 on page 27 and the electrical diagram.
At treatment tank:
Terminal box
Level switch, holding tank (A-1-CL-102) (option)
Level switch, sludge tank (A-1-CL-103) (option)
At terminal box:
Dosing pump, chlorine (A-1-P-023)
Chlorine sensor (A-1-CL-021)
Solenoid valve, process water (A-1-V-034) (option)
Sludge Pump (A-1-P-042) (option)
(required if discharge of sludge by gravity is not possible)
EXTERNAL RELEASE SIGNALS
For automatic control, the "Start/Stop level" of the holding tank has to be con-
nected via a Level switch, holding tank (A-1-CL-102) with no-volt (potential free)
contact to the Switch cabinet.
" Stop level" and " Start level" are realized by one common level switch.
"High level" in sludge tank or sludge-compartment: This will provide an alarm
signal to the SuperMini PLUS when the maximum level has been reached.
4.5.1 CONNECTION OF INVERTER (OPTION)
The inverter has to be connected only at 24 V DC batteries. Do not connect the
inverter at power supply units or at voltage source which are exposed to volt-
age fluctuation.
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The inverter has got the protection class IP23. This means protection against contact
with the fingers, protection against solid foreign bodies with >12 mm and protection
against diagonal water drips (up to a 60 angle).
The inverter has to be installed at an appropriate place on board, because
HAMANN AG does not deliver an additional separate housing.
Do not directly expose the inverter to heat sources.
Pay attention to sufficient cable cross section between battery and inverter.
For details refer to the delivered technical manual for inverter.
Obey also the advice and instructions in the technical manual of the inverter in the
annex.
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Figure 8: Electrical cable/connection scheme
Dosing pump, chlo-
rine (A-1-P-023)
6A1
5H1
-5Q1
Ground to hull
Transfer-macerator
pump (A-1-ZP-100)
Level switch, holding tank
(A-1-CL-102) (option)
Level switch, sludge tank
(A-1-CL-103) (option)
Chlorine sensor
(A-1-CL-021)
Process water pump (A-1-
P-032) or
Solenoid valve, process
water (A-1-V-034) (option)
Sludge Pump (A-1-
P-042) (option)
Terminal box at
treatment tank
Separate mounted
switch cabinet
Power supply
230 V AC
Inverter 24 VDC
from battery (option)
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5. OPERATING/CONTROL ELEMENTS
5.1 SWITCH CABINET AND MULTI FUNCTION DISPLAY (MFD) [6A1]
Operation and monitoring of SuperMini PLUS is done via Multi Function Display
(MFD) [6A1]. The MFD is positioned at the front side of the switch cabinet.
Figure 9: Switch cabinet and MFD
The Operating/control elements have the following functions:
Main Switch [5Q1]: Mains supply voltage.
Indicator light supply voltage [5H1]: Control display of supply voltage.
The buttons at MFD have the following functions (see also Section 7.2 on page 41):
DEL: To reset the password to "0000"
ESCAPE: To exit automatic, parameter level and to exit parameter input fields.
OK: To quit an alarm or to activate fields for input of parameter values and con-
firm parameter values.
Arrow: To move the cursor, to activate/deactivate components or to change val-
ues.
Asterisk (*): Input/output status.
ALT: To show the last displayed fault message.
6A1
5H1
-5Q1
Text display (LCD)
DEL-button
ESCAPE-button
OK-button
Alarm-LED
Status-LED
ALT-button
Asterisk-button
Arrow buttons (up-down-left-right)
Switch cabinet
Multi Function Display (MFD)
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5.2 MANUAL OPERATED VALVES
Figure 10: Manual operated valves
This figure shows Shut off valve, inlet macerator pump (A-1-X-004), and Shut off
valve, cleaning outlet (A-1-X-043), in position open.
For normal operation Shut off valve, cleaning outlet (A-1-X-043), must be closed.
SHUT OFF VALVE, INLET MACERATOR PUMP (A-1-X-004)
The manual operated Shut off valve, inlet macerator pump (A-1-X-004) has to be
in position open for normal operation.
See also "Winter lay-up and decommissioning" on page 89.
SHUT OFF VALVE, CLEANING OUTLET (A-1-X-043)
The manual operated Shut off valve, cleaning outlet (A-1-X-043) has to be in
position closed for normal operation.
See also "Tank cleaning" on page 90.
OVERFLOW VALVE (A-1-H-101)
This control valve is mounted directly at inlet of treatment tank and is required to
adjust a defined flow rate of the Transfer-macerator pump (A-1-ZP-100). A trans-
fer sequence should have a duration time between 30 and 45 seconds.
Shut off valve, cleaning
outlet (A-1-X-043)
macerator pump
(A-1-X-004)
Overflow valve
(A-1-H-101)
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6. COMMISSIONING
The actual installed software version is displayed on Multi Function Display (MFD)
right after the plant is switched on.
6.1 PREPARATION AND FIRST COMMISSIONING
After all installation work of all components has been completed check tank
and piping for foreign objects (bolts, nuts, etc.).
1. Please read the operating and maintenance instruction carefully.
2. Check your serial number on type plate of the Sewage Treatment Plant with that
one given in the plants certificate. They must be the same.
3. Check if all piping connections and directions and all electrical connections are
correct.
Ensure that all electrical connections are carried out according to the relevant
safety regulations. The electrical power supply must correspond with voltage
and frequency specified in the order confirmation and Technical Data!
4. Fill the pump body of the separate mounted Transfer-macerator pump (A-1-ZP-
100) one time with freshwater via the top mounted filling hole to ensure self prim-
ing operation. For this first remove the blind plug and mount it after filling.
5. Open the Shut off valve, inlet macerator pump (A-1-X-004) and all on-board
installed shut off valves at inlet and outlet piping:
Sewage inlet from ships sewage holding tank
Process water supply (Seawater supply)
Sewage discharge line "over board"
Sludge/sediment discharge/outlet line
6. Switch on Main Switch [5Q1]. Also refer to section "Operating/control elements"
on page 28.
At MFD the following start screen appears:
If the Container, chlorine (A-1-B-022) is empty in a little while the message
>CHLOR. SHORTAGE< appears.
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7. In order to test the alarm, place a small metal plate (or similar) between chlorine
tank and the chlorine shortage alarm sensor. By this an adequate filling level of
chlorine is simulated at the sensor.
After pressing the OK button the alarm message >CHLOR. SHORTAGE<
expires and the display switches back to start screen.
Remove the small plate between chlorine tank and the chlorine shortage
alarm sensor.
Alarm message >CHLOR. SHORTAGE< should now appear again.
8. Fill the chlorine container approximately full with Sodium-Hypochlorite.
If the >CHLOR. SHORTAGE< alarm is still shown, the sensor may be has to
be adjusted by moving it closer to chlorine tank (see section 9.2.2 on page
62).
9. Fill the SuperMini PLUS treatment tank with freshwater or seawater.
Fill the Sedimentation chamber (A-1-B-001) of the treatment tank by using a
hose connected to Freshwater flushing connection (A-1-R-058).
Stop tank filling when >LEVEL 65 mm< is reached/exceeded. The actual fill-
ing level is monitored at start screen of the MFD.
The plant is now ready for automatic operation.
10.The following functions should take place when the arrow-up button is pressed:
Process water pump (A-1-P-032) begins operating.
Circulation by Macerator pump (A-1-ZP-005) begins.
Chlorine dosage begins via Dosing pump, chlorine (A-1-P-023) at level L3 for
approximately 3 seconds.
When level L4 is reached, Process water pump (A-1-P-032) stops and three-
way-valve switches over so that treatment tank will be drained via Macerator
pump (A-1-ZP-005).
Further information about normal/automatic operation and operation at Multi
function Display (MFD) can be found in section " Operating/control elements"
on page 28.
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7. OPERATION
The active installed software version will be displayed on Multi Function Display
(MFD) right after the plant is switched on.
7.1 STANDARD OPERATION
When supply voltage is switched ON by Main Switch [5Q1] one of the following dis-
play texts appear and the plant goes into the according operational state. This de-
pends on that state of operation the plant has been when it was switched off.
DISPLAY AT MFD IN NORMAL OPERATION
Display at MFD
Mode/layer at MFD
menu
State of operation
Start screen Plant is not active and not
ready for automatic opera-
tion.
Plant can be switched into
automatic mode according
to"Starting automatic opera-
tion" on page 34.
Automatic mode
>Auto Mode
Ready for
TRANSFER<
Plant is ready-to-operate and
is waiting for transfer release
signal from ships holding
tank.
Filling level in treatment tank
is below "L1".
Automatic mode
>TRANSFER<
Transfer-macerator pump (A-
1-ZP-100) starts according to
filling level in ships holding
tank and sedimentation
chamber of treatment tank is
filled with sewage out of
ships holding tank.
Automatic mode
>Auto mode
Filling<
1-ZP-100) stops.
Process water pump (A-1-P-
032) pumps into treatment
tank.
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POSITION/SEQUENCE OF SWITCH POINTS AND FILLING LEVEL
Switch points / filling level are defined down top:
Automatic mode
>Auto mode
CIRCULATION<
Filling level in process cham-
ber reaches "L2".
032) further drains into the
process chamber.
Intermixture of sewage and
process water circulates
inside of the process cham-
ber.
Dosing pump, chlorine (A-1-
P-023) operates for about 3
seconds.
Filling level inside of the pro-
cess chamber rises and is
between L2 and L4.
Automatic mode
>Auto mode
DISCHARGE<
Filling level inside of the pro-
cess chamber reaches "L4"
Process chamber becomes
drained until filling level is
below "L1".
The plant will then switch into
operation mode
>Ready for TRANSFER<
Sediment Counter
>SED. C.< shows the amount
of treatment cycles to be
awaited for the next sediment
discharge routine.
Level Factory preset Description
L5 420 mm Highest filling level.
>HIGH LEVEL ALARM<.
L4 365 mm Circulation ends.
Discharge begins.
L3 150 mm Chlorine injection.
L2 65 mm Circulation begins.
~ 27 mm Transfer release signal ends and filling of
Reaction & discharge chamber (A-1-B-002)
starts.
L1 20 mm Lowest filling level.
Plant is in standby.
Transfer release signal begins.
End of treatment cycle / discharge stops.
(continued)
Display at MFD
Mode/layer at MFD
menu
State of operation
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STARTING AUTOMATIC OPERATION
From start screen press the arrow-up button to start automatic mode:
The plant either awaits transfer or starts operating according to actual level
inside of treatment tank or last operating mode. See table in section "Standard
operation" on page 32.
A specific fault message may be displayed when the plant is switched on. Then
the plant is not ready for operation.
See next section "Fault messages".
7.1.1 FAULT MESSAGES
FAULT CHLOR. SHORTAGE
As a exceptional case the plant can be operated without chlorine by pressing the OK
button to start automatic operation (see"Starting automatic operation" on page 34).
Display at MFD Meaning Possible reason(s) and
trouble shooting
Chlorine sensor (A-1-
CL-021) has released.
Container, chlorine (A-1-B-
022) has to be refilled.
has to be adjusted correctly.
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FAULT HIGH LEVEL ALARM
Danger of overflow of treatment tank!
When High Level L4 alarm is displayed, the operator must ensure that no more
sewage/liquid gets uncontrolled/unintentional into the treatment tank.
Possible reasons may be:
Sewage feed of sewage from holding tank or process water inlet caused by
hydrostatic pressure.
Backflow of treated sewage caused by hydrostatic pressure.
In these cases the pipe design has to be modified suitably.
The plant can be switched back into automatic operation by pressing the OK button
(see"Starting automatic operation" on page 34).
trouble shooting
Level transmitter, treat-
ment tank (A-1-CL-003),
indicates filling level
above High Level "L4".
Uncontrolled/unintentional fill-
ing of the treatment tank. The
plant is not able to handle all
incoming sewage/liquid.
Uncontrolled/unintentional fill-
ing via inlets and/or outlets
must be stopped.
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FAULT DELAY SED. VALVE / HIGH LEVEL SEDIMENT / OVERL. SED.
PUMP
For a detailed fault finding the actual states of signal inputs can be displayed as fol-
lows:
1. Press OK button > Start Screen will be displayed.
2. Press Asterisk button > Status of In-/Outputs will be displayed.
trouble shooting
3-way valve sludge (A-
1-V-041) do not reach
one of its end positions.
Valve is clogged and has to
be cleaned.
End position switches are
clogged and have to be
cleaned.
Cable connection of end
position switches have to be
checked.
After the malfunction has been
assessed/corrected, the valve
can be manually operated (see
section 7.1.2) to observe cor-
rect function of end position
switches (see below).
Motor protection switch
of Sludge Pump (A-1-P-
042) has released.
Pump is clogged and has to
be cleaned.
Motor winding is damaged
and has to be checked.
Cable connection is damaged
"High Level" sediment
tank.
High Level is reached in sedi-
ment tank and tank has to be
emptied.
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DESCRIPTION:
FAULT PROCESS WATER
After the malfunction has been assessed/corrected, the plant can be switched back
into automatic operation by pressing the OK button (see"Starting automatic opera-
tion" on page 34).
FAULT DISCHARGE
After the malfunction has been assessed/corrected, the plant can be switched back
into automatic operation by pressing the OK button (see"Starting automatic opera-
tion" on page 34).
Inputs
I 1 Start Transfer (signal from ships holding tank)
I 2 Stop Transfer (signal from ships holding tank)
I 4 Motor protection Sludge Pump (A-1-P-042)
I 6 Chlorine deficiency
I 9 Motor driven 3-way valve sludge (A-1-V-041) in end position CLOSED
I 10 Motor driven 3-way valve sludge (A-1-V-041) in end position OPEN
I 11 High level sediment tank
trouble shooting
Treatment cycles "Fill-
ing" and "circulation" last
longer than 7 minutes
and therefore automatic
operation is interrupted.
032) works/drains inade-
quately and has to be
checked.
Process water strainer (A-1-
F-031) is clogged and has to
be checked/cleaned.
Flow rate limiter, process
water (A-1-A-033) is clogged
and has to be checked/
cleaned.
No seawater supply. Seawa-
ter intake has to be checked.
trouble shooting
The process chamber
has not been drained
down completely to fill-
ing level L1 during dis-
charge cycle.
Treated sewage could not
have been drained and out-
lets have to be checked for
free flow.
Macerator pump (A-1-ZP-
005) does not drain the pro-
cess chamber during the nor-
mal time duration of 7
minutes and has to be
checked.
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FAULT LEVEL SWITCH
FAULT TRANSFER
FAULT HIGH LEVEL TRANS
FAULT OVERL. TRANS. PUMP
trouble shooting
ment tank (A-1-CL-003)
is out of function.
Cable connection of Level
transmitter, treatment tank
(A-1-CL-003) is damaged
trouble shooting
The running time of
Transfer-macerator
pump (A-1-ZP-100) of 5
minutes is exceeded.
1-ZP-100) is does not word
correctly or is damaged.
Overflow valve (A-1-H-101)
has not enough opened.
Overflow valve (A-1-H-101) is
blocked.
trouble shooting
The on-board holding
tank is full.
The inflow of sewage into the
on-board holding tank is to
high.
The Level switch, holding
tank (A-1-CL-102) is defec-
tive.
trouble shooting
Motor protection switch
of Transfer-macerator
pump (A-1-ZP-100) has
released.
Pump is clogged and has to
be cleaned.
Motor winding is damaged
Cable connection is damaged
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7.1.2 CHANGING PARAMETER AND MANUAL OPERATION
To enter the parameter level at MFD press the arrow-right button when being in the
main menu:
The display will then show the password entry mask:
The password can be entered now by using the arrow buttons.
Arrow-up button: increases the digit
Arrow-down button: decreases the digit
OK button: confirms users entry
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PARAMETER LEVEL
After the password "2211" has been entered the following parameters can be adjust-
ed manually at MFDs parameter level:
Display at MFD Explanation
Running time of Dosing pump, chlorine (A-1-P-023) can
be adjusted between 0 - 60 s. Factory preset is "3 s".
Refer to section "Measuring of free chlorine" on page 43.
The pump can be started manually by pressing continu-
ously the "arrow up" button.
3-way valve, circulation/discharge (A-1-V-007) can be
switched-overmanually between positions "circulation"
and "discharge".
Macerator pump (A-1-ZP-005) can be stopped and
started manually.
The actual filling level of the treatment tank is displayed.
Transfer-macerator pump (A-1-ZP-100) can be stopped
and started manually.
The actual filling level of the treatment tank is displayed.
Process water pump (A-1-P-032) can be stopped and
started manually.
3-way valve sludge (A-1-V-041) can be operated manu-
ally.
The Sludge Pump (A-1-P-042) (option) can be switched
on or off manually.
Counter for activation of 3-way valve sludge (A-1-V-041)
can be manually adjusted. This counter represents the
number of treatment cycles that must occur before 3-way
valve sludge (A-1-V-041) opens. Factory preset is "5".
The sediment discharge time of the 3-way valve sludge
(A-1-V-041) can be manually adjusted between values
from 0 to 10 s (duration when valve is open). Factory
preset is "2 s".
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7.2 OVERVIEW OF MFD MENU STRUCTURE (VERSION 01.03.2012)
Figure 11: Menu structure of MFD
Start screen
ESC
ESC
ESC
ESC
Fault messages
Parameter level (press ESC to go back to Start screen)
Operation cycle
ESC
Service-
level
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8. MONITORING OF TREATED SEWAGE
Handling chemicals can be dangerous. Review the Material Safety Data Sheets
before handling.
One sub-process in the sewage treatment is the insertion of sodium hypochlorite. In
order to achieve treatment results in accordance with international regulations, mon-
itoring will be required by measuring the concentration of free chlorine leaving the
system, a concentration that should be about 0.5 mg/l and can be determined
through weekly sampling and testing water quality with the test strips for free chlo-
rine.
8.1 SAFETY INFORMATION - CALCIUM HYPOCHLORITE GRANULAR AND SODIUM HYPOCHLORITE
SOLUTION 12-14%
Always refer to the original Material Safety Data Sheets that come along with
the used chemical product!
User responsibility:
Each user should read and understand this information! The material safety
data sheets should be incorporated in individual site safety programs in accor-
dance with applicable hazard communication standards and regulations.
8.2 OPERATING SUPPLY ITEM SODIUM HYPOCHLORITE (CHLORINE)
LIQUID CHLORINE
It is recommended to use sodium hypochlorite solution that is customary in trade with
12 to 15% available chlorine.
Depending of the quality of sodium hypochlorite (chlorine) the running time of Dosing
pump, chlorine (A-1-P-023) must be adjusted between 0 - 60 sec. Factory preset is
"3 sec"
For treatment of about 4 m (1057 US gal) of sewage, approximately 1 liter (0.26 US
gal) of liquid chlorine will be used.
CHLORINE GRANULATE
The alternative to liquid Chlorine when it is not available, is Chlorine granulate with
a concentration of 65 to 75% available chlorine.
The mixing instructions for using Chlorine granulate are as follows:
Fill the chlorine tank with plain water.
Place Chlorine granulate into the water with mix ratio 80 g (2.82 oz.) granulate
for 1 l (0.26 US gal) water.
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Do not fill in too much granulate otherwise the dosing pump`s foot valve inside
the chlorine tank could get clogged.
When using chlorine granulate, approximately 80 g granulate with a concentration of
65 to 75% available chlorine mixed with 1 liter water can be used for 1.7 m of sew-
age.
These mixing instructions can only be applied when chlorine granulate with a
concentration of 65 to 75% available chlorine is used!
8.3 MEASURING OF FREE CHLORINE
METHOD
The testing of the "free chlorine" in the treated sewage needs to be tested weekly.
One method to perform this type of testing is to use the water quality test strips sup-
plied with the plant.
TEST FOR FREE CHLORINE
1. Remove one test strip from the bottle containing water quality test strips.
2. Dip the test strip in the water to be sampled for at least 30 seconds and continu-
ously move back and forth.
3. Compare the colors that are on the test strip to those that are on the color chart
printed on the bottle to determine existing concentration levels. The color pad on
the end of the test strip that estimates the total chlorine will not be considered;
but the color pad in the middle of the test strip will be used to estimate the free
chlorine.
Figure 12: Test strip for test of free chlorine
The free chlorine at the outlet should be 0,5 mg/l.
Chlorine tank Granulate in tank Concentration Treatable sewage
20 l 1.6 kg
6% or 80 g/l
34 m
35 l 2.8 kg 60 m
60 l 4.8 kg 102 m
100 l 8.0 kg 170 m
200 l 16.0 kg 340 m
500 l 40.0 kg 850 m
Test Strip
Pad for measuring
free Chlorine
Pad for measuring
total Chlorine
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STORAGE RECOMMENDATIONS
Keep bottle containing test strips tightly closed.
Store bottle containing test strips at room temperature.
Use only test strips whose storage date is valid.
CONSUMABLE
Qty. Description Remark Part-No.
1 Test strips free Chlorine Package with 50 test strips. 000685
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9. COMPONENTS OF THE PLANT
This section contains specific information about function, technical data and spare
parts for individual components of the plant.
9.1 TREATMENT TANK
This section contains information about the following components:
Macerator pump (A-1-ZP-005)
3-way valve, circulation/discharge (A-1-V-007)
3-way valve sludge (A-1-V-041)
Flow rate limiter, process water (A-1-A-033)
Level transmitter, treatment tank (A-1-CL-003)
Shut off valve, inlet macerator pump (A-1-X-004)
Shut off valve, cleaning outlet (A-1-X-043)
Overflow valve (A-1-H-101)
Shock damper
Figure 13: Treatment tank (assembly group) with attached components
3-way valve sludge
(A-1-V-041)
outlet (A-1-X-043)
Macerator pump
(A-1-ZP-005)
ment tank (A-1-CL-003)
macerator pump
(A-1-X-004)
Overflow valve
(A-1-H-101)
Shock damper
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9.1.1 MACERATOR PUMP (A-1-ZP-005)
In circulation mode the Macerator pump (A-1-ZP-005) ensures circulation process
and also crushes solid matters inside of the sewage. In discharge mode the pump
drains treated sewage over board via Outlet discharge over board (A-1-R-051).
Figure 14: Macerator pump (A-1-ZP-005)
DESIGN AND FUNCTIONAL PRINCIPLE
1 Impeller
2 Shaft
3 Inlet nozzle
4 Volute casing
5 Outlet nozzle
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Macerator pump is a centrifugal pump with open radial impeller. A mechanical seal
is used to seal the shaft.
DISASSEMBLY
The aggregate has been removed from the system and is stored in a clean and level
assembly area.
For position numbers refer to "Cross-sectional drawings" on page 52
1. Position the aggregate vertically on the fan hood.
2. Loosen the hexagon nuts (920) on the casing cover (161). Remove the hexagon
nuts and the hexagon head screws (901).
3. Remove the casing (101) and the O-ring (412).
4. Loosen the screw (900). Remove screw, washer spring (932), impeller wheel
(235) and washer (550).
5. Pull the impeller (230) off the motor shaft.
6. Remove the fitting key (940) from the motor shaft.
7. Loosen the threaded pin (904) on the spacer ring (504) and pull the spacer ring
off the motor shaft.
8. Pull the rotating unit of the mechanical seal (047) off the motor shaft.
9. . Push the stationary unit of the mechanical seal (047) from the rear out of the
casing cover.
ASSEMBLY
1. Installation of casing cover and shaft sealing
a. Moisten the auxiliary seal of the stationary unit of the mechanical seal (047)
with lubricant (alcohol, water).
b. Manually force the stationary unit into the casing cover (161).
c. Position the motor vertically on the fan hood.
d. Slide the splash ring (507) onto the motor shaft.
e. Adjust the casing cover and force it onto the motor flange.
f. Insert hexagon head screws (901) with washers (550.1) into the casing cover
and fasten it to the motor flange.
g. Moisten the auxiliary seal of the rotating unit of the mechanical seal (047) with
lubricant (grease containing PTFE).
h. Push the rotating unit of the mechanical seal onto the motor shaft by a screw-
ing movement in the sense of winding of the spring.
i. Push the spacer ring (504) onto the motor shaft.
2. Installation of impeller and impeller wheel
a. Insert the fitting key (940) into the motor shaft.
b. Slide the impeller (230) with the suction port opposite the casing cover onto
the motor shaft.
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c. Centre the washer (550) (washer side with larger diameter visible from the
top) on the impeller.
d. Centre the impeller wheel (235) on the washer.
e. Insert the screw (900) with the washer spring (932) into the motor shaft and
tighten it.
3. Installation of casing
a. Centre the O-ring (412) on the casing cover (161).
b. Adjust the casing (101) (outlet nozzle opposite the motor feet) and force it
onto the casing cover.
c. Insert the hexagon head screws (901) with the washers (550.1) in the bores
on the casing and casing cover.
d. Screw in the hexagon nuts (920) with washers (550.1) and tighten them
crosswise.
e. Carry out a function check. Manually turn the aggregate at the motor shaft
(fan side).
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TROUBLESHOOTING
Defect Cause Rectification
Motor does not start Motor
One phase of the power supply is inter-
rupted
Check the power supply/check the
motor
Two phases of the power supply are
interrupted
Check the power supply/check the
motor
Motor protection switch has tripped Switch on the motor protection switch
Motor is blocked Check/disassemble the motor
Pump is blocked
Contaminations, foreign bodies inside
the pump
Flush/disassemble/clean the pump
Impeller blocked through calcification Descale the pump
Defective motor bearing Replace the motor bearing
Ice inside pump (solidified medium to
be pumped)
Carefully heat up and defrost the pump
Motor protection trig-
gered
Motor overload The specified operating point has not
been complied with
Motor or pump blocked Check motor/pump, disassemble
motor/pump, remove the cause
Short-circuit in the motor winding Check the motor winding
Motor protection switch has not been
correctly set/is defective
Check setting/replace the motor pro-
tection switch
Excessive power
consumption of the
motor
Pump contamination/calcification Flush/descale/disassemble/clean the
pump
Density/viscosity of the medium to be
pumped is too high
Use media to be pumped complying
with the permissible density recom-
mended in the data sheet. Contact the
manufacturer.
Impeller rubs against the casing Disassemble the pump, replace defec-
tive components
Pump does not
deliver medium to be
pumped
Suction-side/pressure-side fitting is
closed
Open the suction-side/pressure-side
fitting
Suction pipe blocked Check/clean suction pipe and filters
Wrong direction of rotation of the motor Check direction of rotation and swap 2
phases if need be
Pump not vented Vent the pump, fill the pump and suc-
tion pipe
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Flow rate too low Contaminations in the suction opening Clean the inlet nozzle
Internal components are subject to
wear
Replace the affected components
Leaking system Check the system/seal leaking spots
Pump has not been correctly dimen-
sioned
Replace the pump
Motor speed too low Increase speed, contact the manufac-
turer
Pump cavitation Check the temperature of the medium
to be pumped/cool it down.
Excessive filter resistance Check/clean the filter
The suction height is too high or the
inlet height too low
Check the filling level in the tank/open
the suction-side fitting/clean the filter in
the suction pipe.
Excessive suction pipe resistance Modify the suction pipe (cross-section,
length, bends)
Total head too low Motor speed too low Check motor connection and voltage/
increase speed/contact manufacturer
Excessive friction loss Use larger pipe cross-sections
Excessive backpressure Check operating point/clean pipe
Excessive flow rate System's pump pressure is too low At the pressure side: Install a throttle
valve
Overheating of the
pump
Excessive outlet pressure Reduce the pressure loss/increase the
pipe cross-section
Viscosity of the medium to be pumped
is too high
Observe the limit values
Pressure-side fitting is closed Comply with the minimum flow rate/
install a bypass at the pressure side
Temperature of the medium to be
pumped is too high
Cool down the medium to be pumped
Strange noise Pump cavitation Reduce the temperature of the medium
to be pumped, check NPSH
Excessive share of steam in the suc-
tion flow
Reduce the temperature of the medium
to be pumped, check NPSH
Suction-side fitting closed Open the suction-side fitting
Low pressure in the suction pipe Check the suction pipe/switch off the
motor by means of the vacuum switch
Ingress of air in the suction pipe Seal the suction pipe/increase the fill-
ing level in the reservoir
Excessive outlet pressure Reduce the outlet pressure
Leaking pump Defective shaft sealing Replace the shaft sealing
Defective casing sealing Provide the pump with new sealing
Loosened connecting screws/screw
plugs
Tighten the screws/replace the sealing
(continued)
Defect Cause Rectification
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TECHNICAL DATA
CHARACTERISTIC CURVE (50 HZ, 2800 1/MIN)
Max. total head 10 m
Medium to be pumped Sewage
Temperature max. 50 C
Density max. 1000 kg/m
Viscosity max. 100 mm/s
Speed 2800 1/min
Temperature [C] +5 to +40
Relative humidity [%]
long-term
short-term
max. 35
max. 85
Tightening torques [Nm]
M6 8.8
M4 A2/A4-70
M5A2/A4-70
G 1A
G 1 1/4A
10,0
2.2
4.2
110
180
Connection, suction side G1 1/4"
Connection, pressure side G1"
Operating voltage 230 V
Nominal power, electrical 0.75 kW
Protection type IP 54
Insulation class F
Weight 10.4 kg
Total head (m)
Flow rate Q (m/h)
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CROSS-SECTIONAL DRAWINGS
Pos. Quantity Part-No. Designation
- 1 011399
Centrifugal pump, complete
- 1 012377
Ball bearing, A-side
- 1 012378
Ball bearing, B-side
- 1 012360
Pump head
047 1 012359
Mechanical seal
101 1 012361
Pump housing
161 1 012362
Casing/housing cover
230 1 012363
Impeller
235 1 012364
Impeller wheel
412 1 012365
O-ring
504 1 012366
Set collar
507 1 012367
Splash ring (Thrower)
550 1 012368
Disk/washer
550.1 12 012369
Disk/washer
550.2 1 012370
clamp ring
800 1 012376
Electro motor
900 1 012371
Screw
901 4 012372
Hexagon screw
901.1 4 012373
Hexagon screw
920 4 012374
Hexagon nut
932 1 012375
Spring Washer
940 1 000654
Key / Fitting key
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9.1.2 3-WAY VALVE, CIRCULATION/DISCHARGE (A-1-V-007)
3-WAY VALVE SLUDGE (A-1-V-041)
The 3-way valve, circulation/discharge (A-1-V-007) switches the plant over between
circulation and discharge mode.
The 3-way valve sludge (A-1-V-041) controls the sludge discharge to ships sludge
tank.
TECHNICAL DATA
ELECTRICAL CONNECTION
Part-No. 000446
Connections 3/4 i
Material PP (glass fibre reinforced)
Operating voltage 24 VDC
Nominal diameter DN20 PN 10
Material, o-ring FPM
Material, ball seat PTFE
Actuating time ~7 s (180)
red
Output 2 opened
Output 1 opened
Drive
red
End position switch "closed"
End position switch "open"
blue
blue
black
yellow
brown/red
white
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9.1.3 FLOW RATE LIMITER, PROCESS WATER (A-1-A-033)
Figure 15: Flow rate limiter, process water (A-1-A-033)
The flow rate limiter regulates the process water flow rate into the treatment tank.
Type DMB-13,0
Flow regulator, part-No. 004171
Rubber seal, part-No. 000588
Flow rate 13 l/min.
Rubber seal
Flow regulator
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9.1.4 LEVEL TRANSMITTER, TREATMENT TANK (A-1-CL-003)
This level transmitter transmits the filling level of the treatment tank to the switch cab-
inet.
Figure 16: Level transmitter, treatment tank (A-1-CL-003)
Type TK-308
Part-No. 010303
Material, pipe PE
Material, membrane PE
Output (electrical) 420 mA
Measuring range 0500 mm water column (WC)
Operating voltage 1135 VDC
Measuring current 0.4 mA at R
E
= 4kW
0.3 mA at R
E
= 7kW
Measuring voltage 1.7V at R
E
= 4kW
2.1V at R
E
= 7kW
Accuracy 1%
PE
PE-pipe
20 x 1.9 mm
(strengthened)
PE-plate
(160 x 160 x 10)
5
7
density of 1 g/cm
Immersion level at
P
i
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e

l
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g
t
h

R

=

5
0
0

m
m
80 x 75
ca. 64 mm
M 16 x 1.5
32
2
5
71
5
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WIRING
Figure 17: Wiring for Level transmitter, treatment tank (A-1-CL-003)
Input
Resistance sensor
yellow
red
black
Output
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9.1.5 SHUT OFF VALVE, INLET MACERATOR PUMP (A-1-X-004)
This valve works as a manual operated shutoff valve and is positioned at the inlet of
Macerator pump (A-1-ZP-005).
Figure 18: Shut off valve, inlet macerator pump (A-1-X-004)
9.1.6 SHUT OFF VALVE, CLEANING OUTLET (A-1-X-043)
This hand valve is closed in normal operation and has to be opened when treatment
tank gets flushed for cleaning purposes.
See section "Tank cleaning" on page 90.
Figure 19: Shut off valve, cleaning outlet (A-1-X-043)
Type d40 DN32 (lockable)
Part-No. 011645
Diameter d=40 mm
Nominal width DN 32
Nominal pressure PN 16
kv-value 1600 l/min.
Type 546 PVC-U DN20 (lockable)
Part-No. 004371
Diameter d=25 mm
Nominal width DN 20
Nominal pressure PN 16
kv-value 350 l/min.
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9.1.7 OVERFLOW VALVE (A-1-H-101)
This control valve is required for adjusting a defined flow rate of the pump. A transfer
sequence should have a duration time between 30 and 45 seconds.
Figure 20: Overflow valve (A-1-H-101)
SPARE PART LIST
9.1.8 SHOCK DAMPERS
Quantity Name Part-No.
1 Overflow valve 005397
Qty. Description Type Part-No.
4 Shear mount Form 27796 C, 55 Shore 004449
3
4
5
6
1
2
7
8
Pos. Description
01 Valve casing
02 Piston
03 Setting screw
04 Hexagon nut
05 Washer
06 Pin
07 Closed tolerance pin
08 O-ring
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9.2 DOSING STATION, CHLORINE
This section contains information about following components:
Dosing pump, chlorine (A-1-P-023)
Container, chlorine (A-1-B-022)
Screwed cable gland
Pump hose
Foot valve with filter
Hoses for connecting dosing station to treatment tank
Figure 21: Dosing station, chlorine
SPARE PARTS FOR DOSING STATION, CHLORINE
Qty. Designation Remark Part-No.
1 Dosing pump - 000445
1 Pump hose for Dosing pump, chlorine (A-1-P-023). 000691
1 Dosing container with screw top - 010036
1 Screwed cable gland Used as hose connection/bushing for
chlorine suction line.
010190
1 Chlorine sensor (A-1-CL-021) - 000451
1 Foot valve with filter Used as suction valve inside the Con-
tainer, chlorine (A-1-B-022).
003870
1.1 m Hose Between Container, chlorine (A-1-B-
022) and Dosing pump, chlorine (A-1-
P-023).
003871
4 m Hose Between Container, chlorine (A-1-B-
022) and treatment tank.
003871
4 m Hose Between Dosing pump, chlorine (A-1-
P-023) and treatment tank.
003871
Chlorine sensor
(A-1-CL-021)
Container, chlorine
(A-1-B-022)
Dosing pump, chlorine
(A-1-P-023)
Screwed cable gland
Foot valve with filter
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9.2.1 DOSING PUMP, CHLORINE (A-1-P-023)
The Dosing pump, chlorine (A-1-P-023) doses sodium hypochlorite out of the chlo-
rine container into the Reaction & discharge chamber (A-1-B-002) of the treatment
tank via dosing hose and Chlorine injection (A-1-R-054)
In order to change the pump hose, first remove the small cover screws, shown in Fig-
ure 22.
Figure 22: Cover screws of Dosing pump, chlorine (A-1-P-023)
Type F-PK 2,2
Part-No. 000445
Operating voltage 24 V DC
Delivery rate 2.4 l/h
Power requirement 36 W
Rotation speed 48 1/min.
Pump-hose 4 x 7 mm Santoprene
Hose connection 4 x 6 mm
Dimensions 165 x 110 x 138 mm
Flow direction
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Next, loosen the hose adaptors. Pull the pump hose adaptors out of the slots, and
then slip the pump hose out over the rotating unit, as shown below.
Figure 23: Pump hose, adaptors and rotating unit
The pump drive is maintenance-free.
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9.2.2 CHLORINE SENSOR (A-1-CL-021)
The Chlorine sensor (A-1-CL-021) monitors the minimum chlorine filling level.
ADJUSTMENT
The >CHLOR. SHORTAGE< alarm should activate when the chlorine level inside the
tank is low. If the >CHLOR. SHORTAGE< alarm does not activate when the chlorine
level inside the tank is low, the inductive level sensor switch may require adjustment.
Check the air gap between the end of the sensor and the chlorine tank. If the air gap
is too wide, the >CHLOR. SHORTAGE< alarm will be active although there is chlo-
rine in the tank. If the air gap is too small, the alarm may fail to activate when the
chlorine level is low.
Adjust the air gap by loosening the clamp screws as shown. Observe the alarm sta-
tus at different chlorine levels to ensure that sensor is adjusted correctly.
If further adjustment is required, follow these instructions to adjust the sensitivity of
the inductive level switch:
Adjust the sensitivity of the inductive level switch by removing the plastic cover
and adjusting the sensitivity screw.
Turning the adjustment crew clockwise makes the sensor more sensitive.
Turning the screw anti-clockwise makes the sensor less sensitive.
Observe the status of the LED
Figure 24: Chlorine sensor (A-1-CL-021)
Type KG-211
Part-No. 000451
Dimensions 30 x 80 mm
Cable length 2 m
Switching function
NC (normally closed)
closed when liquid/chlorine is not present (LED on)
opened when liquid/chlorine is present (LED off)
LED SWITCH STATUS
ON CLOSED Chlorine level is low
OFF OPEN Chlorine level is okay
adjust
gap
Loosen this screws
to adjust the distance
between sensor and
chlorine tank
Adjustment screw
behind cover screw
LED
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9.3 EXTERNAL AND SEPARATELY MOUNTED COMPONENTS
This section contains information about following components that have to be mount-
ed and connected by the customer according to the P&ID.
Refer also to "Standard Piping and Instrumentation diagram (P&ID)" on page 14.
EXTERNAL STANDARD COMPONENTS
Solenoid valve, process water (A-1-V-034)
Process water strainer (A-1-F-031)
Switch cabinet
EXTERNAL OPTIONAL COMPONENTS
Sludge Pump (A-1-P-042)
Level switch, holding tank (A-1-CL-102)
Level switch, sludge tank (A-1-CL-103)
Shock damper (USCG option)
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9.3.1 TRANSFER-MACERATOR PUMP (A-1-ZP-100)
The Transfer Pump drains a certain amount of raw sewage from ships holding tank
into the treatment tank of SuperMini PLUS and at the same time macerates existing
solids in the sewage.
To achieve this defined amount of sewage, the Overflow valve (A-1-H-101) has to be
adjusted one-time according to specific hydraulic conditions on board. The delivery
time should be between 30 and 45 seconds.
Figure 25: Transfer-macerator pump (A-1-ZP-100)
TECHNICAL DATA
Type SAP-S 230/50Hz SAP-S 250/60Hz
Part number pump 005135 011379
Nominal power, electrical 0.55 kW 1.1 kW
Operating voltage 230 V / 50 Hz 250 V / 60 Hz
Material, housing G-CuSn10
Material, Impeller G-CuSn10
Material, shaft 1.4462
Material, sealing NBR
Connection, suction side 2"
Connection, pressure side 1"
Delivery flow/volume 0,51,0 m/h
Delivery height ~ 10 m
Suction performance max. 0.2 bar
Weight 28.5 kg 29.5 kg
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9.4 INSTALLATION
The pump must be placed on a rigid surface. In case of mounting into a complete
system ensure that there is enough distance behind the fan cover of the motor to al-
low sufficient air flow for the cooling. To low air flow can cause over heating of the
motor.
To ensure self priming operation the pump has to be installed in a horizontal
position.
Attention should be paid that the pump is installed directly by the holding tank
or in its compartment.
CONNECTION OF SUCTION AND DISCHARGE
The pump is equipped with threads according to DIN for connection of suction and
discharge.
The suction / discharge pipe must be connected without any tension to the
pump casing to avoid damages.
For more details refer to " Piping connections" on page 20 and to " Standard
Piping and Instrumentation diagram (P&ID)" on page 14.
ELECTRICAL CONNECTION
The power supply must be identical with the voltage and frequency marked on
the name plate.
The connection of the motor must be carried out by a qualified specialist.
The rules of the German VDE or other/national regulations are to be observed.
A use in systems with special safety requirements is only possible, if a qualified
specialist integrates the necessary safety equipment.
The use in hazardous areas is not allowed.
START UP
Check pump, suction/discharge line and electrical supply to correct connection.
The power supply must be voltage free and protected against switching on be-
fore the connections can be checked!
After the control woks all safety guards have to be re-assembled!
The pump casing must be filled completely with liquid before first start-up.
Dry running can create abnormal wear or can damage pump parts or the
mechanical seal.
The operation manuals of the motor, switch gears and accessories must also be
observed.
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After starting the pumps begins to evacuate the suction line. The gas pumped with
the mixture must be able to bleed easily. The pump starts with the pumping of liquid
after the suction line is evacuated completely. Shortly after start of pumping liquid the
flow might be inconstant, as in some cases there is still some gas remaining in the
pump and/or suction line which can effect the flow.
Right after a constant flow takes place the delivery rate can be adjusted with the
Overflow valve (A-1-H-101), mounted at the treatment tank. For this the setting
screw has to be adjusted until the desired flow rate is reached. If an adequate adjust-
ment is not possible with completely opened or closed valve, another impeller diam-
eter of the pump will be required.
REMOVING FROM OPERATION
After switching off valves in suction and discharge line have to be closed.
Remaining liquid must be drained from the pump. If this liquid is dangerous the nec-
essary safety rules have to be observed.
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FAILURES
Failure Reason Removal
Pump does not turn blocked
Motor damaged
No power available
Remove blockage
Replace motor
Check connection line and
fuses
Pump delivers no liquid Valve in suction/delivery
line is closed
Impeller blocked
Suction line untight or
blocked
Liquid quantity in the cas-
ing to low
Open valves
Clean impeller
Check suction line and
tighten it up
Fill casing with liquid
before starting
Flow to small Impeller partially blocked
Impeller worn out
Gases are in the suction
line or pump
Clean impeller
Give pump to repair
Check pump / discharge
line and improve bleeding
possibility
Pump is leaking on the
shaft
Shaft seal untight Replace shaft seal
Absorbed power to high Duty point not correct
Foreign matter blocks the
pump
Cutting impeller worn out
and particles ar between
cutting impeller and cut-
ting plate.
Adjust duty point
Remove foreign matter
Replace cutting impeller /
cutting plate.
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DIMENSIONAL DRAWING
Figure 26: Dimensions of Transfer-macerator pump (A-1-ZP-100)
~136 295.5
~432
108
1
4
0
90
1
1
2
129.5
7
5
7
1
9
0
Outlet refeeding pipe (A-1-R-
063)
Outlet sewage (A-1-
R-064)
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EXPLOSION DRAWING
Figure 27: Explosion drawing of Transfer-macerator pump (A-1-ZP-100)

1
6
2
9
1
4
.
3
5
5
4
.
3
4
0
0
5
5
0
.
3
1
0
1
4
1
2
.
1
9
1
4
5
5
0
2
3
1
1
3
5
5
6
1
9
1
4
.
1
2
3
0
9
4
0
5
0
4
4
3
3
4
1
2
1
6
1
8
0
1
9
2
0
.
2
5
5
4
.
2
9
0
2
.
2
5
5
4
9
2
0
5
5
4
.
1
9
0
1
.
1
9
0
2
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PARTS LIST
For ordering spare parts please mention the serial number from the name plate to
avoid the delivery of wrong parts.
Pos. Quantity Designation Part-No.
- 1 Centrifugal pump, self priming
SAP-S 230 50Hz
005135
- 1 Centrifugal pump, self priming
SAP-S 250 60Hz
011379
101 1 Housing 005297
135 1 Shear plate 005298
161 1 Casing/housing cover 005299
162 1 Suction cover 005304
230 1 Impeller 005305
231 1 Cutter/Cutting wheel 005306
400 1 Suction cover sealing 005307
412 1 O-seal 005308
412.1 1 O-seal 005309
433 1 Mechanical seal 005310
504 1 Distance ring 005311
550 1 Disk/washer 005312
550.3 1 Disk/washer 005313
554 8 Disk/washer 005314
554.1 4 Disk/washer 005314
554.2 8 Disk/washer 005314
554.3 1 Disk/washer 005315
561 3 Close tolerance grooved pin 005316
801
1 Motor 230 V / 50 Hz, 0.55 kW 005317
1 Motor 250 V / 60 Hz, 1.1 kW 011380
901.1 4 Hexagon screw 003675
902 8 Stud bolt 005318
902.2 8 Stud bolt 005319
914 1 Hexagon socket head cap screw 004049
914.1 2 Hexagon socket head cap screw 005320
914.3 1 Hexagon socket mushroom head
bolts
005321
920 8 Hexagon nut 000838
920.2 8 Hexagon nut 001514
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9.4.1 PROCESS WATER PUMP (A-1-P-032)
The Process water pump (A-1-P-032) is fed by ships seawater supply and drains
seawater to the plant that is used as process water. Alternatively a solenoid valve can
be used if seawater supply with sufficient pressure is ensured.
Figure 28: Process water pump (A-1-P-032)
TECHNICAL DATA
Type SWP 5902-24V DC
Part-No. 004192
Design 5 Chamber Diaphragm
Ports Quick Connect Fittings
Liquid temperature 54C (130 F) max
Delivery rate 19 l/min.
Current consumption max. 5,0 A
Pressure, max. 4.5 bar
Suction head 3.3 m
Dimensions
(Length x Width x Height)
~ 250 x 135 x 140 mm
Material, housing Nylon
Material, valve EPDM
Material, membrane Santoprene
Motor 24VDC Permanent Magnet, Intermittent Duty
Protection Thermal Overload, Automatic Restart
Leads 16 AWG, 16 [40 cm] Red +, 13 [33 cm] Black -
Fuse 7.5 Amp recommended
Control Shut-Off 60 PSI [3.1 Bar] 5 PSI [0.4 Bar]
Restart 30 PSI [1.8 Bar] 5 PSI [0.4 Bar]
Weight ~ 2.3 kg
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MOUNTING
Mount pump within 6 feet of water supply for best performance.
Mount pump for easy access if maintenance is required.
Mount pump in a space of one cubic foot unless adequate ventilation is pro-
vided.
The pump may be mounted in any position.
Choose a solid surface that will not amplify pump vibration. Heat sink must be
free and have air flow across.
The mounting feet are intended to isolate the pump from the mounting surface;
over tightening, or use of oversized screws will reduce ability to isolate vibration/
noise.
Figure 29: Typical pump installation
PLUMBING / PIPING
Reducing unnecessary restrictions to the inlet and the outlet tubing will allow the
pump to run freely, maximizing the Smart Sensors performance, quietness and elim-
inate the possibility of cavitation (starving the pump).
Installation of a strainer, such as HAMANN AG part no. 000463 is strongly rec-
ommended to prevent debris from entering the pump.
HAMANN AG recommends at least 0,3 m of " [13 mm] I.D. flexible high pres-
sure tubing to both ports. Ideally, the pumps ports and strainer should not be
connected to plastic or rigid pipe. The pump's normal oscillation may transmit
through rigid plumbing causing noise, and possibly loosen or crack components.
Quick-connect fittings provide easy installation and removal if required. The fit-
tings are designed with dual o-rings, creating a seal when snapped into place.
Pump may flow better with 3/4 line feeding the pump.
Batt.+
Filter (recommended)
Switch
Inlet
Outlet
Outlet
flexible hose
tight connection
2.5 mm cable
Connection
Fuse
ATTENTION!
The red cable of the pump must be
connected with +pole, otherwise
the controller is damaged.
Earth
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FITTINGS INSTALLATION INSTRUCTIONS
Quick connect fittings provide easy installation and removal if required. The fittings
are designed with dual o-rings, creating a seal when snapped into place.
Figure 30: Connecting of quick connect fittings
For more details refer to " Piping connections" on page 20 and to " Standard
Piping and Instrumentation diagram (P&ID)" on page 14.
ELECTRICAL
The pump should be on a dedicated (individual) circuit protected by the specified
fuse indicated on the motor label.
A U/L approved marine duty switch (ignition protected) rated for 15 amps or
higher is recommended, and must interrupt current flow on the positive (+ red)
lead.
Pump draws 15 milliampere when pump switch is on, even when pump is not
running.
WARNING: Test incoming power with a multimeter to check voltage polarity
(red = +). Red pump wire MUST be connected to positive power or permanent
damage to controller will result! Failures of these type are not covered under
product warranty.
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EXPLOSION VIEW
CHARACTERISTIC CURVE
PERFORMANCE at 24V DC
PRESSURE FLOW CURRENT
BAR PSI GPM LPM AMPS
0.0 0 5.50 20.8 2.22
0.7 10 4.70 17.8 3.20
1.4 20 3.50 13.2 3.75
2.1 30 3.10 11.7 4.25
3.5 50 2.10 7.94 5.00
FLOW AMPS
0.0
1.0
2.0
3.0
4.0
5.0
6.0
F
L
O
W

(
G
P
M
)

0
1
2
3
4
5
6
C
U
R
R
E
N
T

(
A
M
P
S
)

0 10 20 30 40 50
PRESSURE (PSI)
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DIMENSIONS
Dimensions in inch [mm]
TROUBLESHOOTING
1. Pump will not start/blows circuit
Electrical connections, fuse, breaker, main switch, and ground connection.
Is the motor hot? Thermal protector may have triggered; will reset when cool.
Is voltage present at the pump?
Charging System for correct voltage and good ground.
For an open or grounded circuit or motor; improperly sized wire.
For seized or locked diaphragm assembly (water frozen?)
Is wire size too small? Minimum 2.5 mm wire required.
2. Will not prime/sputters (No discharge / Motor runs)
Is the strainer clogged with debris?
Inlet cavitation from restrictions, small tubing? Outlet restrictions?
Is water supply ensured?
Is the inlet plumbing sucking air in air at connections (vacuum leak)?
Is the inlet/outlet plumbing severely restricted or kinked?
Proper voltage with the pump operating.
For debris in pump inlet/outlet valves or swollen/dry valves.
Pump housing and drive assembly for cracks or loose screws.
3. Leaks from pump head or cover
For switch diaphragm leaking under cover.
For puncture diaphragm if water is present in the drive.
Leaks from fitting? Check o-ring in groove? O-ring lubricated properly?
4. Noisy or rough operation
For plumbing which may have vibrated loose.

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Is pump plumbed with rigid pipe causing noise to transmit?
Does the mounting surface amplify noise?
For mounting feet that are loose or compressed too tight.
For loose pump head to motor screws.
For air in system.
The motor with pump head removed. Is noise from motor when it runs alone?
SPARE PARTS
Pos. Qty. Designation Part-No.
- 1 Diaphragm pump, complete 004192
1 1 Valve assembly 010560
2 1 Drive assembly 010561
1
2
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9.4.2 SOLENOID VALVE, PROCESS WATER (A-1-V-034) (OPTION)
TECHNICAL DATA
DIMENSIONS IN MM
Type 205/10/D
Part-No. 001630
DN 10
Diameter d=16 mm
Material, housing PVC-U
Material, sealing EPDM
Temperature, medium -10 60C
Temperature, ambient 0 40C
Protection IP 65 (with cable plug)
Supply pressure (Process water) 1.5 5 bar
Kv-value 0.8 m/h
Weight 0.85 kg
DN A B C F d H H1 L L1
10 134 100 110 52 16 30 15 70 14
Plug rotatable 90
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CONNECTION DIAGRAM FOR PLUG FORM A (DIN EN 175301-803)
Supply voltage
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9.4.3 PROCESS WATER STRAINER (A-1-F-031)
The Process water strainer (A-1-F-031) filters the seawater that is used as process
water in the treatment process.
The strainers position relative to the treatment plant and the pipework is described in
section "Process water inlet (A-1-R-052)" on page 21 and in section "Standard Piping
and Instrumentation diagram (P&ID)" on page 14.
DIMENSIONS.
Type 1160 (0.4mm)
Part-No. filter, complete 010104
Part-No. filter strainer 010095
Filter fineness 0.4 mm
Process connection 1/2" inside
Material, housing Brass nickel plated
Material, filter strainer AISI 316L (stainless steel)
Material, cap/cover Transparent PA 6
L
H
H1
G
Df
Hf
G
A
B
H 105 mm
H1 62 mm
L 99 mm
A 20 mm
B 20 mm
Hf 75 mm
Df 49 mm
G 1/2
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9.4.4 SLUDGE PUMP (A-1-P-042) (OPTION)
The optional sludge pump drains sediment/sludge out of the Sedimentation chamber
(A-1-B-001) into the ships sludge tank/container or into a separate compartment of
ships holding tank.
Figure 31: Sludge Pump (A-1-P-042)
A sludge pump is only required if sludge draining is not possible by gravity.
INSTALLATION INSTRUCTIONS
The SuperMini PLUS can be mounted in every possible position. Due to that and the
possibility to turn the hose connectors for suction and pressure the mounting position
of the pump can be adapted to the mounting area on board.
When installing the pump and an outboard outlet below the water level you
have to take care about an additional safety installation to prevent against wa-
ter incoming from outboard.
The pressure line has to be installed in form of a swan neck or a loop. The height
of the loop has to be installed in minimum 500 mm above the water level. For con-
veying outboard a seacock with a diameter of 1 (38 mm) has to be installed in the
hull of the ship.
Type M 230V RG-G 1 1/2" (50Hz) M 240V RG-G 1 1/2" (60Hz)
Part No. 003233 011292
Operating voltage/frequency 230VAC 50Hz 240VAC 60Hz
Nominal power, electrical 0.25 kW
Nominal current 1.6 A
Delivery rate, max. 20 l/min.
Pressure head 8 m
Suction head 5 m
Connections 1 1/2"
Material Bronze
Continuous operation 1-2 hours
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Every through hull connection below the waterline is a potential risk. For your
safety and for the safety of your ship the installation of the faeces pump should
be done by a qualified and special trained person.
For safety reasons the sea cock has to be mounted in such a way that a good and
fast operating is possible.
All sea cocks below the water line has to be closed when going ashore, during
high waves and strong heeling. When disregarding this order water may flood
inside.
INSTALLATION OF THE PUMP
Select a location that will give sufficient clearance for the installation of the hoses and
maintenance of the pump. The faeces pump M can be mounted in every possible po-
sition. If necessary the housing of the pump can be turned in 45 steps by loosing the
mounting screws. For the installation of the pump you will need 4 screws M6 with a
length according to the thickness of the mounting flange of the pump and the mount-
ing surface, 4 self-locking nuts M6 or nuts M6 and liquid nut-locking compound, as
well 8 washers suitable for M6.
Place the pump on to the selected position and mark the positions for the 4 bolt holes
on the mounting surface.
Remove the pump and drill 4 holes of 7 mm diameter on the marked positions
through the mounting surface. Now the faeces pump M can be screwed and fastened
to the mounting surface.
INSTALLATION OF THE HOSES
The cross section of the pressure and suction pipe has not to be smaller than 1
( 38 mm) at every position. Otherwise the pump do not have full power and the
lipped rings and the diaphragm will wear out earlier. For connecting the pump you
need a spiral reinforced flexible hose with a diameter of 1 ( 38 mm). We recom-
mend a odour safe vacuum faecal hose.
When laying the hoses please take care that the hoses not become kinked or will
guide over sharp edges and corners. Secure the ends of all hoses with stainless steel
worm drive hose clamps. If it is difficult to fit the hose on to the hose connector, soften
the hose by dipping the end of it in hot water or by heating the end gently with a hot
air gun.
The ends of all hoses has to be secured with stainless steel worm drive hose
clamps. When disregarding this order water may flood inside and the boat may
sink which may result in loss of life.
For more details refer to " Standard Piping and Instrumentation diagram
(P&ID)" on page 14.
ELECTRICAL INSTALLATION
The electrical connection to the power supply system has to be done by spe-
cial qualified persons according your national electrical regulations. For im-
proper Installation we exclude every liability.
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please make sure that the on-board voltage equals the data on type-plate of the
motor of the pump.
when having DC-voltage please take care that the connecting cable must not be
mixed up (red cable = plus, black cable = minus)
the mixing up of the cables can be damage the motor of the pump
please use cable with a sufficient cross section. The cross sections of the cables
has to be calculated by a qualified person and has to be installed according your
national regulations. We recommend a cross section of 2.5 mm.
the motor of the pump has to be secured by an overload fuse. We recommend
the installation of an automatic fuse (time lag fuse). When using a melting fuse
an additional ON / OFFswitch has to be installed in the PLUScable
take care of the correct direction of rotation of the motor of the pump
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DIMENSIONS
Figure 32: Dimensions of Sludge Pump (A-1-P-042)
120 Q
182
3
6
5
178
3
4
1
4
4
0
1
5
4
268
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EXPLOSION DRAWING
Figure 33: Explosion drawing of Sludge Pump (A-1-P-042)
SPARE PART LIST
Pos Qty. Designation Part-No.
- 1 Pump, complete M 230V RG-G 1-1/2" (50 Hz) 003233
- 1 Pump, complete M 240V RG-G 1-1/2" (60 Hz) 011292
0350009
0101052
1 Repair Set:
- 1 Diaphragm
- 2 of Lipped ring
000015
0101052 2 Lipped ring 000016
MEMBRAN
DRUCKLIPPENVENTIL
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9.4.5 LEVEL SWITCH, HOLDING TANK (A-1-CL-102) (OPTION)
LEVEL SWITCH, SLUDGE TANK (A-1-CL-103) (OPTION
These optional level switches can be delivered and are required if the ships holding
tank/sludge tank is not equipped with a suitable level control that can be used by the
control unit of the SUPER MINI PLUS.
For more details please refer to section "Standard Piping and Instrumentation dia-
gram (P&ID)" on page 14.
Figure 34: Level switch, holding tank (A-1-CL-102)
PE 78
K
adjustment
rings (welded)
PE-Pipe
20 x 1.9 mm
K
K
P
E
-
P
l
a
t
e
(
1
6
0

x

1
6
0

x

2
0
)
3
2
1
*
1
0
1
2
7
3
c
a
.

6
1

m
m
density of 1 g/cm
immersion level at
PE 78
M
i
n
i
m
u
m

D
i
s
t
a
n
c
e

1
1
0

m
m
1 K
K
K
2
3
1
2
3
4 1
6
2 5
3
C
O
M
N
C
N
O
(
b
la
c
k
)
(
r
e
d
)
(
y
e
llo
w
)
Contacts
NC
NO
N
o
r
m
a
l
F
u
n
c
t
io
n
T
S

-

2

-

H
A
N

6
* Minimum distance for K1 without adjustment ring:
- min. 50 mm (to the top)
- min. 60 mm (to the bottom)
NO
1
6
0
.
0
0
d
1
1
.
0
0
1
3
0
.
0
0
130.00
d
2
0
.
5
0
Mounting Plate Hole Pattern
160.00
d
9
5
.0
0
Mounting Hole in Tank for Level Switch
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Figure 35: Level switch, sludge tank (A-1-CL-103)
SPARE PARTS
Holding tank (TS-2) Sludge tank (TS-2/1)
Part-No. Level switch 000429 005124
Part-No. Sealing 004949
PE 78
Stellring
verschweit
PE-Rohr
20 x 1.9 mm
(strengthened)
P
E
-
P
l
a
t
t
e

(
1
6
0

x

1
6
0

x

2
0
)
Stecker
HAN 6E
1
0
1
2
7
3
c
a
.

6
1

m
m
Dichte 1 g/cm
Eintauchtiefe bei
1 K 1 4 1
C
O
M
N
C
N
O
(
s
c
h
w
a
r
z
)
(
r
o
t
)
(
g
e
l
b
)
Steckerbelegung
NC
a
k
t
i
v
e

F
u
n
k
t
i
o
n
T
S

-

2
/
1

-

H
A
N

6

E
R
o
h
r
l
n
g
e

RK

=

x
x
x

m
m
1
(
N
C
-
a
b
o
v
e
)
switching voltage
switching current
switching capacity
max. 230 V
max. 1 A
max. 60 VA
1
6
0
.
0
0
d
1
1
.0
0
1
3
0
.
0
0
130.00
d
2
0
.
5
0
Mounting Plate Hole Pattern
160.00
d
9
5
.0
0
Mounting Hole in Tank for Level Switch
connec-
PE-pipe
immersion level
at density of 1 g/
P
i
p
e

l
e
n
g
t
h

R
P
E
-
p
l
a
t
e
adjustment
ring welded
contacts
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9.4.6 SHOCK DAMPER (USCG OPTION)
DIMENSIONS AND WEIGHTS
TECHNICAL DATA:
PART NUMBERS:
9.4.7 SWITCH CABINET WITH MULTI FUNCTION DISPLAY (MFD) [6A1]
The switch cabinet contains the complete control for the Sewage Treatment Plant
and for all external/separate mounted components. The Multi Function Display
(MFD) [6A1] is mounted at the front side of the switch cabinet.
Cable
mm
M
d
mm
L
mm
H
mm
B
mm
b
mm
p
mm
q
mm
Weight
kg
6.3 M6 7.0 146 64 81 131.0 13 16 ca. 0.44
Cable Stainless steel 1.4401 (AISI 316)
Bars Aluminum 3.3211, chromized (6061)
Temp. Range 0 C to 50 C
Elec. Conductivity <2x10-3 W
Tolerances
Fastening holes 0.2 mm
Element width and
height
2 mm
Type Number Number of loops Part-No.
H63-146-64-81-6M 2 6 000474
H63-146-64-81-8M 2 8 000475
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1
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10. CLEANING AND MAINTENANCE SCHEDULE
If operating with chlorine it is necessary to protect hands with rubber gloves
and eyes with safety glasses. See section " Installation" on page 19.
10.1 PERIODICITY PLAN FOR NORMAL CONTINUOUS OPERATION
STILL STAND PERIODS OF MORE THAN 72 HOURS
When it is planned to not use the plant for more than 72 hours then the Sedi-
mentation chamber (A-1-B-001) needs to be maintained/cleaned as described
in section 10.3 on page 90.
Term Activity See also:
Weekly
Check Process water strainer (A-1-F-
031) if clogged.
Section 9.4.3 on page 79.
Testing of free chlorine. Section 8.3 on page 43.
Monthly
Cleaning of treatment tank. Section 10.3 on page 90.
External visual check of the plant. .
Check Dosing pump, chlorine (A-1-P-
023), hoses and adapters for proper
fitting.
Section 9.2 on page 59.
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10.2 WINTER LAY-UP AND DECOMMISSIONING
The treatment plant's main tank and piping will have to be cleaned by flushing it with
fresh water. Afterwards it must be completely drained. Consult section 10.3 for prop-
er procedure. To drain away any remaining fluids, remove the Shut off valve, inlet
macerator pump (A-1-X-004).
Figure 36: Unscrew coupling
Figure 37: Remove valve
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10.3 TANK CLEANING
A monthly cleaning of the tank's Sedimentation chamber (A-1-B-001) and/or in the
Reaction & discharge chamber (A-1-B-002) is advised.
CLEANING OF SEDIMENTATION CHAMBER (A-1-B-001)
Consequently, the tank's Freshwater flushing connection (A-1-R-058) should be
connected with a water hose to a freshwater or seawater supply with sufficient
pressure.
A suitable hose should be connected to Shut off valve, cleaning outlet (A-1-X-
043) and led to a suitable location or containment.
Open Shut off valve, cleaning outlet (A-1-X-043).
In order to control the draining away of sludge contents, set the 3-way valve
sludge (A-1-V-041) at the Parameter level of the MFD control to >open<.
Drain the sludge contents via Shut off valve, cleaning outlet (A-1-X-043) to a
suitable location or containment.
Manually close Shut off valve, cleaning outlet (A-1-X-043), completely filling sed-
iment chamber with flushing water and then drain by opening valve. Repeat until
drain off runs clean.
Set the 3-way valve sludge (A-1-V-041) at the Parameter level of the MFD con-
trol back to position >closed<.
Freshwater flushing
connection (A-1-R-058)
Inlet sewage
(A-1-R-057)
Clearing tank
(A-1-B-044)
Outlet sludge
(A-1-R-062)
Macerator pump
(A-1-ZP-005)
macerator pump
(A-1-X-004)
Outlet discharge over
board (A-1-R-051)
outlet (A-1-X-043)
Overflow valve
(A-1-H-101)
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CLEANING OF REACTION & DISCHARGE CHAMBER (A-1-B-002)
For cleaning, manually start the Process water pump (A-1-P-032) by setting the
Parameter level of the MFD control to >open<.
Filling of the Reaction & discharge chamber (A-1-B-002) will begin.
Manually start the Macerator pump (A-1-ZP-005) by setting to >RUN<. The filling
level is displayed.
While water is being circulated, start the Dosing pump, chlorine (A-1-P-023) by
pressing the arrow-up button to add a little chlorine to assist in cleaning.
When the level has reached approximately 300 mm go to the mask 3-way valve,
circulation/discharge (A-1-V-007) and set to >discharge< to let the contents be
discharged* overboard.
When the tank is empty (control by observing mask with level indication)
stop the Process water pump (A-1-P-032)
stop the Macerator pump (A-1-ZP-005)
reset the 3-way valve, circulation/discharge (A-1-V-007) back to >circula-
tion<.
Repeat the hole procedure if necessary.
Alternatively, it is possible to fill the tank by using the Freshwater flushing connection
(A-1-R-058), until "high level" is reached in Reaction & discharge chamber (A-1-B-
002), causing an automatic discharge (according to applicable regulations such as
IMO resolution MEPC.157(55)) overboard.
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11. SPARE PARTS ORDERING
For placing a spare parts order, it is absolutely necessary to give the quantity, des-
ignation and part number.
12. ELECTRICAL DIAGRAM
The electrical diagram is available on the following pages in the annex.
Technical Support Service@HamannAG.com
Spare Parts Spares@HamannAG.com
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