System air KBR 280D2 User manual

ИНСТРУКЦИЯ
Systemair KBR 280D2

Document in original language | · 004
Thermo box
KBR, KBR/F
Installation and Operating Instructions GB

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© Copyright Systemair AB
All rights reserved
E&OE
Systemair AB reserves the rights to alter their products without notice.
This also applies to products already ordered, as long as it does not affect the previously agreed specifications.

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Contents
1 General information.........................................1
1.1 Notice symbols......................................1
1.1.1 Instruction symbols.....................1
2 Important safety information .............................1
2.1 Personnel .............................................1
2.2 Personal protective equipment..................2
2.3 5 rules of electrical safety ........................2
3 Warranty.......................................................2
4 Delivery, transport, storage ...............................2
5 Description ....................................................3
5.1 Intended use ........................................3
5.2 Technical data .......................................4
5.3 KBR and KBR/F ......................................4
6 Name plate and type key ..................................5
7 Accessories....................................................6
8 Installation.....................................................6
8.1 Assembly/Disassembly impeller —
Internal rotor motor ................................7
9 Electrical connection ........................................9
9.1 Electrical connection accessories ...............9
9.2 Protecting the motor............................. 10
9.3 Variable-speed fans.............................. 10
10 Commissioning ............................................. 11
11 Operation .................................................... 11
12 Troubleshooting/maintenance/repair ................ 12
12.1 Troubleshooting................................... 12
12.2 Maintenance....................................... 13
13 Cleaning...................................................... 14
14 Deinstallation/dismantling............................... 14
15 Disposal ...................................................... 14
16 Commissioning Report.................................... 15
17 EU Declaration of conformity............................ 16
18 EU Declaration of conformity — Smoke extract
fans ...........................................................16

General information | 1
1 General information
1.1 Notice symbols
Danger
Direct hazard
Failure to comply with this warning will lead
directly to death or to serious injury.
Caution
Hazard with a low risk
Failure to comply with this warning may lead to
moderate injuries.
Warning
Potential hazard
Failure to comply with this warning may lead to
death or serious injury.
Important
Hazard with risk of damage to objects
Failure to comply with this warning will lead to
damage to objects.
Note:
Useful information and instructions
1.1.1 Instruction symbols
Instruction Instruction with xed sequence
♦Carry out this action 1. Carry out this action 3. (if applicable, further actions)
♦(if applicable, further actions) 2. Carry out this action
2 Important safety information
Planners, plant builders and operators are responsible for the proper assembly and intended use.
♦Read the operating instructions completely and carefully.
♦Keep the operating instructions and other valid documents, such as the circuit diagram or motor instructions, with
the fan. They must always be available at the place of use.
♦Observe and respect local conditions, regulations and laws.
♦Abide by the system-related conditions and requirements of the system manufacturer or plant constructor.
♦Safety elements may not be dismantled, circumvented or deactivated.
♦Only use the fan in a awless condition.
♦Provide generally prescribed electrical and mechanical protective devices.
♦During installation, electrical connection, commissioning, troubleshooting, and maintenance, secure the location and
premises against unauthorised access.
♦Do not circumvent any safety components or put them out of action.
♦Before any work on the fan, test absence of voltage.
Even when the motor is stopped, dangerous voltages may be present on terminals.
♦Keep all the warning signs on the fan complete and in a legible condition.
♦The device is not to be used by persons (including children) with reduced physical, sensory or mental capabilities, or
lack of experience and knowledge, unless they have been given supervision or instruction.
♦Do not allow children to play with the device.
2.1 Personnel
The fan may only be used by qualified, instructed and trained personnel. The persons must know the relevant safety di-
rectives in order to recognise and to avoid risks. The individual activities and qualifications can be found in Table 1 Qual-
ifications, page 2.
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2|Warranty
Table 1 Qualifications
Activities Qualifications
Storage, operation, transport, cleaning, disposal Trained personnel (see following note)
Electrical connection, commissioning, electrical
disconnection Electrical expert or matching qualification
Installation, disassembly Fitter or matching qualification
Maintenance Electrical expert or matching
qualification
Fitter or matching
qualification
Repair
Electrical expert or matching
qualification
Fitter or matching
qualification
Smoke extraction fans and EX fans only by agreement with
Systemair.
Note:
The operator is responsible for ensuring that personnel are instructed and have understood the contents of
the operating instructions. If something is unclear, please contact Systemair or its representative.
2.2 Personal protective equipment
♦Wear protective equipment during all work in the vicinity of the fan.
• protective working clothes
• protective working shoes
• protective working gloves
• helmet
• goggles
• hearing protection
2.3 5 rules of electrical safety
1. Disconnect (disconnection of
the electrical system from
live components at all
terminals)
2. Prevent reactivation
3. Test absence of voltage
4. Ground and short-circuit
5. Cover or restrict adjacent live parts
3 Warranty
For the assertion of warranty claims, the products must be correctly connected and operated, and used in accordance
with the data sheets. Further prerequisites are a completed maintenance plan with no gaps and a commissioning re-
port. Systemair will require these in the case of a warranty claim. The commissioning report is a component of this
document. The maintenance plan must be created by the operator, see section 12.2 Maintenance, page 13.
4 Delivery, transport, storage
Safety information
Warning: Risk from rotating fan blades
♦Prevent access by unauthorised persons by safety personnel or access protection.
Warning: Suspended loads
♦Do not walk under suspended loads.
♦Make sure that there is nobody under a suspended load.
Delivery
Each fan leaves our plant in an electrically and mechanically proper condition. We recommend transporting the fan to
the installation site in the original packaging.
Checking delivery
♦Check the packaging and the fan for transport damage. Any findings should be noted on the cargo manifest.
♦Check completeness of the delivery.
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Description |3
Unpacking
When opening the transport packaging, there is a risk of damage from sharp edges, nails, staples, splinters etc.
♦Unpack the fan carefully.
♦Check the fan for obvious transport damage.
♦Only remove the packaging shortly before assembly.
Transport
Safety information
Warning: Electrical or mechanical hazards due to fire, moisture, short circuit or malfunction.
♦Never transport the fan by the connecting wire, terminal box, impeller, protection grille, inlet cone or silencer.
♦In open transport, please make sure that no water can penetrate into the motor or other sensitive parts.
♦We recommend transporting the fan to the installation site in the original packaging.
Caution: If transported without care during loading and unloading, the fan may be damaged.
♦Load and unload the fan carefully.
♦Use hoisting equipment that is suitable for the weight to be hoisted.
♦Observe the transportation arrows on the packaging.
♦Use the fan packaging exclusively as transport protection and not as a lifting aid.
Storage
♦Store the fan in the original packaging in a dry, dust-free location protected against weather.
♦Avoid the effects of extreme heat or cold.
Hazard due to loss of function of the motor bearing
♦Avoid storing for too long (recommendation: max. 1 year).
♦Check that the motor bearing functions properly before installation.
5 Description
5.1 Intended use
All KBR- versions:
• The fan is intended for installation in ventilation systems.
• The fans are exclusively intended for extract air applications.
KBR
• The fan is suitable for extracting contaminated air
(dust, kitchen exhaust).
KBR/F
• The fan is suitable for conveying contaminated air.
• The smoke extraction units KBR/F are used in case of
fire to extract smoke gases, as well as in normal
working conditions of up to 200°C.
Incorrect use
Incorrect use refers mainly to using the fan in another way to that described. The following examples are incorrect
and hazardous:
• Conveying of explosive and combustible media
• Conveying of aggressive media
• Operation in an explosive atmosphere
• Operation without duct system
• Operation with the air connections closed
• Installation outside without weather protection
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4|Description
5.2 Technical data
Max. ambient temperature [°C] see data sheet, available in our online catalogue.
Sound pressure [dB] see data sheet, available in our online catalogue.
Voltage, current, frequency, enclosure class, weight see name plate of the fan
The motor data can be found on the name plate of the motor, or in the technical documents of the motor
manufacturer.
The data on the name plate of the fan apply to "standard air" according to ISO 5801.
KBR
• Temperature range [°C] of transported air = -20 to 120 (This is the maximum range. For the temperature range of
your fan, please check the data sheet.)
KBR/F
• Temperature range [°C] of transported air = -20 to 200 or up to 400°C/120 min (once)
5.3 KBR and KBR/F
Table 2 Dimensions
50
L
50
J
K
A
F
B
29
D
E
G
C
38
H
M
G
E
KBR
KBR/F
A B C D E F F
KBR/F
G H J K K
KBR/F
LM
280 171,5 537 295 360 625 125 60 280 234 291 70 8 620 55
315 187,5 600 339 398 690 125 60 315 249 307 70 8 770 55
355 206,7 655 372 451 770 125 60 355 273 331 70 8 770 55
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Name plate and type key | 5
6 Name plate and type key
1
2
3
4
5
6
7
1Type designation 5Insulation class
2Voltage/current/frequency 6Article number/production number/manufacturing date
3 Input power 7 Certifications
4Enclosure class/fan impeller speed/
weight
Table 3 Type key
KBR 355 EC -L
-L More power version
Normal power version
-K Less power version
Motor type
EC Electronically commutated/1 phased or 3 phased
E4 4 poled/controllable by frequency converter/1 phased
DV 4 poled voltage controllable/3 phased
D2 2 poled/controllable by frequency converter/3 phased
D2–4 2–4 poled/controllable by frequency converter/3 phased
Duct Diameter
Fan type
KBR Thermo fan
KBR/F Thermo fan — Smoke extraction fan
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6|Accessories
7 Accessories
For details of the accessories, please check our online catalog or contact Systemair.
1
2
3
3
8
Accessories KBR
1
2
3
3
4
4
5
5
6
6
7
8
Accessories KBR/F
Table 4 Accessories
1 ALS-KBR Drain plug 5 EVH Flexible connection AXC 400°C
2 WSD-KBR-2 Weather roof for motor 6 RSA Silencer
3 ASF Flexible connection 7 LRK Air-operated damper
4 UGF Transition flange WBK Wall bracket
8 Installation
Safety information
♦Observe 2 Important safety information, page 1
♦Use installation material with fire resistance classes that meet temperature requirements.
♦Provide contact and intake protection and ensure safety distances according to DIN EN ISO13857 and DIN 24167-1.
♦To reduce transmission of vibration to the duct system, we recommend flexible connections from our accessory
range, see chapter Accessories.
Preconditions
♦Ensure that the fan and all its components are
undamaged.
♦Fit the fans in such a way that there is sufficient
access for installation, troubleshooting, maintenance
and repair.
♦Protect against dust and moisture when installing.
♦Ensure that the information on the name plates (fan
and motor) matches up with the operating conditions.
Important
Damage to the bearings or other parts of the fan can occur.
♦Do not place a duct bend directly before or after the fan!
♦Ensure a smooth and constant air flow to the device.
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Installation | 7
Important
Damage to the bearings or other parts of the fan
can occur.
♦Do not place a duct bend directly before or
after the fan!
♦Ensure a smooth and constant air flow to the
device.
Ø D
min.
2,5x Ø D
min.
2,5x Ø D
• Round duct system: D= Nominal diameter
• Rectangular duct system: D= Hydraulic diameter
Installation positions
Important
Damage to the fan if condensation water cannot drain.
♦Ensure that the drain plug is always at the lowest point of the fan to ensure that the condensation water
can drain.
8.1 Assembly/Disassembly impeller — Internal rotor motor
If an external rotor motor is used, the motor and impeller can`t be seperated.
Important
Damage to the motor and impeller.
The ball bearing of the motor and the balanced impeller may be damaged by forceful impacts.
♦Attach the impeller and/or the shaft extension to the shaft or the rotor without forceful impacts.
♦Do not separate the impeller and the hub. They were balanced as one unit by Systemair.
Note:
The hub can be heated for easier assembly and disassembly, for example with a hot-air blower.
• Precondition for assembly: the wedge is in the intended groove.
• Tools: hexagon socket wrench and suitable tool for removal, torque wrench for the taper clamping bush.
1 Motor
1
2
3
4
5
6
6
87
2Motor shaft
3Sleeve (not available at every fan)
4Shaft extension (not available at every fan)
5Hexagon socket screw
6Impeller
7Steel hub
8Aluminium hub
The hub is shown without impeller due to better lucidity.
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8| Installation
Disassembly
1. Aluminium hub 1. Steel hub 2. 3. 4.
1.
2.
1.
2.
Assembly
1. 2. 3. 4. 5. Aluminium hub
=
Use screw locking
The set screw must
push on the wedge
of the shaft.
2.
1.
Use screw locking
5. Steel hub 6. Steel hub
Tighten the screws
slightly
Tighten the two
screws evenly with
the tightening torque
according to table 5.
Table 5 Tightening torques for various types of bush
Type of bush 1008 1108 1210 1215 1310 1610 1615 2012 2517 3020
Tightening
torque [Nm]
5.7 5.7 20 20 20 20 20 31 49 92
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Electrical connection | 9
9 Electrical connection
Safety information
♦Observe 2 Important safety information, page 1
♦Prevent the ingress of water into the connection box.
Connection
♦Check if the data on the nameplate matches the
connection data.
♦Complete the electrical connection according to the
circuit diagram.
♦Fans with EC- motors must be switched on/off via the
control input.
♦Connect the cable end in a dry environment.
♦Install a circuit breaker in the permanent electrical
installation, with a contact opening of at least 3 mm
at each pole.
Protective grounding wire
The protective grounding must have a cross-section equal to or greater than that of the phase conductor.
Residual current circuit breaker
All-current-sensitive residual current circuit breakers are required for use in alternating-current systems with 50/60
Hz, in combination with electronic devices such as EC motors, frequency converters or uninterruptible power supplies
(UPS).
9.1 Electrical connection accessories
The following wiring diagrams show the electrical connections between accessories and
fans (with EC motor) or frequency converters (e.g. FRQ, FRQS, FXDM) which can be
controlled with a 0–10V signal. If you are not sure if your fan is equipped with an EC- motor
please see chapter 6 Name plate and type key, page 5.
motor/frequency
converter
Wire- colours of motors with carried out cables: +10V = red 0..10V/PWM =
yellow
GND = blue
Controll via 0–10V signal
MTP 10 MTP 20 S-5EC/FRQ
S-5EC/FRQ
10V
GND
A
EC-Basic MTV—1/10 EC-Vent
EC-Vent
IN/10V
OUT/PWM
GND
IN/RPM TACH
+10V
0...10V/PWM
GND
optional
PWM
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10 | Electrical connection
Controll via switching on / off
The following fans are equipped with a DIN1 connection:
KBR 355EC-L
Din1: enable electronics
• enable: pin open or voltage 5–50 V DC
• disable: bridge to GND
CO2RT-R(-D) IR24–P
24V AC
CO2RT-R-D
Supply
Neutral
Common
Relay NO
Relay NC
+10V
0...10V
GND
Din1
24V AC or DC
IR24-P
24V
Neutral
Common
Relay NO
Relay NC
+10V
0...10V
GND
Din1
9.2 Protecting the motor
Note:
In fans equipped with an EC motor, there is no additional motor protection needed. The motor protection is
integrated in the electronics of the motor.
Important
Damage to motor due to overcurrent, overload or short circiut.
♦Lead-out temperature monitors must be integrated in the control circuit in such a way that, if a fault
occurs, the motor cannot switch on again automatically after it has cooled down.
♦Motor lines and temperature monitor lines should be laid separately on principle.
♦Without thermal protection: Use a motor protection switch!
9.3 Variable-speed fans
Warning
Resonant frequencies may result in increased vibration in certain speed ranges. These vibrations may
destroy components.
♦Only operate the fan outside these speed ranges.
♦Pass through these speed ranges so quickly that any vibration cannot exceed the admissible resonant
frequency values.
♦Observe the operating instructions of the frequency converter.
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Commissioning |11
Caution
Damage as a result of incorrect commissioning of the frequency converter.
♦Install the fan and frequency converter as near as possible to one another.
♦Use shielded cables.
♦All components (fan, frequency converter and motor) must be grounded.
♦Avoid running the fan via the frequency converter below 10 Hz.
♦Heating of the motor due to use of a variable frequency drive must be checked in the application by the
customer.
♦Never exceed the maximum impeller rotation speed indicated on the name plate of the fan.
♦In any case Systemair recommends an all-pole sine filter if the fan is operated with a frequency
converter.
10 Commissioning
Warranty claims can only be made if commissioning work is carried out correctly and written evidence thereof is
provided.
Safety information
♦Observe 2 Important safety information, page 1
Preconditions
♦Installation and electrical connection have been
correctly performed.
♦Before switching the fan on, check for externally
visible damage and ensure that the protective
equipment functions properly.
♦Inlet and outlet are free.
♦Cable glands are tight.
♦Safety devices have been fitted.
Commissioning of speed-controlled fans
Check the fan for vibrations at all normal operation speeds during commissioning. Determine and evaluate vibrations
on the housing and bearing areas in accordance with DIN ISO 14694 depending on motor power and positioning.
Measurable vibration velocities depend e.g. on following factors:
• positioning • bottom section/foundation state • flow conditions
The working point of the fan, as well as used external devices and accessories, also influence the running
characteristics.
Tests
Do the tests requested in the commissioning report (16 Commissioning Report, page 15)
11 Operation
Safety information
♦Observe 2 Important safety information, page 1
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12 | Troubleshooting/maintenance/repair
12 Troubleshooting/maintenance/repair
Safety information
♦Observe 2 Important safety information, page 1
12.1 Troubleshooting
Table 6 Troubleshooting
Fan does not run
smoothly
Impeller imbalance Rebalancing by a specialist company if possible,
otherwise contact Systemair.
Soiling on the impeller Clean carefully, rebalance
Material decomposition on the
impeller due to aggressive
material conveyed.
Contact Systemair
Impeller rotates in wrong
direction.
Change direction of rotation (swap two phases in case of
a 3– phase motor).
Contact Systemair
Deformation of impeller due to
excessive temperature.
Ensure that the temperature does not exceed the
certified value/Install new impeller.
Vibrations, oscillations Check the installation of the fan/check the duct system,
see 8 Installation, page 6.
Fan operation in resonant
frequency range Consider chapter 9.3 Variable-speed fans, page 10
Air output of fan too
low
Impeller rotates in wrong
direction.
Change direction of rotation if possible, otherwise contact
Systemair.
Wrong wiring configuration (e.g.
Y instead of Delta). Check and possibly correct the wiring configuration.
Pressure losses too high. Optimize the line routing.
Flow regulators not or only
partly open. Check opening position on site.
Intake or pressure ducts are
blocked. Remove the blockage.
Grinding sounds
when starting or
operating the fan
Check if the duct connections of
the fan are strained. Loosen the duct connections and realign it.
Thermal contacts/
resistors have
triggered
Impeller rotates in wrong
direction.
Change direction of rotation (swap two phases in case of
a 3– phase motor).
Missing phase In case of a 3 phase standard motor (not EC), check if all 3
phase are present.
Motor overheated Check the cooling impeller (if used), measure the motor
winding (if possible) / contact Systemair.
Capacitor (if used) not or not
correctly connected. Connect the capacitor correctly.
Motor blocked Contact Systemair
Fan does not reach
nominal speed
Defective motor winding
Check the winding by resistance measurement (if
possible).
Contact Systemair
Control units (if used) such as
frequency converter or
transformer are set incorrectly.
Correct the settings of the control units.
Mechanical blockage Remove the blockage.
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