REITZ Design KXE User manual

2017
Translation of the Original Instructions
Single Stage Radial Fan
Design KXE
See chapter 20 of this operating manual
for detailed addresses of all companies of the REITZ Group.

Operating_Manual_Fan_KXE_04_en.docx Issued 2017
Please read this operating manual carefully.
In case of doubt, or if certain points are unclear, please
clarify them with REITZ first.
The operating manual, as well as the spare parts lists and
documentation of sub-suppliers, is a separate part of the
overall documentation. The overall documentation must be
made available to the personnel appointed for operating and
maintenance work.
OPERATING MANUAL: RADIAL FAN KXE
2017 REITZ HOLDING GMBH & CO. KG
Copyright on the operating manual
REITZ Holding GmbH & Co. KG holds the copyright in this operating manual.
This operating manual is intended for technical personnel performing the following work on the fan:
transport, installation, commissioning, operation, service, troubleshooting, maintenance, repair,
decommissioning, dismantling, disposal. Instructions and drawings of a technical nature may not be
copied, in whole or in part, distributed, imparted to third parties or used for the purpose of competition
without prior authorisation.
This operating manual was drawn up with the utmost care. Liability for direct and/or indirect damage
caused as a result of delivery or utilisation of this operating manual is excluded, wherever legally
permissible.

Table of contents
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Table of contents
1. Preface ................................................................................................................................. 6
2. Introduction ......................................................................................................................... 7
2.1 Legal notices ........................................................................................................................... 8
2.2 EC Declarations ....................................................................................................................... 9
2.3 Utilisation of the operating manual ........................................................................................... 9
2.4Regulations and standards .................................................................................................... 10
3. Fundamental safety instructions ..................................................................................... 11
3.1 Symbols and warning information .......................................................................................... 11
3.2 Authorised personnel ............................................................................................................. 13
3.2.1 Qualified persons ..................................................................................................... 13
3.2.2 Electrical specialists ................................................................................................. 13
3.3 Personal protective equipment .............................................................................................. 14
3.4 Overview of hazards .............................................................................................................. 16
3.5 Obligations of the operating company .................................................................................... 18
3.5.1 Intermediate storage ................................................................................................ 18
3.5.2 Measures in the event of a power failure .................................................................. 18
3.6 Risk of slipping, tripping or tumbling ...................................................................................... 19
4. Product description .......................................................................................................... 20
4.1 Intended use .......................................................................................................................... 21
4.2 Product identification and labelling......................................................................................... 24
4.3 Technical data ....................................................................................................................... 25
4.4 Drive ...................................................................................................................................... 27
4.4.1 Motor ....................................................................................................................... 27
4.4.2 Variable speed control (optional) .............................................................................. 27
4.5 Additional components .......................................................................................................... 27
5. Accessories ....................................................................................................................... 28
5.1 Anti-vibration mounts ............................................................................................................. 28
5.2 Flexible connections .............................................................................................................. 28
5.3 Monitoring devices ................................................................................................................. 28
5.4 Additional accessories ........................................................................................................... 28
6. Transport ........................................................................................................................... 29
6.1 Transport with a crane ........................................................................................................... 29
6.2 Transport with a truck ............................................................................................................ 30
6.3 Packaging .............................................................................................................................. 30
6.4 Transport damage ................................................................................................................. 31
6.5 Intermediate storage .............................................................................................................. 32
7. Installation ......................................................................................................................... 33
7.1 Preparing for installation ........................................................................................................ 34
7.2 Mounting and alignment ........................................................................................................ 35
7.3 Assembling the fan ................................................................................................................ 36
7.3.1 Procedure ................................................................................................................ 37

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7.3.2 Screw connections ................................................................................................... 38
7.4 Securing the fan .................................................................................................................... 39
7.4.1 Anti-vibration mount ................................................................................................. 40
7.4.2 Spring phonolators (spring type anti-vibration mounts) ............................................ 41
7.4.3 Stone bolts ............................................................................................................... 41
7.5 Insulation of the fan ............................................................................................................... 42
8. Measures prior to commissioning ................................................................................... 43
8.1 Aligning the coupling ............................................................................................................. 44
8.2 Checking the impeller gap ..................................................................................................... 47
8.3 Connecting the duct work ...................................................................................................... 49
8.4 Fitting the flexible connections ............................................................................................... 51
8.5 Activating the re-lubrication devices ....................................................................................... 53
8.5.1 Bearings .................................................................................................................. 54
8.5.2 Shaft seal ................................................................................................................. 56
8.6 Connecting the shaft seal ...................................................................................................... 57
8.7 Electrical connection .............................................................................................................. 59
8.8 Connecting the monitoring devices ........................................................................................ 62
8.9 Monitoring devices limit values .............................................................................................. 63
8.9.1 Vibrations ................................................................................................................. 64
8.9.2 Temperatures .......................................................................................................... 65
8.10 Connecting the cooler fan ...................................................................................................... 66
8.11 Checking the lubricant ........................................................................................................... 67
8.12 Connecting the external oil supply system ............................................................................. 70
8.13 Checking the final installation condition ................................................................................. 71
9. Start-up .............................................................................................................................. 73
9.1 Switching on the fan .............................................................................................................. 74
9.2 Checking the sense of rotation .............................................................................................. 74
9.3 Powering up the fan ............................................................................................................... 75
9.3.1 Direct connection ..................................................................................................... 77
9.3.2 Star-delta starting..................................................................................................... 77
9.3.3 Variable speed control ............................................................................................. 77
9.4 Switching off the fan .............................................................................................................. 80
10. Operation ........................................................................................................................... 81
10.1 Regulation via variable speed control .................................................................................... 83
10.2 Emergency shutdown ............................................................................................................ 83
10.3 Exceeding limit values ........................................................................................................... 83
10.4 Minimum duration of operation .............................................................................................. 84
10.5 Minimum speeds ................................................................................................................... 85
10.6 Maximum speeds .................................................................................................................. 86
11. Fault and rectification ....................................................................................................... 87
12. Inspecting the fan ............................................................................................................. 91
12.1 Weekly inspections ................................................................................................................ 92
12.2 Monthly inspections ............................................................................................................... 93

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12.3 Annual inspections ................................................................................................................ 94
13. Maintenance ...................................................................................................................... 95
13.1 Lubricants .............................................................................................................................. 97
13.2 Bearings ................................................................................................................................ 99
13.2.1 Grease-lubricated single bearing ........................................................................... 101
13.2.2 Grease-lubricated multiple bearing block ............................................................... 102
13.2.3 Oil-lubricated single bearing ................................................................................... 104
13.2.4 Oil-lubricated multiple bearing block....................................................................... 105
13.2.5 Oil change intervals ............................................................................................... 105
13.3 Shaft seal ............................................................................................................................ 106
13.3.1 Seal locking plate ................................................................................................... 107
13.3.2 Chamber seal ........................................................................................................ 107
13.3.3 Labyrinth seal ........................................................................................................ 108
13.4 Shaft earthing ...................................................................................................................... 110
14. Repair ............................................................................................................................... 112
14.1 Requesting a REITZ service technician ............................................................................... 114
14.2 Requesting spare parts ........................................................................................................ 114
15. Decommissioning ........................................................................................................... 115
16. Recommissioning ........................................................................................................... 117
17. Dismantling ..................................................................................................................... 119
18. Waste disposal ................................................................................................................ 121
19. Annex ............................................................................................................................... 122
19.1 Inspections in accordance with the checklist ........................................................................ 122
20. Addresses of the REITZ group....................................................................................... 124
21. List of figures .................................................................................................................. 127
22. Tables index .................................................................................................................... 128

Preface
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Read the entire operating manual meticulously.
Should you have any questions or ambiguities, please
contact us immediately. We would be more than happy to
provide support and to clarify any queries.
This operating manual constitutes one part of the overall
documentation. The overall documentation must be made
available to the personnel appointed to operating and
maintenance works at all times.
Additional documents of the overall documentation include:
- Fan data sheet
- Spare parts list
- Performance curve (optional)
- General drawing of fan
- Additional drawings (optional)
- EC Declaration of Conformity or EC Declaration of
Incorporation
- Instructions for storage and corrosion protection for
fans
- Supplier documentation
This operating manual is intended exclusively for personnel
performing the following work on the fan:
Transport, mounting, commissioning and start-up, operation,
operating, troubleshooting, maintenance, repair, shutting-
down, dismantling, disposal.
All work on the fan must be carried out exclusively by
competent persons.
This operating manual must be diligently retained for
subsequent referral.
NOTICE!
This operating manual, as well as all documents
included in delivery must be accessible to all persons
involved with work on or with the fan at all times.
1. Preface

Introduction
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This operating manual provides a description of the fan and
information regarding handling of the product, from delivery
to disposal.
This operating manual has been compiled to prevent
personal injury, material damage to property, functional
failure and harm to the environment. Adherence to the
instructions is prerequisite for a safe, flawless operation and
prolonged service life.
This operating manual exclusively refers to the fan, but not to
the electrical equipment. Installation of an electric drive does
not constitute the fan becoming electrical equipment.
This operating manual describes and represents optional
components that may not be included within the scope of
delivery. Many illustrations are simplified representations.
In the event that instructions for components or accessory
parts are not available in the overall documentation, please
notify us immediately in this regard. We would be more than
happy to forward these missing documents to you.
We reserve the right to perform technical modifications to the
fan within the context of improving performance
characteristics and continued development.
This generally-applicable operating manual applies for all
fans of this particular structural design. All fans are designed
and produced in accordance with EC Machinery Directive
2006/42/EC.
Fan configuration in accordance with ATEX (optional):
This operating manual also applies for fans which are
intended for use in potentially explosive environments
pursuant to Directive 2014/34/EU (ATEX).
2. Introduction

Introduction
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This operating manual, as well as all text, drawings, pictures
and other representations therein are protected by copyright.
Copies of any type – including extracts thereof – as well as
utilisation and/or disclosure of the content is not permitted
without prior declaration of release in writing from the
manufacturer and/or Reitz Holding GmbH & Co. KG.
Infringements in this regard shall result in an obligation to
provide compensation for damages. The assertion of
additional claims remains reserved. This operating manual
may only be forwarded without special approval of the
manufacturer if forwarded as a complete document, and only
together with the product with which it was supplied.
This operating manual is intended exclusively for personnel
performing the following work on the fan:
Transport, mounting, commissioning and start-up, operation,
operating, troubleshooting, maintenance, repair, shutting-
down, dismantling, disposal.
Liabilities for direct and / or indirect damages that are related
to the delivery and / or the usage of this operating manual
are excluded, as far as legally permitted.
The manufacturer is not liable in particular for damage,
whether direct or indirect, caused as a result of:
- Negligence of this operating manual
- Negligence of information pertaining to the fan
- Employment of insufficiently competent persons
- Unauthorised modifications
- Incompetent mounting and installation
- Incompetent electrical connection
- Improper operation
- Any use other than use as intended
- Deficient or incompetent maintenance
- Utilisation of accessory parts or spare parts other than
specifically designated (original) parts
Moreover, the provisions stipulated in the delivery
agreement, the General Terms and Conditions, as well as
the delivery conditions of the manufacturer and the legal
stipulations valid at the time of signing the contract apply for
this operating manual.
2.1 Legal notices

Introduction
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Upon receipt of delivery, the entire consignment should be
inspected for transport damage and completeness.
Document any transport damage, preferably with photos,
and notify the following of this damage immediately:
- the shipping company
- the insurance company
- the manufacturer REITZ
The EC Declaration of Conformity and the EC Declaration of
Incorporation will be delivered as separate documents.
The following symbols appear in this operating manual with
their meanings listed as follows:
 Handling instructions
Perform these instructions step-by-step and in the
specified sequence.
- Bullet point
NOTICE!
Signifies useful information and explanations.
NOTICE!
Signifies separate supplier documentation.
2.2 EC Declarations
2.3 Utilisation of the operating
manual

Introduction
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The fan is configured in conformity with the standards
specified as follows:
- DIN 24166 “Fans; technical delivery conditions”
(German Industrial Standard)
- VDMA 24167 “Ventilatoren –
Sicherheitsanforderungen”
(Industrial fans, safety requirements - VDMA –
Verband Deutscher Maschinen- und Anlagenbau eV –
German Engineering Federation)
- DIN EN ISO 12100 “Safety of machinery - General
principles for design”
- DIN EN ISO 12499 “Industrial fans - Mechanical safety
of fans - Guarding”
- DIN EN 60204-1 “Safety of machinery - Electrical
equipment of machines”
- DIN EN 61000-6-2 “Electromagnetic compatibility
(EMC) - Immunity standard for industrial environments”
- DIN EN 61000-6-4 “Electromagnetic compatibility
(EMC) - Emission standard for industrial environments”
The impeller has been balanced in accordance with
DIN ISO 1940-1 “Mechanical vibration - Balance quality
requirements for rotors in a constant (rigid) state”.
Fan configuration in accordance with ATEX (optional):
If the fan is intended for use in potentially explosive
environments pursuant to Directive 2014/34/EU (ATEX), the
fan complies additionally with the standards specified as
follows:
- DIN EN 1127-1 “Explosive atmospheres - Explosion
prevention and protection”
- DIN EN 14986 “Design of fans working in potentially
explosive atmospheres”
- DIN EN 13463-1 “Non-electrical equipment for use in
potentially explosive atmospheres”
- DIN EN 13463-5 “Non-electrical equipment for use in
potentially explosive atmospheres - Protection by
constructional safety 'c'”
2.4 Regulations and standards

Fundamental safety instructions
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Please observe all safety instructions in this operating
manual, as well as the safety instructions in the supplier
documentation.
A warning sign featuring the following symbols and
instructions for the protection of persons, as well as
protection against material damage to property and harm to
the environment is mounted on the fan.
DANGER!
Risk of fatalities!
Serious physical injury with potentially fatal
consequences.
DANGER!
Risk of fatalities due to electrocution!
Serious physical injury with potentially fatal
consequences.
 To be performed exclusively by an electrical
specialist!
DANGER!
Risk of fatalities from entanglement, drawing-in
or trapping!
Serious physical injury with potentially fatal
consequences.
 Warning against automatic operation!
3. Fundamental safety
instructions
3.1 Symbols and warning
information

Fundamental safety instructions
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DANGER!
Risk of fatalities due to explosion!
Serious physical injury with potentially fatal
consequences.
 Warming against the generation of sparks and hot
surfaces!
DANGER!
Risk of burns!
Severe personal injury, burns.
 Personal protective equipment must be worn!
DANGER!
Risk of fatalities or severe damage to health due
to inhalation or contact with eyes
Release of hot or dangerous gases.
 Personal protective equipment must be worn!
WARNING!
Damage to hearing resulting from noise!
 Ear protectors must be worn!
ATTENTION!
Harmful to the environment!
 Dispose of materials in an environmentally-friendly
manner.
NOTICE!
Signifies useful information and explanations.
NOTICE!
Read the operating manual.

Fundamental safety instructions
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Any involvement with the radial fan presupposes certain
minimum levels of knowledge. Only qualified persons may
perform work on the fan.
Additionally, each qualified person must be granted
respective authorisation by the person responsible for the
plant prior to commencing work.
Qualified persons in terms of the § 2, clause 7 German
Health and Safety at Work Regulations (“Betriebssicherheits-
verordnung BetrSichV”) is personnel that due to professional
training, work experience and their current occupational
activity has the necessary expert knowledge for testing the
working devices.
Qualified persons performing work on the fan must also
possess adequate knowledge in the following areas:
- Regulations for the prevention of accidents
(e.g. German BG regulations)
- Safety regulations
- Directives and accepted engineering standards.
Furthermore, qualified persons must also fulfil the following
requirements:
- Ability to assess the work allocated to them with regard
to dangers
- Ability to identify and prevent possible hazards to
persons, as well as material damage to property and
harm to the environment
Work on the electrical components of the fan may only be
performed by trained electrical specialists. These electrical
specialists must also fulfil the requirements stipulated for
qualified persons.
3.2 Authorised personnel
3.2.1 Qualified persons
3.2.2 Electrical specialists

Fundamental safety instructions
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Personal protective equipment must be worn as
health protection and as prevention against injury at
all times when performing work on the fan.
DANGER
All tasks with and on the fan!
Fatalities or extremely serious injuries as a result of
transport, mounting, commissioning and start-up, operation,
operating, troubleshooting, inspection, maintenance, repair,
shutting-down, dismantling and disposal.
→
Wear personal protective equipment.
→
Observe safety regulations.
→
Observe the regulations for the prevention of accidents.
The minimum equipment includes:
- Head protection (e.g. protective helmet)
- Eye protection (e.g. safety glasses)
- Protective footwear (e.g. industrial footwear with steel
toe caps)
- Hand protection (e.g. industrial gloves)
- Hearing protection (e.g. ear plugs)
- Reflective jacket
- Appropriate working clothes
NOTICE!
Additional protective equipment must be worn
wherever required for the respective work or due to
the hazardous nature of the work, e.g. safety harness
as fall arrester.
3.3 Personal protective equipment

Fundamental safety instructions
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The following Occupational Safety Regulations for safety and
health at work apply in Germany (BG rules - BGR):
- Wearing of protective clothing (BGR 189)
- Wearing of foot and leg guards (BGR 191)
- Wearing of head protection (BGR 193)
- Wearing of ear protection (BGR 194)
- Wearing of industrial gloves (BGR 195)
- Use of protective equipment against falling (BGR 198)
Familiarise yourself with the respective rules, regulations and
guidelines applicable to your situation (country in which
installation is performed) and ensure that they are observed
accordingly.

Fundamental safety instructions
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The following overview of hazards is generally applicable for
all fans and all structural designs.
Familiarise yourself with the hazards and residual risks
outlined herein for all tasks involving the fan.
Furthermore, observe all instructions conveyed in the
respective chapters of this operating manual.
Manner of hazard
Location of hazard
Hazard
Preventative measures
Crushing, shearing,
impact, tipping
During transport of the
fan and during
assembly and
installation
Risk of fatalities, injury
to persons, material
damage to property
and harm to the
environment
Never stand beneath
suspended loads, always
use appropriate lifting
equipment, secure the
load for transport, only set
loads down on suitable
ground surfaces, wear
personal protective
equipment
Impact, abrasion,
generation of sparks,
risk of explosion
All rotating parts with
traces of corrosion (e.g.
impeller, motor shaft),
hot surfaces
Risk of fatalities, injury
to persons, material
damage to property
and harm to the
environment
Remove corrosion,
observe minimum gap,
avoid abrasion from
rotating parts on fixed
parts
Seizing,
entanglement,
drawing-in, trapping,
friction, grazing
All rotating parts
Risk of fatalities, injury
to persons, material
damage to property
and harm to the
environment
Fit protective hoods, never
reach into gap, wear
close-fitting clothing, tie up
and cover long hair, wear
personal protective
equipment
Electric shock
All electrical parts
Risk of fatalities
Never carry out work on
live parts, disconnect the
power and secure against
unintentional reactivation,
cordon off the danger
zone, replace faulty parts,
renew insulation
3.4 Overview of hazards
Table 3-1 Overview of hazards and preventative measures (all structural designs)

Fundamental safety instructions
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Manner of hazard
Location of hazard
Hazard
Preventative measures
Squirting of fluids,
leaking of gases,
ejection of parts
Housing sectional
splitting, connection
points, inspection
openings, shaft seal,
condensate drain
Risk of fatalities, injury
to persons, material
damage to property
and harm to the
environment
Never switch on the fan
unless the inspection
opening and condensate
drain are closed, seal any
points of leakage with the
impeller at a standstill,
wear personal protective
equipment
Cutting, stabbing
All sharp edges, parts
with corners
Physical injury (injury
from cuts)
Wear personal protective
equipment
Burns
Hot surfaces (e.g.
housing, pedestal,
bearings, lifting lugs,
condensate drain)
Physical injury
Never touch hot surfaces,
wear personal protective
equipment, cordon off the
danger zone
Noise
Fan in general
Physical injury
(damage to hearing)
Wear ear protectors
Slipping, tripping,
tumbling
Accessible parts of the
fan (e.g. pedestal), area
immediately
surrounding the fan
Risk of fatalities, injury
to persons, material
damage to property
and harm to the
environment
Clean up any escaping
lubricants, feed in the
supply lines from above,
maintain order and
cleanliness, rectify tripping
hazards (e.g. kinks in
cables)
Falling
All working positions
higher than 1 metre
above the ground, all
openings and
depressions, ladders
Risk of fatalities, injury
to persons, material
damage to property
and harm to the
environment
Mount working platforms,
erect secure barriers (not
warning tape), wear fall
arresters (e.g. safety
harness), never carry out
work from a ladder, never
use damaged ladders,
ensure stability of ladders
Combination of
hazards
All danger zones
Risk of fatalities, injury
to persons, material
damage to property
and harm to the
environment
All work on the fan may
only be carried out by
qualified persons in
compliance with the
regulations for the
prevention of accidents
and safety regulations
Table 3-2 Overview of hazards and preventative measures (all structural designs) -
continued

Fundamental safety instructions
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The operating company and/or plant manufacturer is
responsible for:
- the necessary protective measures on site, such as
barriers, enclosures, working platforms
- provision of personal protective equipment
- ensuring use of the fan as intended
- protection of the motor against overload and
overheating
- transport, installation and commissioning of the fan
- inspections, maintenance, repairs on the fan and its
accessories to ensure correct functioning
- rectification of faults
- decommissioning, recommissioning, dismantling and
disposal of the fan
NOTICE!
Refer to further obligations of the operating company
outlined in chapter 8.7 Electrical connection.
If the fan is not installed in the plant within three months
following delivery, the operating company and/or the plant
manufacturer is responsible for correct intermediate storage
of the fan and its accessories.
NOTICE!
Refer to the separate instructions for storage and
corrosion protection for fans.
The control system of the plant in which the fan is installed
must be configured to ensure that no hazards are posed in
the event of the power supply failing, for example as a result
of inflow at inlet, back pressure or reverse flow at discharge.
Shut-off devices must be installed and incorporated in the
control system of the plant in order to prevent this hazardous
situation.
As the power supply is re-established, the original state must
be restored once again.
3.5 Obligations of the operating
company
3.5.1 Intermediate storage
3.5.2 Measures in the event of a
power failure

Fundamental safety instructions
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Ensure safety and the prevention of accidents for all tasks.
Ensure that all necessary measures for occupational health
and safety and accident-prevention have been implemented
by the operating company and/or the plant manufacturer.
DANGER
Transport routes, installation sites, workplaces
Fatalities or extremely serious injuries resulting from
accidents.
→
Observe the regulations for the prevention of accidents.
→
Observe safety regulations.
→
Ensure safety in the workplace.
The following list outlines a few essential points for
establishing safe working conditions:
- Mark out traffic routes, keep these routes clear and
ensure that they are sufficiently illuminated
- Keep the working environment clean and tidy
- Level any unevenness of floors and installation sites
- Rectify any risk of slipping, e.g. snow and icy
conditions, wet conditions, leaking lubricants
- Keep walking and standing areas clean and clear of
obstacles
- When using ladders for access: wear a fall arrester
(e.g. safety harness)
- Risk of falling when working higher than 1 metre above
the ground, as well as with openings and depressions
- Secure hazard zones with fixed barriers or railings or
working platforms. Never use warning tape!
3.6 Risk of slipping, tripping or
tumbling

Product description
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The fan of KXE design is a welded single-stage radial fan.
Power is transmitted from motor shaft to fan shaft by a
flexible coupling.
There are four variants of bearing:
Lubricant
Bearings
For re-lubrication
intervals and oil
quantities, refer to
chapter …
Grease
Single bearing
13.2.1
Grease
Multiple bearing block
13.2.2
Oil
Single bearing
13.2.3 and 13.2.5
Oil
Multiple bearing block
13.2.4 and 13.2.5
The bearing is lubricated with grease or oil.
All variants of bearing are described in this operating manual
in their own respective chapter.
NOTICE!
Refer to the weight specifications and the dimensions
in the separate general drawing of the fan.
Any independent modification on the fan will
invalidate the declaration of conformity and is strictly
prohibited. Modifications which have first been
agreed with REITZ, however, are permitted.
4. Product description
Table 4-1 Variants of bearing