REMBE Q-FlapCompact II User manual

page 1of 91 USB-QFLCII-14804/0
Translation of the original instruction
Operating and Maintenance Instruction Manual
Q-FlapCompact II/Q-Flap Compact II Plus
Inlet Isolation Device

page 2of 91 USB-QFLCII-14804/0
Operating and Maintenance Instruction Inlet Isolation Device Q-FlapCompact II-
US
© 2014 REMBE® Safety + Control
Copyright of this document:
Copyright of this document remains with REMBE® Safety + Control
This operating manual is designed for installation, operating, monitoring and servicing personnel. It
contains regulations and directives as well as drawings of a technical nature. All information
included in this manual should be treated as strictly confidential. It must not be used for
competitive purposes and may not be copied, in full or in part, or be made available to or passed
on to third parties.

page 3of 91 USB-QFLCII-14804/0
EC Declaration of Conformity
We hereby declare that
Q-FlapCompact II/Q-FlapCompact II Plus back pressure flap
corresponds explosive decoupling of the following EU directive, harmonized standards and
technical specification as far as services provided by the customer have been carried out
according to our reg- ulations, mentioned directives and standards and operation of the
back pressure flap in accordance with the intended use:
94/9/EC (ATEX 95) System and explosion protection systems for application in explosion endangered areas
Labelling protection system (DN 140 - DN 1000) 1026 D St1
Labelling protection system (DN 140 - DN 315) 1026 D St2
Labelling system (only for ProFlapII-St1) II 3D c T
60°C EC-type examination FTZU 07
ATEX 0008X Quality management production: FTZU 07
ATEX Q 003
Following harmonized standards and technical specifications have been applied:
prEN 16447 Back pressure flaps for explosive decoupling, last update: 09/2012
EN ISO 80079-34 Explosive areas - part 34: application of quality management
systems for the system fabrication
EN 61241-14 Electrical operating agent for application in areas with
combustible dust, part 14: selection and construction (VDE
0165-2)
prEN 13463-1 Non-electric systems for application in explosive areas - part 1:
Basis and requirements, last update: 05/2007
EN 13463-5 Non-electric systems for application in explosive areas - part 5:
Protection by constructive safety "c"; last update: 2005/03
TRBS 2153 Technical rule for operational safety "Avoidance of ignitions
because of electrostatic charge"
Kirchheim, 05.12.2012
i.V.
i. V. Dipl. Ing. (BA) J. Kuhn
Head of Quality Management
Keller Lufttechnik GmbH
+ Co. KG Neue
Weilheimer Straße 30
73230 Kirchheim unter Teck

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Contents
1 Technical data................................................................................................................................... 7
2 General information ........................................................................................................................ 11
2.1 Icons............................................................................................................................................... 11
2.2 Application of this Operating and Maintenance Instructions manual.............................................. 12
2.3 Intended use................................................................................................................................... 12
2.4 Personnel qualification.................................................................................................................... 14
2.5 Warranty ......................................................................................................................................... 15
3 Safety.............................................................................................................................................. 16
3.1 Safety warning................................................................................................................................ 16
3.2 Warning notices on the inlet isolation device.................................................................................. 17
3.3 Inspections...................................................................................................................................... 17
3.4 Health hazard due to exhausted substances.................................................................................. 18
3.5 Danger of crushing and overturning................................................................................................ 18
3.6 Crash hazard/danger of falling........................................................................................................ 19
3.7 Electrical hazards............................................................................................................................ 19
3.8 Fire and explosion hazard............................................................................................................... 20
3.8.1 Explosion protection document....................................................................................................... 20
3.8.2 Classifications of hazardous zones................................................................................................. 21
3.8.3 Avoiding sources of ignition............................................................................................................ 22
3.8.4 Additional explosion protection measures to reduce the effects of explosions .............................. 23
3.9 Safety instructions during assembly and operation........................................................................ 24
3.10 Safety during maintenance and inspection..................................................................................... 25
3.10.1 Measures to be taken prior to performing maintenance.................................................................. 25
3.10.2 Safe system shutdown.................................................................................................................... 25
3.10.3 Safety instructions during maintenance.......................................................................................... 25
3.11 Monitoring function.......................................................................................................................... 26
4 Functional description: introduction................................................................................................. 27
4.1 Functional description Q-FlapCompact II/Plus............................................................................... 27
4.1.1 Inspection lid................................................................................................................................... 29
4.1.2 Q-FlapCompact II/Plus locking mechanism................................................................................... 29

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4.1.3 Q-FlapCompact II/Plus closed-position sensor (Formerly known as deposit sensor).................... 32
4.2 Additional monitoring: Q-FlapCompact II Plus ................................................................................ 34
4.2.1 Wear and tear sensor (Q-FlapCoompact II Plus only) ................................................................... 34
4.3 Optional Level sensor (optional sensor for Q-FlapCompact II or Q-FlapCompact II Plus)............. 35
4.4Monitoring panel requirements........................................................................................................ 36
4.4.1 Locking mechanism requirements ................................................................................................. 37
4.4.2 Closed-position sensor (formerly deposit sensor) requirements.................................................... 38
4.4.3 Wear and tear sensor requirements................................................................................................ 39
4.4.4 Optional level sensor requirements................................................................................................ 40
5 Transport and storage prior to commissioning................................................................................ 41
5.1 Transport......................................................................................................................................... 41
5.2 Storage prior to commissioning....................................................................................................... 41
6 Assembly and commissioning......................................................................................................... 42
6.1 Installation location requirements.................................................................................................... 42
6.2 Installation conditions...................................................................................................................... 43
6.3 Mounting distances and measures ................................................................................................. 46
6.4 Terminal box wiring diagram........................................................................................................... 48
6.5 Commissioning............................................................................................................................... 49
7 Operation........................................................................................................................................ 50
8. Inspection and maintenance plan ................................................................................................... 51
8.1 Safety during maintenance and inspection..................................................................................... 51
9 Maintenance ................................................................................................................................... 52
9.1 Safety during maintenance and inspection..................................................................................... 52
9.2 Preparation for inspection/maintenance work................................................................................. 52
9.3 Safe system shutdown.................................................................................................................... 53
9.4 Inspection lid opening and closing.................................................................................................. 53
9.5 Inspection for wear and material deposits....................................................................................... 56
9.6 Check the bolted and screwed connections................................................................................... 59
9.7 Inspect the seals............................................................................................................................. 59
9.8 Check flap blade ease of movement............................................................................................... 59
9.9 Inspect the locking mechanism....................................................................................................... 61
9.10 Adjusting the locking mechanism.................................................................................................... 63
9.11 Inspecting the closed-position sensor............................................................................................. 65

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9.12 Adjusting the closed-position sensor............................................................................................... 66
9.13 Optional feature: Level sensor inspection (if installed)............................................. 67
9.14 Optional feature: Adjusting the level sensor (if installed) ............................................................... 68
10 Spare parts ..................................................................................................................................... 72
11 External documents........................................................................................................................ 73
11.1 Technical Data Switch Amplifier (not supplied by manufacturer)................................................... 74
11.2 Technical Data Shotbolt Lock Unit.................................................................................................. 79
11.3 Technical Data: Closed-Position Sensor......................................................................................... 83
11.4 Technical Data KI505A (optional) ................................................................................................... 86
11.5 Operating Instructions KI505A........................................................................................................ 88
12. Annex.............................................................................................................................................. 91
12.1 Q-FlapCompact II/Plus Inlet isolation device sequence of operation with
REMBE®, INC. Monitoring Panel .................................................................................................... 91

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1 Technical data
Bolt
Hole pattern (row 2) on center
Width
Inspection lid range
Nominal
Total length
Bolt size, bolt length (number per flange)

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Unit
Q-FlapCompact II / Q-FlapCompact II plus series /
DN
DN
140
160
200
250
280
315
355
400
Installed length
mm
420
470
530
590
630
660
730
750
inch
16.54
18.50
20.87
23.23
24.80
25.98
28.74
29.53
Width
mm
380
400
440
490
520
570
630
680
inch
14.96
15.75
17.32
19.29
20.47
22.44
24.80
26.77
Height
mm
560
580
610
660
690
740
790
830
inch
22.05
22.83
24.02
25.98
27.17
29.13
31.10
32.68
Inspection lid range
mm
390
420
460
480
520
540
590
645
inch
15.35
16.54
18.11
18.90
20.47
21.26
23.23
25.39
Bolt circle diameter
mm
182
200
241
292
332
366
405
448
inch
7.17
7.87
9.49
11.50
13.07
14.41
15.94
17.64
Bolt size
M10
M10
M10
M10
M10
M10
M10
M10
Bolt length
mm
30
30
30
30
35
35
35
35
inch
1.18
1.18
1.18
1.18
1.38
1.38
1.38
1.38
Number of bolts
8
8
8
8
8
8
8
12
Maximum opening
angle of the flap
blade
20° 20° 20° 20° 20° 20° 30° 30°
Weight
kg
36
41
46
55
60
69
89
99
lbs.
79.37
90.39
101.41
121.25
132.28
152.12
196.21
218.26
Pressure loss at
20 m/s
Pa 400 ~400 ~400 320 ~330 340 ~370 ~400
Maximum reduced
excess pressure in
the enclosure (filter)
Bar 0.7 0.7 0.7 0.7 0.7 0.7 0.5 0.5
Pressure shock
resistance of the
inlet isolation device
Bar 1.5 0.95 0.95 0.95 0.95 0.95 0.6 0.6
Design available for
dust explosion class
St1
X X X X X X X X
Design available for
dust explosion class
St1 aluminum dust
(no heating value
restriction)
X X X X X X - -
Design available for
dust explosion class
St2
X X X X X X - -
Technical data
for size
DN 140 (5.51’’) to
DN 400 (15.75’’)

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Unit
Q-FlapCompact II / Q-FlapCompact II plus series /
DN
DN
450
500
560
630
710
800
900
1000
Installed length
mm
810
870
930
1090
1190
1320
1470
1625
inch
31.89
34.25
36.61
42.91
46.85
51.97
57.87
63.98
Width
mm
730
790
850
1100
1180
1260
1360
1460
inch
28.74
31.10
33.46
43.31
46.46
49.61
53.54
57.48
Height
mm
880
930
990
1110
1200
1270
1380
1500
inch
34.65
36.61
38.98
43.70
47.24
50.00
54.33
59.06
Inspection lid range
mm
700
760
820
880
950
1060
1190
1310
inch
27.56
29.92
32.28
34.65
37.40
41.73
46.85
51.57
Bolt circle diameter
mm
497
551
629
698
775
861
958
1067
inch
19.57
21.69
24.76
27.48
30.51
33.90
37.72
42.01
Bolt size
M10
M10
M12
M12
M12
M12
M12
M12
Bolt length
mm
35
35
35
35
35
35
35
35
inch
1.38
1.38
1.38
1.38
1.38
1.38
1.38
1.38
Number of bolts
12
12
16
16
16
24
24
247
Maximum opening
angle of the flap
blade
30° 30° 30° 30° 30° 30° 30° 30°
Weight
kg
112
127
145
255
295
334
395
455
lbs.
246.92
279.99
319.67
562.18
650.36
736.34
870.83
1003.10
Pressure loss at 20
m/s
Pa ~430 450 ~450 ~500 ~500 ~500 ~500 ~500
Maximum reduced
excess pressure in
the enclosure (filter)
Bar 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
Pressure shock
resistance of the
inlet isolation device
Bar 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6
Design available for
dust explosion class
St1
X X X X X X X X
Design available for
dust explosion class
St1 aluminum dust
(no heating value
restriction)
- - - - - - - -
Design available for
dust explosion class
St2
- - - - - - - -
Technical data
for sizes
DN 450 (17.72)to
DN 1000 (39.37’’)

page 10 of 91 USB-QFLCII-14804/0
Unit
Q-FlapCompact II / Q-FlapCompact II plus series /
DN
DN
140
160
200
250
280
315
355
400
Maximum Kst value
bar x
m/s
200 200 200 200 200 200 200 200
Minimum mounting
distance dust
explosion class St 1
m
2.6
2
2
2
2
2
2.6
2.6
ft. 8.53 6.56 6.56 6.56 6.56 6.56 8.53 8.53
Maximum mounting
distance dust
explosion class St 1
m
6.6
7
7
7
7
7
6.6
6.6
ft. 21.65 22.97 22.97 22.97 22.97 22.97 21.65 21.65
Unit
Q-FlapCompact II / Q-FlapCompact II plus series /
DN
DN
450
500
560
630
710
800
900
1000
Maximum Kst value
bar x
m/s
200 200 200 200 200 200 200 200
Minimum mounting
distance dust
explosion class St 1
m
2.6
2.6
2.6
3
3
3
3
3
ft. 8.53 8.53 8.53 9.84 9.84 9.84 9.84 9.84
Maximum mounting
distance dust
explosion class St 1
m
6.6
6.6
6.6
7
7
7
7
7
ft. 21.65 21.65 21.65 22.97 22.97 22.97 22.97 22.97
Unit
Q-FlapCompact II / Q-FlapCompact II plus
series / DN
DN
140
160
200
250
280
315
Maximum Kst value
bar x
m/s
200 200 200 200 200 200
Minimum mounting
distance at St 1
aluminum dust (no
heating value
restriction)
m3.5 3.5 3.5 3.5 3.5 3.5
ft. 11.48 11.48 11.48 11.48 11.48 11.48
Maximum mounting
distance dust
explosion class St 1
aluminum dust (no
heating value
restriction)
m4.5 4.5 4.5 4.5 4.5 4.5
ft. 14.76 14.76 14.76 14.76 14.76 14.76
Unit
Q-FlapCompact II / Q-FlapCompact II plus
series / DN
DN
140
160
200
250
280
315
Maximum Kst value
bar x
m/s
300 300 300 300 300 300
Minimum mounting
distance at dust
explosion class St 2
m3.6 3.5 3.5 3.5 3.5 3.5
ft. 11.81 11.48 11.48 11.48 11.48 11.48
Maximum mounting
distance at dust
explosion class St 2
m77.5 7.5 7.5 7.5 7.5
ft.
22.97
24.61.
24.61
24.61
24.61
24.61
Mounting
distance for dust
explosion class1
sizes
DN 140 (5.51’’) to
DN 400 (15.75’’)
Mounting
distance for dust
explosion class1
sizes
DN 450 (17.72’’)
to DN1000
(39.37’’)
Mounting
distance for
aluminum dust
explosion class1
(no heating value
restriction))
Mounting
distance at dust
explosion class 2