ZIEHL-ABEGG ER25C User manual

RH..C and ER..C
RH..C radial impellers and ER..C plug fans in explosion proof
design in compliance with Directive 2014/34/EU (ATEX).
Directly powered with IEC standard motor for use in
explosive atmospheres, zone 1 (category 2) and zone 2
(category 3).
Assembly instructions
Keep for reference!
VENTILATOR-Typenschild
einkleben!
L-BAL-F019-GB 2021/12 Index 003 Part.-No. 00282064-GB
english

Content
1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Scope of documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Structure of the assembly instructions . . . . . . . . . . . . . . . . . . . . 5
1.3 Target group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4 Exclusion of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.5 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 Hazards and intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3.1 Special hazards when operating in explosive atmospheres . 8
2.3.2 Improper use / reasonably foreseeable misuse . . . . . . . . . . 9
2.4 Explanations of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.5 Product safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.6 Requirements placed on the personnel / due diligence . . . . . . . 11
2.7 Work on the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.8 Modifications / interventions in the device . . . . . . . . . . . . . . . . . 12
2.9 Operator’s obligation of diligence . . . . . . . . . . . . . . . . . . . . . . . . 12
2.10 Employment of external personnel . . . . . . . . . . . . . . . . . . . . . . . 12
3 Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.1 Application / operational area . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.1.1 Application area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.1.2 Explosion protection zone . . . . . . . . . . . . . . . . . . . . . . . . 13
3.1.3 Equipment class . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.1.4 Temperature class . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.1.5 Fan marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2 Name plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.3 Transport, storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.4 Disposal / recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.2 Particularities when mounting explosion protected fans . . . . . . . 16
4.2.1 Installation, protection from external influences . . . . . . . . . . 17
4.2.2 Protect from the penetration of foreign bodies . . . . . . . . . . 17
4.2.3 Protection against contact with rotating and stationary parts . 17
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4.2.4 Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.3 Assembly of ER..C plug fans . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.4 Special instructions on the installation of series fans ER..C . . . . 19
4.5 Mounting RH..C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.6 Connection of pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.7 Connection lead & terminal box . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.8 Assembly in a humid atmosphere . . . . . . . . . . . . . . . . . . . . . . . 22
5 Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.2 Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.3 Frequency inverter and EMC . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.4 Electrical connection, grounding and protection . . . . . . . . . . . . . 25
5.5 Mains connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.5.1 Line Voltage/Rotat. Direction . . . . . . . . . . . . . . . . . . . . . . 26
5.5.2 Required quality attributes for the mains voltage . . . . . . . . . 26
5.6 Motor protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.1 Prerequisites for commissioning . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.2 During start-up check the following . . . . . . . . . . . . . . . . . . . . . . . 27
6.3 ER..C resonant frequencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7 Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7.1 Code of behaviour in the event of faults . . . . . . . . . . . . . . . . . . . 35
7.2 Possible causes and remedial measures . . . . . . . . . . . . . . . . . . 35
8 Service work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
8.1 Repairs / maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
8.2 Particularities when using in explosive atmospheres . . . . . . . . . 38
8.2.1 Bolted connections and ground connections . . . . . . . . . . . 39
8.2.2 Motor and bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8.2.3 Impeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8.2.4 Load-bearing parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8.2.5 Clearances and gap dimension . . . . . . . . . . . . . . . . . . . . 40
8.2.6 Flexible connections and seals . . . . . . . . . . . . . . . . . . . . . 40
8.3 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
9 Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
9.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
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9.2 EC Declaration of Incorporation . . . . . . . . . . . . . . . . . . . . . . . . . 42
9.3 EU declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
9.4 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
9.5 Manufacturer reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
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1 General notes
Compliance with the following instructions is mandatory to ensure the functionality and
safety of the product. If the following instructions given especially but not limited for
general safety, transport, storage, mounting, operating conditions, start-up, mainte-
nance, repair, cleaning and disposal / recycling are not observed, the product may not
operate safely and may cause a hazard to the life and limb of users and third parties.
Deviations from the following requirements may therefore lead both to the loss of the
statutory material defect liability rights and to the liability of the buyer for the product that
has become unsafe due to the deviation from the specifications.
1.1 Scope of documentation
This document is valid for ER..C and RH..C type centrifugal fans (see rating plate)
suitable for use in an explosive atmosphere.
The complete documentation for the product consists of these fan assembly instructions
and the motor operating instructions.
To ensure the final suitability of the product for the permissible conditions of use
specified in the order acknowledgement, it is absolutely imperative to observe the
fan assembly instructions and the motor operating instructions. In particular, this
applies to safety instructions, storage, transport, assembly and service.
If necessary, you can request the motor operating instructions from the motor manufac-
turer in your desired language.
Information
In the case of fans with the quality mark (see rating plate), please note the related
specifications depending on the application location!
1.2 Structure of the assembly instructions
Before installation and start-up, read this assembly instructions carefully to ensure
correct use!
We emphasize that these assembly instructions apply to specific units only, and are in
no way valid for the complete system!
Use these assembly instructions to work safely with and on the device. They contain
safety instructions that must be complied with as well as information that is required for
failure-free operation of the device.
Keep these assembly instructions together with the device. It must be ensured that all
persons that are to work on the device can refer to the assembly instructions at any time.
Keep the assembly instructions for continued use. They must be passed-on to all
successive owners, users and final customers.
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1.3 Target group
The assembly instructions address persons entrusted with planning, installation, com-
missioning and maintenance and servicing and who have the corresponding qualifica-
tions and skills for their job.
1.4 Exclusion of liability
Concurrence between the contents of these assembly instructions and the described
hardware and software in the device has been examined. It is still possible that non-
compliances exist; no guarantee is assumed for complete conformity. To allow for future
developments, construction methods and technical data given are subject to alteration.
We do not accept any liability for possible errors or omissions in the information con-
tained in data, illustrations or drawings provided.
ZIEHL-ABEGG SE is not liable for damage due to misuse, improper use or as a
consequence of unauthorized repairs or modifications.
1.5 Copyright
These assembly instructions contain copyright protected information. The assembly
instructions may be neither completely nor partially photocopied, reproduced, translated
or put on data medium without previous explicit consent from ZIEHL-ABEGG SE. In-
fringements are liable for damages. All rights reserved, including those that arise through
patent issue or registration on a utility model.
2 Safety
2.1 Safety instructions
This chapter contains instructions to prevent personal injury and property damage.
These instructions do not lay claim to completeness. In case of questions and problems,
please consult our company technicians.
Attention!
•Non-compliance with the information and safety instructions listed in these assembly
instructions can cause serious health and safety risks!
Be aware of the following Points:
•The fans are intended exclusively for use in zone 1 and 2 explosive atmospheres for
gases (see rating plate).
•The conveyance of solid matter or solids content in the conveying medium is not
permissible and can lead to dangerous situations. ZIEHL-ABEGG rejects any liability
for damage of any kind as a result of such use.
•The temperature classes of fan and motor are allowed to be different, but they must
be defined according to the ignition temperature of conveying media.
•The fans must be operated in the temperature ranges specified on the rating plate.
•The operating data on the rating plate are specified for an air density of 1.2 kg/m
3
.
•Assembly and electrical connection may only be carried out by skilled personnel in
compliance of applicable standards and these assembly instructions.
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•Start-up and maintenance of the device may only be carried out by skilled personnel,
who have completed ATEX training for correct performance of their work.
•The motor overheating protection equipment must be connected. Improper con-
nection will invalidate the manufacturer's warranty. Furthermore, this might lead to
explosion hazards.
•Protection of the motor against unusual heating in compliance with EN 60204 must be
ensured.
•If the fan is accessible, guard grilles complying with EN 13857 must be installed.
These must not be changed and must be adequately secured.
•Pay attention to objects at a greater height which might fall down.
•Pay special attention to material combinations according to EN 14986.
•Since a residual risk due to falling objects, incorrect behaviour, etc. cannot be
completely ruled out, the designer, operator or manufacturer of the installation or
system in which the fan is to be installed, must prevent any potentially hazardous
situation from arising by means of appropriate safety measures in line with standard
EN ISO 12100 and especially standard EN 14986.
•The operator is responsible for maintenance of the fan.
•Compliance with the EMC Directive only exists if the fan is directly connected to the
main power supply. If the fan is installed in a system or combined with other products,
the system manufacturer is responsible for compliance with the EMC Directive.
Responsibility of users
•The owner or operator must ensure that the equipment (fan and electrical system) is
used according to the description in these instructions and kept in good operating
condition.
•The user shall only put the fan into operation after it has been properly installed.
•The fan must be operated in accordance with the assembly instructions.
•To ensure operability, safety devices (especially the overheating protection equip-
ment) must be checked regularly.
•The instructions for installation and use must be complete and available to users at
any time.
•Users must be trained with regard to the hazards associated with the operation of an
installation in an explosive atmosphere and the intended use of the installation.
•No safety and warning instructions on the fan may be removed, and the user must
make sure that they are legible.
•The persons responsible for the installation, start-up, operation and maintenance of
the device must be competent and possess sufficient experience to correctly perform
their work.
•In addition, they must know the European standards and guidelines (at national and
regional level and if applicable the in-house regulations) for safety and hazard
prevention. A new user may only work under the supervision of an experienced
operator.
•This device must not be used by persons with limited physical and mental abilities.
Moreover, the minimum legal age must be observed, the users must be adequately
trained.
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2.2 Intended use
Attention!
•The fans are only intended for the conveyance of air or mixtures similar to air.
•Only
fans marked with are permitted for the conveyance of or installation in
explosive atmospheres!
•Any other use above and beyond this is considered not for the intended purpose
unless agreed otherwise by contract. The manufacturer will not be liable for any
damage resulting from this. The individual or company using it bears the sole risk.
•Reading these document and complying with all contained instructions -especially the
safety notifications contained therein -are considered part of intended use.
•The documentation for connected components must also be observed (e.g. frequency
inverters).
•Observe the permissible temperature classes on the rating plate.
•Due to their safe design, ZIEHL-ABEGG ER...C plug fans from Group II, Category 2G,
3G for gas with ignition protection type "h" ("c") are suitable for conveying Group IIA
and IIB explosive atmospheres for Zone 1 and Zone 2.
The following usage limits apply:
–Maximum conveying medium temperature range -20...+40 °C (with suitable motors
also up to +60 °C)
–maximum absolute pressure in the range from 0.8 to 1.1 bar
–maximum part by volume, oxygen 21 %
–maximum installation height 2000 m above mean sea level
In addition, a maximum drive motor ambient temperature of +40 °C must not be
exceeded. In exceptional cases, motors may also be suitable for operation at ambient
temperatures up to 60 °C (see motor rating plate) or installation at altitudes of more than
2000 m above sea level (in some cases with reduced power).
2.3 Hazards and intended use
2.3.1 Special hazards when operating in explosive atmospheres
When operating a fan in an explosive atmosphere and when conveying explosive gases
with the fan, comply especially with the following potential hazards and ignition sources
stated below:
•Contact between rotating parts (impeller) and stationary parts (inlet nozzle) can result
in friction, grinding or impact sparks.
•Development of friction, grinding or impact sparks due to the intake of foreign bodies
or through foreign bodies which fall into the fan.
•Development of sparks caused by the discharging or electrostatically charged compo-
nents. Especially plastic surfaces and surfaces with high layer thickness are a hazard
potential due to dust deposits.
•Hot surfaces, e.g. due to an overload or through frictional heat caused by contact of
rotating parts with stationary parts.
•Strong vibrations (e.g., due to imbalance) which can lead to parts becoming hot (e.g.,
due to a bearing defect) or due to rotating and stationary parts touching each other.
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•Release of an explosive atmosphere from the inside to the outside or from the outside
to the inside, thus resulting in an explosive atmosphere (zone entrainment).
•The following sections explain additional risks and the required measures to minimise
or avoid them.
2.3.2 Improper use / reasonably foreseeable misuse
•Operation in an environment for which the EPL / device category of the fan is not
suitable.
•Operation in a medium with an impermissible temperature class.
•Conveyance of aggressive, corrosive, abrasive or adhesive media.
•Conveyance of dust and media containing particles.
•Transfer of solids or solids content in the transfer medium.
•Operation in an unintended installation position with vertical motor shaft (plug fan ER
only allowed with horizontal motor shaft, motor feet downwards).
•Operation at unacceptably high speeds. The maximum permitted speed is specified
on the rating plate.
•Operating conditions which are associated with impermissibly strong vibrations or
which lead to exceeding the maximum permissible frequency of vibrations.
•Use with direct contact with foodstuffs or cosmetic and pharmaceutical products.
•Use of the fan as an independent household appliance.
•Use with vibration loading by customer device. Resonant operation and operation
with severe vibrations or oscillation.
•Operation with iced up impellers.
•Conveyance of liquid media.
•Use of the fan and add-on parts (e.g. guard grille) as a resting surface or climbing aid.
•Operation of the fan as a safety component or for the performance of safety-relevant
functions in the sense of EN ISO 13849-1.
•Blocking or braking of the fan by inserting objects.
•Loosening of fan blade, impeller and balancing weight.
•If a fan is operated with a frequency inverter, unacceptably high vibrations can occur
in narrowly limited speed ranges. Constant running is therefore not permitted. The
impeller can burst - danger of serious or even mortal injury!
•Use as fire gas or smoke extraction fan.
•All applications not listed in the intended use.
•Fans and parts of fans must never be changed or altered without authorisation. The
following measures apply, for instance, as non-intended:
–Removing or replacing components or individual parts of the fan with non-identical
parts.
–Absence of loose accessories supplied, which are required to ensure intended use
(e.g. expansion joints, guard grille, vibration damper).
–Drilling holes.
–Welding parts on.
–Modifying the coating (e.g. grinding off, painting over).
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–Only the following components may be fastened to the fan: Air flow components
(expansion joints for pipes or ductwork), loose accessories supplied, parts for the
drive motor electrical connection. The fan may only be connected to pipes or a
ductwork system using an expansion joint. Only the mounting options specially
intended for the purpose must be used for assembling or connecting these compo-
nents.
–Jobs or conditions which do not comply with the instructions stated in these
operating instructions on storage, installation, transport, connection, maintenance,
service, cleaning and which deviate with the special instructions on explosion
protected fans listed below.
Attention!
Not the manufacturer, rather the operator of the device is liable for any personal harm or
material damage arising from non-intended use.
2.4 Explanations of symbols
Safety instructions are highlighted with warning triangles and are depicted
according to the degree of hazard as follows.
Attention!
General hazardous area. Death or severe injury or significant property damage can
occur if the corresponding precautions are not taken!
Danger due to electric current
Danger by dangerous, electric voltage! Death or severe injury can occur if the
corresponding precautions are not taken!
Information
Important additional information and advice for user.
2.5 Product safety
The device conforms to the state of the art at the time of delivery and is fundamentally
considered to be reliable. The device and its accessories must only be used in a flawless
condition and installed and operated in compliance with the assembly instructions and/or
operating instructions. Operating outside the device's technical specifications (see name
plate and attachment / technical data) can lead to a defect in the device and additional
damage!
Information
A separate fault and performance monitoring-system with an alarm signal function is
necessary in order to prevent personal injuries and material damages during malfunc-
tions and in case the device fails. Substitute operation must be taken into consideration!
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