Klein ENG Series User manual

Installation instruction
For all radial blowers for use in category
1 and 2, 21 and 22 explosive atmospheres
001_KL01_01

Installation instruction for radial blowers for areas subject to gas and dust explosion hazards
02/2016 KARL KLEIN Ventilatorenbau GmbH
Page 1
Printed in Germany
We reserve the right to change the information and illustrations shown in this Installation
instruction made as a result of technical advancements. The reprint, translation and
reproduction of any kind, including excerpts, require the manufacturer's written approval.
This Installation instruction is not subject to update services.
You may inquire with the manufacturer for the most current revision.
KARL KLEIN Ventilatorenbau GmbH
Waldstraße 24D-73773 Aichwald
Phone.: +49 7 11 - 36 90 6-0
Fax.: +49 7 11 - 36 90 6-950
Internet: www.karl-klein.de
e-mail: [e-mail]
Revision: 02/2016

Installation instruction for radial blowers for areas subject to gas and dust explosion hazards
02/2016 KARL KLEIN Ventilatorenbau GmbH
Page 2
Table of Contents
1Preliminary remarks ......................................................................................................... 5
1.1 Manufacturer's instructions to the operating entity.............................................................5
1.2 Operating entity obligations for blowers located in explosive atmospheres.......................5
1.3 Symbols used ..................................................................................................................... 7
1.4 Type plates and instruction labels ......................................................................................8
2Designated use ................................................................................................................. 9
2.1 Limitations to the use and special considerations for designated uses ............................. 9
2.2 Non-designated uses..........................................................................................................10
3Safety................................................................................................................................. 10
3.1 Basic safety instructions ..................................................................................................... 10
3.2. Emissions..........................................................................................................................11
3.1.1 Dust.....................................................................................................................................11
3.1.2 Noise................................................................................................................................... 11
3.1.3 Vibrations............................................................................................................................11
3.2 Overheating protection .......................................................................................................12
4Transportation and storage............................................................................................. 13
5Description........................................................................................................................ 14
6Assembly/installation....................................................................................................... 15
6.1 General safety instructions for assembly and operation .................................................... 15
6.2 Hook-up/ installation ...........................................................................................................16
6.3 Assembly and installation specifications for explosive areas.............................................16
6.4 Blower mounting................................................................................................................. 17
7Maintenance, care and repair instructions .................................................................... 18
7.1 Maintenance and care ........................................................................................................ 18
7.2 Inspect and exchange bearings..........................................................................................18
7.3 Repair instructions and procedures.................................................................................... 18
8Additional steps to be taken when deploying blowers in zone 21 .............................. 19
8.1 Vibration threshold values .................................................................................................. 19
9Disposal............................................................................................................................. 19
10 Annex................................................................................................................................. 20
Table of Contents

Installation instruction for radial blowers for areas subject to gas and dust explosion hazards
02/2016 KARL KLEIN Ventilatorenbau GmbH
Page 3
Comply with safety instructions!
Please read all safety instructions contained in this Installation instruction with care.
Familiarize yourself with the operation of the blower before placing it into service. It will be
too late to do so when doing the work!
Never permit someone without the proper technical knowledge to install and operate this
blower.
Applicability
This Installation instruction applies to all blowers with the following model designations:
(ENG …or DNG …) II (2 or 3) G c (IIB or IIC) (T3 or T4);
(EMV … or DMV …) II (2 or 3) G c (IIB or IIC) (T3 or T4);
(EMVL … or DMVL …) II (2 or 3) G c (IIB or IIC) (T3 or T4);
(ESV2 … or DSV2 …) II (2 or 3) G c (IIB or IIC) (T3 or T4);
(ESV4 … or DSV 4 …) II (2 or 3) G c (IIB or IIC) (T3 or T4);
DHV … II (2 or 3) G c (IIB or IIC) (T3 or T4);
(EEG … or DEG …) II (2 or 3) G c ( IIB or IIC) (T3 or T4);
(ENG …or DNG …) II (2 or 3) D c T125°C;
(EMV … or DMV …) II 3 D c T125°C;
(EMVL … or DMVL …) II (2 or 3) D c T25°C;
(ESV2 … or DSV2 …) II (2 or 3) D c T125°C
(ESV4 … or DSV 4 …) II (2 or 3) D c T125°C;
DHV … II (2 or 3) D c T125°C;
(EEG … or DEG …) II (2 der 3) D c T125°C;
(ENG …or DNG …) II (2 or 3) GD c (IIB or IIC) (T3 or T4) / T125°C;
(EMV … or DMV …) II 3 GD c (IIB or IIC) (T3 or T4) / T125°C;
(EMVL … or DMVL …) II (2 or 3) GD c (IIB or IIC) (T3 or T4) / T125°C;
(ESV2 … or DSV2 …) II (2 or 3) GD c (IIB or IIC) (T3 or T4) / T125°C;
(ESV4 … or DSV 4 …) II (2 or 3) GD c (IIB or IIC) (T3 or T4) / T125°C;
DHV … II (2 or 3) GD c (IIB or IIC) (T3 or T4) / T125°C;
(EEG … or DEG …) II (2 or 3) GD c ( IIB or IIC) (T3 or T4) / T125°C;
Purpose of the Installation instruction
This Installation instruction accompanies the equipment. It also contains the Installation
instruction.
The Installation instruction was prepared by the manufacturer on the basis of their
knowledge and experience with design, production and operating procedures.
The operating entity may supplement this manual with special instructions (for instance for
supervisory and reporting duties, operating specific maintenance and care schedules), in
particular to establish special cleaning intervals to remove dust deposits on the motors.

Installation instruction for radial blowers for areas subject to gas and dust explosion hazards
02/2016 KARL KLEIN Ventilatorenbau GmbH
Page 4
Symbols used in this Installation instruction
The graphic representations and drawings are basic illustrations of a blower. They are not to
scale and do not correspond to the proportions of all blowers in the product range.
These illustrations are only intended as a guide.
Detailed dimensions and views are shown in the catalog.
Copyright
The copyright for this Installation instruction remains with KARL KLEIN Ventilatorenbau
GmbH.
This Installation instruction may not be reproduced in whole or in part without prior approval
by KARL KLEIN Ventilatorenbau GmbH.

Installation instruction for radial blowers for areas subject to gas and dust explosion hazards
02/2016 KARL KLEIN Ventilatorenbau GmbH
Page 5
1 Preliminary remarks
1.1 Manufacturer's instructions to the operating entity
As the operating entity, you are responsible for:
the correct technical and designated use of the blower by trained personnel,
compliance with safety regulations and safety instructions and any occupational safety
and accident prevention measures,
the technical training of the operating personnel on the equipment, and for their
awareness of the Installation instruction.
preventing hazardous dust deposits and/or the timely cleaning of the motor surfaces.
1.2 Operating entity obligations for blowers located in explosive
atmospheres
The Operational Safety Directive [BetrSichV or equivalent other national regulations] and the
11th Directive to the Machinery and Product Safety Act [11th GPSGV] require the operating
entity to make a variety of provisions for the use of machinery in explosive atmospheres.
Pursuant to §3 of the Operational Safety Directive [BetrSichV or equivalent other national
regulations], the operating entity is required to conduct a hazard assessment of the area
where the machinery is to be used. This assessment is intended to recognize and to take
into consideration hazards that may arise when using the machinery in combination with the
production materials and the environment.
Pursuant to §4 Operational Safety Directive [BetrSichV or equivalent other national
regulations], the operating entity is responsible for taking any required steps and for
selecting the equipment that is suited for the conditions at the deployment location and that
will ensure safety and health protection if used as designated.
To do so, the operating entity may refer to our KLEIN catalog, which contains detailed
technical specifications and notes regarding uses.
When conducting the hazard assessment and selecting a suitable machine, the operating
entity must apply machine directive 2006/42/EC/ of the European Parliament and the
Operational Safety Commission, the ATEX directive and the applicable harmonized
standards (EN), for instance EN 14986, Designs for blowers for the use in explosive
atmospheres or EN 1127-1, Explosive Atmospheres.
The operating entity is solely responsible select the equipment (blower) suitable for the
intended area and the intended location.
Repair and/or service work on explosion protected blowers may only be performed by the
manufacturer or by a repair shop authorized to do so. After the work on the blowers is
completed, the dust explosion protection must have been returned to operational status.
1 Preliminary
remarks

Installation instruction for radial blowers for areas subject to gas and dust explosion hazards
02/2016 KARL KLEIN Ventilatorenbau GmbH
Page 6
Product Warranty
KARL KLEIN Ventilatorenbau GmbH provides a product warranty as part of its general terms
and conditions of sale and delivery.
The warranty is rendered null and void if the installation and operating procedures described
in this Installation instruction, in particular the designated uses, are not complied with.
Any unauthorized reconfiguration or modification of the blower is prohibited.
Only use replacement parts and accessories that were approved by KARL KLEIN
Ventilatorenbau GmbH. The use of other parts may impair the function.
The operating entity is liable for any resulting damages.
KARL KLEIN Ventilatorenbau GmbH does not assume liability or honor warranty claims for
damages resulting from customer performed repairs or an incorrect blower installation.
1 Preliminary
remarks

Installation instruction for radial blowers for areas subject to gas and dust explosion hazards
02/2016 KARL KLEIN Ventilatorenbau GmbH
Page 7
1.3 Symbols used
This Installation instruction uses the following symbols. These are complementary to safety
and damage prevention instructions.
Attention Electrical Power Shock!
Designates potentially occurring hazardous situations. Not observing these warning labels
can result in death, serious injuries or property damage.
Attention!
Designates a potentially occurring hazardous situation. Not observing these labels can result
in injuries or property damage.
Instruction!
Application instructions for the optimum use of the equipment and other useful information.
1 Preliminary
remarks

Installation instruction for radial blowers for areas subject to gas and dust explosion hazards
02/2016 KARL KLEIN Ventilatorenbau GmbH
Page 8
1.4 Type plates and instruction labels
Instruction!
The specifications on the type plate are important for the designated use.
All labels and plates must be legible at all times. Illegible or lost type plates and
warning labels must be replaced immediately.
G
The information on the type plates identifies the respectively desired blower type and rating.
The information on the type plate corresponds to the performance ratings that were ordered.
These may be subject to change.
Instruction!
The values shown on the type plate take precedence.
Other performance ratings are found in the order confirmation
1 Preliminary
remarks

Installation instruction for radial blowers for areas subject to gas and dust explosion hazards
02/2016 KARL KLEIN Ventilatorenbau GmbH
Page 9
2 Designated use
Instruction!
For instance, the blower may be labeled as II 2 GD c IIB T4
Equipment class II; Category 2; D = Dust; G = Gas; c = design safety
IIB = explosion subgroup according CENELEC / IEC / NEC 505
T3 = up to 200 °C surface temperature
T4 = up to 135 °C surface temperature
The blower can be used in atmospheres subject to dust and gas-explosion hazards for
zones 1 and 2, 21 and 22.
In reference to EN 1127-1, this means for Zone 1 that the blower is intended for use in those
areas where an atmosphere capable of producing an explosion, in the form a mixture of
combustible gas, vapor or mist with air, may occasionally form under normal operating
conditions.
In reference to EN 1127-1, this means for Zone 2 that under normal operating conditions, an
atmosphere capable of producing an explosion, in the form a mixture of combustible gas,
vapor or mist with air, normally does not form or only forms for brief periods.
In reference to EN 1127-1, this means for Zone 21 that the blower is intended for use in
those areas where an atmosphere capable of producing an explosion, in the form of a
combustible dust-cloud mixed with air may occasionally form under normal operating
conditions.
In reference to EN 1127-1, this means for Zone 22 that under normal operating conditions,
an atmosphere capable of producing an explosion, in the form of a combustible dust-cloud
mixed with air, normally does not form or only forms for brief periods.
The designated use encompasses observing and complying with the specifications and
instructions in this Installation instruction.
2.1 Limitations to the use and special considerations for
designated uses
The designated operation also includes:
The conveyed medium may not contain solid or liquid contaminants. Use a filter as
needed (see KLEIN list of accessories).
When conveying aggressive media, the blower corrosion protection mechanisms must
first be adapted to the material characteristics. (Consult the manufacturer).
If the blower is to be used in an open blowing configuration, or if it is likely that a hazard
exists for the downstream machine or installation if the blower wheel breaks, a
protective screen must be mounted to the blower exhaust opening.
The blower may only be operated in an installed condition, i.e. mounted to or into
systems and machines.
Ventilated air flow at fan inlet with higher or lower values than the specified limits of 0.8
to 1.1 bar for absolute pressure and –20°C to +60°C for temperature are not permitted,
max. allowed oxygen content is 21 volume percent.
Ambient atmospheres with higher or lower values than the specified limits of 0.8 to 1.1
bar for absolute pressure and –20°C to +40°C for temperature are not permitted, max.
allowed oxygen content is 21 volume percent.
The blower may only be operated with an installed intake protective screen.
2 Designated Use

Installation instruction for radial blowers for areas subject to gas and dust explosion hazards
02/2016 KARL KLEIN Ventilatorenbau GmbH
Page 10
2.2 Non-designated uses
Non-designated and hazardous uses specifically include
conveying of explosive or combustible media in zone 20 and zone 0; the blower may
only be used in zones 1, 21 and 2, 22 with a corresponding marking on the type plate;
conveying abrasive media;
conveying without a suitable intake protective screen;
operation without a motor cut-off switch;
use in underground mining operations;
any other use that deviates from the designated uses, and which will result in a
hazardous condition.
3 Safety
3.1 Basic safety instructions
Klein blowers are designed and produced in accordance with generally accepted technology,
occupational and accident prevention practices and in accordance with the requirements of
the ATEX- directive for machines and protective systems for the designated use in explosive
environments, as well as the requirements of the Machine and Product Safety Act [GPSG or
equivalent other national regulations]. They correspond to the state of the art.
Nevertheless, blowers in operation can be the source of hazardous conditions, especially
when hazardous conditions are created as a result of
inappropriate use or
non-designated use
.
For this reason, all instructions for the use of the blower must be adhered to.
3 Safety

Installation instruction for radial blowers for areas subject to gas and dust explosion hazards
02/2016 KARL KLEIN Ventilatorenbau GmbH
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Instruction!
The blower may only be placed into operation when in impeccable overall condition,
only with an undamaged housing and impeller wheel, and only with a fully operational,
safe electrical hook-up. Operating a defective machine is a danger to life and limb.
Easily ingested materials, such Styrofoam, fabric rags, or similar may not be located in
the vicinity of the intake. Care must be taken that sufficient clearance is provided to the
intake.
Take note of the air exhaust direction and area. The fragments from an impeller wheel
failure must be prevented from damaging the downstream equipment to be cooled.
The electrical installation must correspond to the requirements of the machine into
which the blowers are to be installed (i.e. motor cut-off switch).
The personnel must be familiar with all steps described in this Installation instruction that
relate to the proper operation and use of this equipment.
In areas with dust build-up and dust load in the environment; the dust deposits must be
held low enough to prevent the dust smoldering temperature from being reached;
Explosion-protected blowers may not be repaired by the customer. To maintain the
explosion protection, blowers may only be repaired or maintained for preventive
purposes by the manufacturer.
To avoid combustion hazards from dust deposits, cleaning intervals must be rigorously
complied with. The cleaning operation must be performed with diligence.
The dust buildup must not exceed a thickness of 5mm.
3.2. Emissions
3.1.1 Dust
The incidence of hazardous emissions is dependent on the various media to be conveyed
3.1.2 Noise
The noise profile depends on the installation type, on the environmental conditions and the
respective operating load on the blower.
The operating noise levels of the blower can reach high levels for certain installation types
and usages. The values can range from 60 to 110 dB (A). Detailed acoustic pressure levels
can be found in the KLEIN catalog.
If work must be performed in the vicinity, appropriate noise protection steps must be taken
by the operating entity as part of its duties in accordance with the Operational Safety
Directive [BetrSichV or equivalent other national regulations], for instance hearing protection.
3.1.3 Vibrations
KLEIN blowers are designed to such a high balance quality grade that no dangerous
vibrations will occur.
The vibrations resulting from the unavoidable residual imbalance can be reduced by
installing the equipment with vibration dampers, thus preventing the vibration from being
transferred to other components.
3 Safety

Installation instruction for radial blowers for areas subject to gas and dust explosion hazards
02/2016 KARL KLEIN Ventilatorenbau GmbH
Page 12
External vibrations or impacts must be prevented from being transferred to the blower. The
blower must not be exposed to dynamic forces.
3.2 Overheating protection
To avoid potential overheating, the operating entity can request a thermal winding protector
when placing the order.
Under all circumstances, the operating entity must avoid excessive dust buildup on the
surface by timely cleaning. The dust buildup must not exceed a thickness of 5mm.

Installation instruction for radial blowers for areas subject to gas and dust explosion hazards
02/2016 KARL KLEIN Ventilatorenbau GmbH
Page 13
4 Transportation and storage
Instruction!
To transport and install the equipment safely, a suitable lifting strap should be used. The
blower should be secured in such a way that balance is maintained.
Only transport the equipment with suitable rigging and lifting implements. Prevent the blower
from tipping.
The lifting eyes on the blower housing are not intended as the sole means of lifting the entire
blower. The motor must always be secured separately!
Attention!
During transport, body parts are subject to a crushing hazard between the blower and the
surroundings.
Instruction!
Dispose of packaging materials properly. Do not burn them.
Storage instructions!
Before transporting the blower to the installation site, the equipment should only be stored in
enclosed, dry areas.
Storage in open spaces that are protected by roofing is permitted for only short periods.
The blower must be protected against damaging environmental influences and mechanical
damage.
4 Transportation and Storage

Installation instruction for radial blowers for areas subject to gas and dust explosion hazards
02/2016 KARL KLEIN Ventilatorenbau GmbH
Page 14
5 Description
Standard configuration
KLEIN blowers are radial blowers with a ball-bearing mounted electrical drive.
The respective medium is ingested axially and exhausted radially in the desired direction
(see illustration).
Flow direction of the medium
003_KL01_01
5 Description

Installation instruction for radial blowers for areas subject to gas and dust explosion hazards
02/2016 KARL KLEIN Ventilatorenbau GmbH
Page 15
6 Assembly/installation
6.1 General safety instructions for assembly and operation
Warning! Life threatening electrical shock hazard!
A life threatening electrical shock hazard exists if the blower cable ends are connected
without first disconnecting the electrical power.
Always disconnect power prior to working on components that are electrically
energized.
Correspondingly, the electrical hook-up may only be performed by a qualified and
trained electrician who is trained in installation procedures in explosive environments.
Trained electricians are persons who are familiar with the assembly, installation, initial
startup and operation of the equipment/machine and possess an appropriate
qualification, or who are familiar with safety technology standards in the maintenance
and use of appropriate protective gear and accident prevention procedures as a result of
a corresponding education or training.
The installation depends on the requirements placed on the blower and the function
specific conditions at the installation location (on the machine or the equipment).
Only use spark-free tools when performing assembly and installation work in explosive
environments.
6 Assembly/installation

Installation instruction for radial blowers for areas subject to gas and dust explosion hazards
02/2016 KARL KLEIN Ventilatorenbau GmbH
Page 16
6.2 Hook-up/ installation
Instruction!
The terminal assignments on the terminal block can be found in the terminal box. It is
mandatory to comply with the circuit diagram! A correct hook-up ensures trouble-free
operation.
Instruction!
Connecting and control cables must be installed to EMV standards in accordance with
operating requirements and the respective local regulations.
6.3 Assembly and installation specifications for explosive areas.
Additional mandatory requirements:
Instruction!
The blower may only be mounted at one location! Either at the exhaust flange, the blower
base and/or motor console or at the intake mounting flange.
Instruction!
The operating entity must install a suitable motor cut-off switch.
The minimum specifications for this (nominal current and teperiod) is shown on the type plate.
Attention!
During installation, body parts are subject to a crushing hazard between the blower and the
surroundings.
If the blower is operated with an open intake, the surrounding area must be free of
ingestible objects.
Minimum distance between a wall and the cooling-blower enclosure is 20 mm
The motor breaker or motor cut-off switch must correspond to the nominal motor rating
shown on the motor specification (type plate).
6 Assembly/installation

Installation instruction for radial blowers for areas subject to gas and dust explosion hazards
02/2016 KARL KLEIN Ventilatorenbau GmbH
Page 17
6.4 Blower mounting
Attention! Potential for damage to the equipment!
A double sided mounting must be avoided. This can result in damage and failure of blower
components.
Decouple the structure bound sound by installing a canvas expansion sleeve.
The blower may only be mounted using one location! Either at the exhaust flange, the blower
base and/or motor console or at the intake mounting flange.
Installation examples:
0
0
4
_
K
L
0
1
_
0
1
At the exhaust flange at the motor console
At the intake mounting flange for wall installation
005_KL01_01
6 Assembly/installation

Installation instruction for radial blowers for areas subject to gas and dust explosion hazards
02/2016 KARL KLEIN Ventilatorenbau GmbH
Page 18
7 Maintenance, care and repair instructions
Instruction!
Depending on the intended use of the blower and the respective system concept, the
operating entity may consider additional cleaning and/or maintenance intervals.
Unauthorized repair of damage or exchange of components are hazardous. This renders the
explosion protection features ineffective.
7.1 Maintenance and care
When using condensation water drainage holes, or when the equipment is deployed in
locations with dew buildup, causing condensation water to collect in the motor's interior,
the collected condensation water must be drained in regular intervals via the
condensation water drainage opening at the lowest point of the bearing enclosure; the
drainage opening must be subsequently resealed.
The dust buildup on the equipment surface must not exceed a thickness of 5mm.
The blower wheel must be regularly inspected for contamination and cleaned to identify
imbalances of the blower wheel early, and to prevent imbalances.
7.2 Inspect and exchange bearings
Inspect the unimpeded operation of bearings in regular intervals by monitoring the
operating noises; replace as needed.
The ball bearings must be replaced by the manufacturer or an authorized repair shop
after no more than 18,000 operating hours or 3 years.
7.3 Repair instructions and procedures
Do not perform customer repairs on defective, damaged or unevenly running blowers, but
send the equipment to the manufacturer for repair.
The manufacturer will ensure that repairs are performed properly and that the equipment is
properly balanced.
Only qualified and trained personnel should perform the disassembly of the blower.
Attention! Potential for damage to the
equipment!
When balancing weight clips (1) are relocated or
removed from the blower fins, an imbalance results.
Never perform repairs on the blower on your own. If
the assembly is not performed properly, any
subsequent use may create an explosion hazard.
006_KL01_01
1
7 Maintenance, care and repair instructions

Installation instruction for radial blowers for areas subject to gas and dust explosion hazards
02/2016 KARL KLEIN Ventilatorenbau GmbH
Page 19
8 Additional steps to be taken when deploying blowers in
zone 21
Instruction!
Pursuant to DIN EC 14986, a permanent vibration monitoring system that is mounted
directly to the blower has been mandatory since May 2007 on blowers operating in zone
21.
Blowers can be procured from Karl Klein with the corresponding devices installed. In this
case, the customer will be provided with an installed vibration sensor and an optional,
separate monitoring device.
The monitoring device must be installed outside of the explosive area. Please refer to the
corresponding Installation instruction.
When implementing a customer designed solution, the following issues need to be taken
into consideration:
Only vibration sensors that are certified for zone 21 may be used.
The vibration sensor should preferably be installed on the A-side bearing enclosure
of the drive motor, in a horizontal orientation to the installation orientation.
The nominal sensor signal must be transmitted to a control or monitoring device that
is located outside of the explosive area. The control must shut the blower down if the
blower reaches critical vibration levels.
8.1 Vibration threshold values
Threshold values in
accordance with ISO
14694
Rigid mount
mm/s
Flexible mount
mm/s
Starting value
4.5
6.3
Alarm threshold
7.1
11.8
Cut-off value
9.0
12.5
The values apply to blowers in industrial settings.
9 Disposal
Reusing defective blowers and/or their components, such as the blower impeller wheels,
roller bearings, etc. can result in property damage and personal injury, as well as damage to
the environment.
All blower components must be properly disposed of in compliance with the national and
international laws and regulations.
7 Maintenance, care and repair instructions