à In the event of uncertainties with regard to the content of the operating and installation instructions, please contact the manufacturer (contact data: see www.knf.com). Please have the type and serial number of the pump ready.

Read the operating and installation instructions before you commission the pump.

à Give the operating and installation instructions only completely and unchanged to the next owner.

à Keep the operating and installation instructions within reach at all times.

Project pumps For customer-specific project pumps (pump models that begin with "PJ" or

"PM"), there may be deviations from the operating and installation instructions.

à For project pumps, also observe the agreed specifications.

à The deviations are listed in the accompanying specifications sheet

(CPD).

Optional contents Project-specific options may be included in the operating and installation instructionsThese are marked as "optional". It is also possible that projectspecific deviations may not be included in the operating and installation instructions.

Motor The operating and installation instructions apply for the pump part.

à Also observe the operating instructions for the motor in the appendix.

à Also observe the operating instructions for the coupling in the appendix.

1.2 Exclusion of liability

The manufacturer assumes no liability for damages and malfunctions resulting from failure to observe the operating and installation instructions.

The manufacturer assumes no liability for damages and malfunctions resulting from changes or modifications to the device and improper handling.

The manufacturer assumes no liability for damages and malfunctions resulting from impermissible spare parts and accessories.

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About this document Diaphragm pump N0150 EX

1.3 Symbols and markings

Warning notice

WARNING

A notice that warns you of danger is located here.

Possible consequences of a failure to observe the warning notice are specified here. The signal word, e.g. warning, indicates the danger level.

à Measures for avoiding the danger and its consequences are specified here.

Danger levels

Signal word

DANGER

WARNING

CAUTION

NOTICE

Meaning warns of immediate danger warns of possible danger warns of a possibly dangerous situation warns of possible damage

Consequences if not observed

Death or serious injury or serious damage will result.

Death, serious injury or serious damage is possible.

Minor injury or damage is possible.

Damage is possible.

Tab.1 Danger levels

Other notices and symbols

à An activity to be carried out is specified here (a step).

1. The first step of an activity to be carried out is specified here.

Follow other sequentially numbered steps.

This symbol indicates important information.

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Diaphragm pump N0150 EX

Explanations of pictograms

Pictogram Meaning

General warning symbol

About this document

Warning of hot surface

Warning of electrical voltage

Warning of explosive atmosphere

Warning of poisonous substances

Warning of hand injuries through crushing

Observe the operating instructions

General mandatory sign

Wear hearing protection

WEEE

Symbol for separate tracking of electrical and electronic devices. The use of this symbol means that this product must be disposed of with normal household waste.

Tab.2 Explanations of pictograms

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Use Diaphragm pump N0150 EX

2 Use

2.1 Proper use

The pumps are intended exclusively for transferring gases and vapors.

Operating parameters and conditions

Responsibility of the owner

Only install and operate the pumps in accordance with the operating pa-

rameters and conditions described in Chapter 4 Technical data and Chap-

ter 2.3 Use in potentially explosive areas .

Pumps with ATEX designation do not always satisfy the regulations for potentially explosive areas in countries outside of the EU.

Requirements on the transferred medium

Only pumps that are fully assembled and in the condition as delivered may be operated.

Make sure that the installation location is dry and that the pump is protected against rain, splash, gushing, and drip water as well as from other contaminants.

The pump is suitable for transferring potentially explosive atmospheres and for operation in potentially explosive atmospheres.

Check the tightness of the connections between the pipes of the application and the pump (or the connection of the pump) at regular intervals.

Leaky connections carry the risk of releasing dangerous gases and vapors from the pump system.

Before transferring a medium, check whether the medium can be transferred danger-free in the specific application.

Before using a medium, check the compatibility of the media-contacting components (see

4 Technical data ) with the medium.

Risk of dangerous gas mixtures during pump operation if diaphragm breaks: Depending on the medium being transferred, breakage of the diaphragm can result in a dangerous mixture if the medium mixes with the air in the compressor housing or the surroundings.

Make certain that no risk of explosion arises even in extreme operating situations (temperature, pressure) and in the event of system breakdowns.

Only transfer gases that remain stable under the pressures and temperatures that arise in the pump.

Variable frequency drive Pumps with three-phase motor are designed for operation with a variable frequency drive in the speed range 500 – 1500 rpm (50 Hz) or 600 – 1800 rpm (60 Hz) (see also Chapter Electrical connection).

2.2 Improper use

The pumps are not suitable for use below ground.

The pumps are not suitable for delivering:

Dusts

§ Fluids

§ Aerosols

§ Biological and microbiological substances

§ Explosives

§ Fibers

§ Foodstuffs.

Pumps that can produce both vacuum as well as overpressure may not be used to simultaneously produce vacuum and overpressure.

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Diaphragm pump N0150 EX

2/2G

Ex h

IIB + H2

Use

This function can be made possible on a project basis following consultation with KNF Customer Service.

No overpressure may be applied to the suction side of the pump.

This function can be made possible on a project basis following consultation with KNF Customer Service.

2.3 Use in potentially explosive areas

Only pumps and drives in the corresponding equipment category and temperature class may be operated in potentially explosive atmospheres

(zones).

The pumps have the following EU explosion protection designation:

Designation Description

Symbol for explosion-proof pumps

Equipment group (see Chapter

2.4.1 Device groups

)

Device category (see Chapter 2.4.2 Device categories for gas )

Symbol indicates that the device complies with one or more ignition protection types

Symbol for ignition protection type (see Chapter

2.4.5 Ignition protection type

)

Explosion groups (see Chapter

2.4.3 Explosion groups

)

Temperature class (see Chapter

2.4.4 Temperature classes )

Equipment protection level (See Chapter 2.4.6 Equipment protection level for gas )

Special operating conditions (See Chapter

2.4.7 Special operating conditions )

Tab.3

An ignition hazard assessment in accordance with standards DIN EN ISO

80079-36 and DIN EN ISO 80079-37 was performed for the pumps. The protective goals were reached by applying ignition protection type constructional safety "c".

The explosion protection designation can also be found at the following location:

§ Type plate of the pump

Drive The pump drive must have at least the same explosion protection as the pump.

2.4 Explanations of the explosion protection designation

2.4.1 Device groups

Device group I Device group I applies for devices that are used in underground plants of mines as well as their underground systems that could be endangered by methane and/or combustible dusts.

Device group II Device group II applies for devices that are used in other areas that could be endangered by an explosive atmosphere.

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Use Diaphragm pump N0150 EX

2.4.2 Device categories for gas

The device category describes the frequency and the duration of the occurrence of explosive atmospheres during operation.

Device category

Description

1G Devices of this category are designed for use in areas in which an explosive atmosphere consisting of a mixture of air and gases, vapors or mists is present constantly or for long periods of time or often.

2/2G

2/-G

3/-G

Devices of this category are designed for use in areas in which an explosive atmosphere consisting of a dust/air mixture is present constantly or for long periods of time or often.

Devices of this category are designed for use in areas in which it is to be expected that an explosive atmosphere consisting of gases, vapors or mists forms occasionally.

Devices that extract from zone 1 and are designed for use in areas in which it is to be expected that an explosive atmosphere consisting of gases, vapors or mists forms occasionally.

Devices that extract from zone 1 but are not designed for installation in a potentially explosive atmosphere (zone).

Devices of this category are designed for use in areas in which it is to be expected that an explosive atmosphere consisting of a dust/air mixture forms occasionally.

Devices of this category are designed for uses in areas in which it is to be expected that an explosive atmosphere resulting from gases, vapors or mists occurs, though in all likelihood occurs only seldom and for a very short length of time.

Devices that extract from zone 2 but are not designed for installation in a potentially explosive atmosphere (zone).

Devices of this category are designed for uses in areas in which it is to be expected that an explosive atmosphere resulting from stirred-up dust occurs, though in all likelihood occurs only seldom and for a very short length of time.

Tab.4

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Diaphragm pump N0150 EX Use

2.4.3 Explosion groups

Combustible gases and vapors are classified according to explosion groups(I, IIA, IIB and IIC) and temperature classes. The following table shows the classification of the most common combustible gases and vapors.

I Methane

–

IIA Acetone

Ethane

Ethyl acetate

Ammonia

Ethyl chloride

Benzene

Acetic acid

Carbon monoxide

Methane

Methanol

Methyl chloride

Naphthalene

Phenol

Propane

Toluene i-amyl acetate n-butane n-butyl alcohol

Cyclohexanone

1,2dichloroetha ne

Acetic anhydride

Gasoline

Diesel fuel

Jet fuel

Heating oils n-hexane

IIB Town gas Ethylene

Ethyl alcohol

Hydrogen sulfide

IIC Hydrogen Acetylene –

–

Acetaldehyde

T5 T6

–

Ethyl ether – –

– – Carbon disulfide

Tab.5

The classification of gases and vapors into groups with respect to explosion group and temperature class applies for the transferred medium as well as for the pump surroundings.

Transferred medium The device must only be used to transfer gases and vapors that belong to the respective explosion group and the corresponding temperature class

(or lower), (see designation on the type plate) or which are not explosive and not combustible.

Surroundings of the device The devices may only be operated in an environment with an atmosphere that belongs to the respective explosion group and the corresponding temperature class (or below) (see designation on the type plate) or which is not explosive and not combustible.

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2.4.4 Temperature classes

Maximum surface temperature The maximum surface temperature is the highest temperature reached by a surface of the device under the most unfavorable conditions.

Ignition temperature The maximum surface temperature of the device must always be lower than the lowest ignition temperature of the gas/air or vapor/air mixture in which it is used.

Temperature class The maximum surface temperature is derived from the construction of the device and is stated as the temperature class.

Temperature class

Tab.6

Max. surface temperature

[°C]

450

300

200

135

100

Ignition temperature

[°C]

> 450

> 300

> 200

> 135

> 100

> 85

The temperature class of the pump was determined using air. If gas mixtures consisting mainly of gases with a greater isentropic exponent than that of air (helium, argon, xenon, neon, krypton) are pumped, compressing these mixtures can give rise to higher gas temperatures, and consequently higher surface temperatures as well. This must be taken into account and if necessary tested before operating the pump. When gas mixtures of this kind are pumped, it is recommended to run the pump with water cooling connected.

2.4.5 Ignition protection type

Designation h h h

Tab.7

Description

Constructional safety "c"

Ignition source monitoring "b"

Liquid immersion "k"

An ignition hazard evaluation according to the standards DIN EN ISO

80079-36 and DIN EN ISO 80079-37 was carried out for the devices.The

protective goals were reached by applying ignition protection type constructional safety "c".

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Diaphragm pump N0150 EX Use

2.4.6 Equipment protection level for gas

The equipment protection level describes the frequency and the duration of the occurrence of explosive atmospheres in an area.

Equipment protection level

Description* Constructional safety

Devices with very high protection level for use in potentially explosive areas.

With these devices, there is no risk of ignition during normal operation or in the event of foreseeable or infrequent faults/ malfunctions.

Very high

Devices with high protection level for use in potentially explosive areas in which there is no risk of ignition during normal operation or in the event of foreseeable or infrequent faults/malfunctions.

High

Gc Device with increased protection level for use in potentially explosive areas.

There is no risk of ignition during normal operation. The devices have a number of additional protection measures which ensure that, in the event of commonly foreseeable faults in the device, no danger of ignition exists.

Tab.8 *according to DIN EN ISO 80079-36

Increased

2.4.7 Special operating conditions

The devices must not be installed outdoors.Commissioning may only be performed with suitable weather- and corrosion-protection paneling.

§ The devices must be installed in a way that ensures they are not exposed to UV radiation.

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Safety Diaphragm pump N0150 EX

3 Safety

Observe the safety notices in Chapters

7 Installation and connection

and

8 Operation

The pumps are produced in accordance with the generally recognized rules of engineering, as well as the occupational health, safety and accident prevention regulations. Nevertheless, dangers can arise during their use that lead to injuries to the user or third parties or to damage to the pump or other property.

Only use the pumps in perfect technical condition, for their intended purpose, safely and aware of the dangers and in observation of the operating instructions.

The components that are to be connected to the pumps must be designed according to the pneumatic data of the pumps.

When connecting the pumps to the electrical power, observe the corresponding safety rules.

Personnel Make sure that only specially trained personnel or trained and instructed personnel work on the pumps. This applies in particular for connection and maintenance work.

Working in a safety conscious manner

Make sure that the personnel have read and understood the operating instructions, particularly the chapter on safety.

Observe the regulations on accident prevention and safety during all work on the pumps and during operation.

Avoid contact with the heads and housing parts, as the pump heats up during operation and may remain hot for some time after operating.

When working on the pump, make certain that the pump is disconnected from mains and without power.

Classification of a pump environment

Use in potentially explosive environment

Ensure that no hazards arise from gas flowing when gas connections are open, from the effects of noise or from hot, corrosive, dangerous and environmentally hazardous gases.

When classifying a pump environment in a potentially explosive area

(zone), observe the "Guideline for Preventing Danger from Explosive Atmospheres, with a Collection of Examples – Explosion Protection Guidelines – (EX-RL)".

For special cases or if there are doubts about the definiton of potentially explosive atmospheres, inform the supervisory authorities and ask them to make a decision.

The following applies for use in a potentially explosive environment consisting of gases, vapors and mists:

The lowest ignition temperature of the potentially explosive atmospheres that comes into question must be higher than the so-called "maximum surface temperature" of the pump.

According to DIN EN ISO 80079-36, the maximum surface temperature is the highest temperature that is achieved during operation under the most unfavorable conditions (but within the accepted tolerances) of a part or on a surface of the pump.

The maximum surface temperature is determined as a function of the pump design and is indicated on the pump type plate as the temperature class.

Explosion protection The introduction of ignition sources such as sparks, open flames and hot surfaces into potentially explosive atmospheres can cause explosions.

Therefore, when transporting, installing, and performing any work on the device in a potentially explosive atmosphere:

§ Only perform work when there is no possibility of a potentially explosive atmosphere.

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Diaphragm pump N0150 EX Safety

§ Only use tools and lifting gear that are approved for use in potentially explosive atmospheres.

Handling of hazardous media Upon breakage of the diaphragm and/or leaks, the transferred medium mixes with the air in the surroundings and/or in the pump housing. Make sure that a dangerous situation cannot arise as a result.

When pumping hazardous media, observe the safety regulations for the handling of said media.

Handling of combustible media Make certain that the temperature of the medium is always sufficiently below the ignition temperature of the medium so as to prevent ignition or explosion. This also applies for abnormal operating situations.

Note that the temperature of the medium increases when the pump compresses the medium.

Therefore, make certain that the temperature of the medium also remains sufficiently below the ignition temperature of the medium even when it is compressed to the maximum permissible operating pressure of the pump.

The maximum permissible operating pressure of the pump is stated in

Chapter 4 Technical data

Make certain that the permissible ambient temperature ( 4 Technical data )

is not exceeded.

Where applicable, also take into account external energy sources (such as radiation sources) that could additionally heat the medium.

In case of doubt, contact KNF Customer Service.

Environmental protection Store all spare parts so that they are protected according to environmental protection regulations. Observe national and international regulations. This applies in particular to parts that are contaminated with toxic substances.

Proper disposal and recycling help to protect natural resources and the environment. The end user is responsible for disposing of old devices according to the national and international regulations. Alternatively, KNF products (old devices) may also be returned to KNF for a fee (see chapter

12 Returns

EU/EC directives/standards See EC/EU Declaration of Conformity

Customer service and repairs The pumps are maintenance-free. However, KNF recommends periodic inspection of the pump for obvious changes in noise or vibration.

Only have repairs to the pumps performed by qualified KNF personnel.

Housings with electrically live components may only be opened by specialist personnel.

Use only genuine spare parts from KNF when performing servicing work.

Only have repairs to the motors performed by the responsible KNF Customer Service.

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Technical data Diaphragm pump N0150 EX

4 Technical data

4.1 Technical data

Pump materials

N0150ST EX

N0150.1.2ST EX

N0150.3ST EX

Assembly

Head plate, intermediate plate

Diaphragm

Reed valves

Valve limiter

Slotted cap screw

O-ring

Conrod plate

Retainer plate

Connection (N0150.1.2, N0150.3

only)

Tab.9

Material

Stainless steel

PTFE-coated

Stainless steel

FPM

Aluminum

Stainless steel

Pneumatic values

Parameter Value

N0150ST

Max. permissible operating pressure [bar rel*]

-Continuous operation

1.0

Ultimate vacuum [mbar abs.]

130

Flow rate at atm. pressure [l/min]** 100 ± 10%

Tab.10 *Bar rel related to 1013 hPa

**Liters in standard state (1013 hPa, 20 °C)

Pneumatic connections

Pump type

N0150

N0150.1.2, N0150.3

Tab.11 *Acc. to ISO 228

Connection for water cooling

Value

N0150.1.2ST

1.0

130

200 ± 10%

Value

Thread size G 1/2*

Pump type

N0150

N0150.1.2

N0150.3

Tab.12 *Acc. to ISO 228

Value

Thread size G 1/4*

Value

N0150.3ST

0.5

100 ± 10%

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Diaphragm pump N0150 EX Technical data

Other parameters

Parameter

Permissible ambient temperature

[°C]

Value

+5 to +40

Permissible media temperature [°C] +5 to +40

Dimensions

N0150 EX

N0150.1.2 EX

N0150.3 EX

See Fig. 8, Kapitel 7.1 Installing the pump

See Fig. 9, Kapitel 7.1 Installing the pump

See Fig. 10, Kapitel 7.1 Installing the pump

Gas tightness* of the pump head

Protection class of pump

< 6 x 10-3 mbar l/s

IP 20

Noise** Max. 70-80 dB (A)

Tab.13 *The gas tightness of the pump head is no longer ensured after the pump head is opened or after replacing diaphragm and valve plates/seals. A leak test can be used to determine whether the original gas tightness is achieved again. The gas tightness of the pump head is no longer ensured after the pump head is opened or after replacing diaphragm and valve plates/seals. A leak test can be used to determine whether the original gas tightness is achieved again.

**Max. emission sound pressure level over the entire pressure range with gas connections attached

Electrical data

Parameter

Voltage [V]

Frequency [Hz]

Power P

[W]

Max. current consumption [A]

Drive protection class

Fuse (PTC thermistor sensor)

Value

See drive type plate

See type plate and operating instructions for drive

See operating instructions for drive Max. permissible line voltage fluctuations

Relative air humidity

Max. installation altitude

Tab.14

80% for temperatures to 31 °C, decreasing linearly to 50% at 40 °C

(non-condensing).

See operating instructions for drive

Weight

Pump type

N0150

N0150.1.2

N0150.3

Tab.15

Value [kg]

Approx. 67

Approx. 82

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Technical data

Coupling

Parameter

EX-designation

Size

Tab.16

Diaphragm pump N0150 EX

Value

II 2G h IIC T6…T4 Gb

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Diaphragm pump N0150 EX Product description and function

5 Product description and function

Design

1 Pump outlet

2 Pump inlet

3 Electrical terminal box

4 Motor

5 Motor fan cover

6 Connection for water cooling

1 Pump outlet

2 Connection for water cooling

3 Union nut

4 Head connection

5 Motor

6 Motor fan cover

7 Electrical terminal box

8 Pump inlet

Fig.1 Design N0150.1.2 EX

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Product description and function

1 Pump outlet

2 Connection for water cooling

3 Union nut

4 Head connection

5 Motor

6 Motor fan cover

7 Electrical terminal box

8 Pump inlet

Fig.2 Design N0150.3 EX

Diaphragm pump N0150 EX

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Diaphragm pump N0150 EX

1 Outlet valve

2 Inlet valve

3 Transfer chamber

4 Diaphragm

5 Eccentric

6 Connecting rod

Function of a diaphragm pump

Product description and function

Fig.3 Function of a diaphragm pump

Diaphragm pumps transfer, compress (depending on the version) and evacuate gases and vapors.

The elastic diaphragm (4) is moved up and down by the eccentric (5) and the connecting rod (6). In the downwards stroke, it aspirates the gas to be transferred via the inlet valve (2). In the upwards stroke, the diaphragm presses the medium out of the pump head via the outlet valve (1). The transfer chamber

(3) is separated from the pump drive by the diaphragm.

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Transport Diaphragm pump N0150 EX

6 Transport

General

CAUTION

Personal injury and/or property damage due to incorrect or improper transport of the pump

In the event of incorrect or improper transport, the pump can fall down, be damaged or injure persons.

à Use suitable auxiliary means if necessary

(carrying strap, lifting gear, etc.).

à Where appropriate, wear suitable personal protective equipment (e.g., safety shoes, safety gloves).

CAUTION

Risk of injury from sharp edges on the packaging

There is a risk of injury from cutting on the sharp edges when grabbing corners or when opening the packaging.

à Where appropriate, wear suitable personal protective equipment (e.g., safety shoes, safety gloves).

Only for two-headed pumps:

CAUTION

Personal injury and/or property damage due to incorrect or improper transport of the pump

If the pump is raised and/or carried on the connection during transport, leaks and/or damages to the pump may result.

à Do not carry the pump on the pneumatic connection.

à Transport the pump in the original packaging to the installation location.

à Store the original packaging of the pump (e.g. for later storage).

à Inspect the pump for transport damage after receiving it.

à Document any transport damage in writing.

à Remove any transport locking devices on the pump prior to commissioning.

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Diaphragm pump N0150 EX Transport

Parameter

Storage temperature [°C]

Value

+ 5 to + 40

Transport temperature [°C]

Permissible humidity (non-condensing) [%]

- 10 to + 60

30 to 85

Max. storage period

(Aging, ball-bearing grease) [Mon.]

Tab.17 Transport parameter and storage parameter

NOTICE

Prior to commissioning, make sure that the pump has reached the ambient temperature (

4 Technical data ).

Transport with carrying strap

Fig.4 Position of carrying strap (example)

1. Pull the carrying strap under the pump (see Fig. 4).

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Transport Diaphragm pump N0150 EX

1 M12 screw

Fig.5 Fastening the carrying strap (pump shown as an example)

2. Fasten the carrying strap between compressor housing and motor

(Fig. 1, see Fig. 5).

3. Make certain that the lifting load cannot be transferred from the belt to the pump connection.

4. Lift the pump from the packaging with the help of lifting gear.

5. Lower the pump carefully at the installation location.

Transporting with lifting eyebolt

1. Loosen the M12 screw (1).

Fig.6 Loosen the M12 screw (pump illustrated as an example)

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Diaphragm pump N0150 EX Transport

2. Screw the transport eyebolt (2) hand-tight into the threaded hole.

The transport eyebolt (2) is available as an accessory (see 11.2 Accessories ).

2 Transport eyebolt

Fig.7 Transport eyebolt (depicted pump as an example)

3. Lift the pump out of the packaging with the aid of lifting gear.

4. Lower the pump carefully at the installation location.

5. Remove the transport eyebolt (2).

6. Screw the M12 screw (1) back into the thread.

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Installation and connection Diaphragm pump N0150 EX

7 Installation and connection

The pumps are only to be installed in accordance with the operating pa-

rameters and conditions described in Chapter 4 Technical data .

à Observe the safety notices (see Chapter Safety).

DANGER

Risk of dangerous gas mixtures during pump operation

Depending on the medium being transferred, breakage of the media-contacting components can result in a dangerous mixture if the medium mixes with the air in the compressor housing or the surroundings.

à Before using a medium, check the compatibility of the media-contacting components

(see

4 Technical data ) with the medium.

Mounting dimensions

7.1 Installing the pump

à Store the pump at the installation site prior to installation to bring it up to the ambient temperature.

à For mounting dimensions, see following figures:

Fig.8 Mounting dimensions N0150 EX

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Diaphragm pump N0150 EX Installation and connection

Fig.9 Mounting dimensions N0150.1.2 EX

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Installation and connection Diaphragm pump N0150 EX

Cooling air supply

Fig.10 Mounting dimensions N0150.3

WARNING

Risk of explosion due to lack of cooling air supply

à Mount the pump so that the fan wheel of the pump can draw in sufficient cooling air.

à Ensure sufficient ventilation or heat dissipation in the vicinity of the pump.

WARNING

Danger of burning on hot surfaces

Hot surfaces could occur if the pump overheats.

à When installing the pump, make sure that sufficient cooling air infeed and discharge is ensured.

Immediate environment of the hot pump parts

Installation location

à During installation, make sure that no combustible or thermally deformable objects are positioned in the immediate proximity of the hot pump parts (head, drive).

à Make sure that the installation location is dry and that the pump is protected from rain, spray water, splash water, dripping water and other contaminants.

à Make sure that the installation location is accessible for service.

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Diaphragm pump N0150 EX Installation and connection

à Make sure that access to moving parts is prevented.

The IP protection class of the pump motor is specified on the type plate.

à Mount the pump at the highest point in the system to prevent condensate from collecting in the pump head.

à Protect the pump from dust.

à Protect the pump from vibration and impact.

WARNING

Personal injury and/or property damage from vibrations

Pump vibrations, in combination with adjacent components, can result in crushing and/or damage to these components.

à Make sure that pump vibrations cannot lead to dangers in combination with adjacent components.

Installation position à The pump must be installed in the depicted installation position. Use metal screws to fasten the pump at the attachment points indicated in

Chapter

7 Installation and connection .

7.2 Electrical connection

DANGER

Danger to life from electric shock

à Only have the pump connected by an authorized specialist.

à Only have the pump connected if the power supply is disconnected.

WARNING

Risk of explosion from electrostatic charge

à Connect the pump so that the risk of ignition from electrostatic charge is avoided.

à Carefully ground the pump.

à When connecting to a power source, carefully read and observe the motor operating instructions (including the notice on insulation resistance measurement).

à When connecting to a power source, observe the applicable regulations, directives, and technical standards.

WARNING

Automatic restart after interruption of the power supply

If the power supply is interrupted or the thermal overload fuse of the motor is activated, the pump will automatically restart.

à Take appropriate protective measures.

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Installation and connection

Potentially explosive atmospheres

Fastening the connection cables

PTC thermistor sensor

Diaphragm pump N0150 EX

à Install a device for separating the pump motor from the electrical mains in the electrical installation.

Install an Emergency Off device such that it is not possible for there to be an automatic restart or for hazardous situations to persons and property to occur.

à Only place the electrical equipment that is necessary for the operation of the pump .

à Take lightning protection measures.

Fasten the connection cables so that

– the cables do not come into contact with movable or hot parts.

– the cables cannot be worn or damaged on sharp corners or edges

– no tensile and pressure forces are exerted on the connection point of the cables (strain relief)

The motors are equipped standard with PTC thermistor sensors for monitoring against overheating (see operating instructions for motor).

The three-phase motors are suitable for operation with frequency converters (see operating instructions for the motor).

7.3 Pneumatic connection

CAUTION

Personal injury or property damage through ejected plugs

If not removed, the plugs on the pressure side of the pump can be ejected during operation by the resulting overpressure.

à Remove the plugs during installation.

à Wear appropriate personal protective equipment.

Connected components

Pressure relief device

Only connect components to the pump that are designed for the pneu-

matic data and thermal requirements of the pump. (see Chapter 4

Technical data ).

à Protect the compressors by means of a pressure relief device between the pressure-side connections of the compressor and the first shut-off valve.

WARNING

Risk of explosion during pressure limitation resulting from the medium mixing with the environment

à Make certain that there is no risk of explosion posed by the medium mixing with the environment.

Pump discharge à If the pump is used as a vacuum pump, safely (with respect to medium and noise) drain the hot pump discharge that may, under certain circumstances, occur at the pneumatic outlet of the pump.

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Diaphragm pump N0150 EX Installation and connection

Decoupling à KNF recommends mechanically decoupling the pump from the pipe system, e.g., through the use of flexible hoses or pipes. In this way it is possible to prevent the transfer of possible pump vibrations and noises to the system.

Connecting the pump

A marking on the pump head indicates the flow direction.

CAUTION

Risk of injury from mixing up suction side and pressure side

Mixing up the suction side and pressure side can result in breakage of connected components on the suction side and pressure side.

à Observe the marking of inlet and outlet on the pump head.

1. Remove the protective plugs from the gas connection threads.

2. Connect the suction line and the pressure line (for mounting dimen-

sions, see Chapter 4 Technical data

3. Lay the suction line and the pressure line at a downward angle to prevent condensate from running into the pump.

7.4 Connecting water cooling (optional)

Water cooling (see 11.2 Accessories ) can increase the service life

of the diaphragm, particularly with high pressures or high ambient temperature.

Operating parameters

Parameter

Water temperature [°C]

Value

+ 5 to + 30

Water pressure [bar g] < 1.0

Water flow rate [l/min] > 1.0

Tab.18 Recommended parameters for connecting the water cooling

1. Connect the water cooling system to the provided hose connections.

Safely drain the water discharge.

The flow direction is allowed in both directions.

Mounting dimensions For mounting dimensions, see the following dimensional drawings:

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Installation and connection Diaphragm pump N0150 EX

Fig.11 Mounting dimensions pump series N0150 EX

Fig.12 Mounting dimensions pump series N0150.1.2 EX

Translation of Original Operation and Installation Instruction, english, KNF 321729 11/22

Diaphragm pump N0150 EX Installation and connection

Fig.13 Mounting dimensions pump series N0150.3 EX

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Operation

Diaphragm pump N0150 EX

8 Operation

8.1 General

WARNING

Risk of burns from hot pump parts and/or hot medium

Some pump parts may be hot during or after operation of the pump.

à Allow the pump to cool after operation.

à Take protective measures to protect against touching hot parts.

WARNING

Damage to the pump due to oveheating

If gases with a greater isentropic exponent than that of air (helium, srgon, xenon, neon, krypton) are pumped, compressing these gases gives rise to higher gas temperatures.The higher temperatures may impair the functional capabilities of the parts of the pump that are in contact with the media. and possibly also adjacent components (e.g., ball bearings). This in turn will shorten the service life of the pump.

à If necessary, contact KNF Customer Service.

WARNING

Risk of explosion due to excessively high surface temperature

à Before pumping gas mixtures of this kind, check the surface temperature before running the pump.

à When pumping gas mixtures of this kind, run the pump with water cooling connected.

WARNING

Injury to eyes

Coming too close to the inlet/outlet of the pump may result in injury to the eyes due to the present vacuum/operating pressure.

à Do not look into the pump inlet/outlet during operation.

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Diaphragm pump N0150 EX Operation

à Only operate the pumps in accordance with the operating parameters

and operating conditions described in Chapter 4 Technical data

and in

Chapter

2.3 Use in potentially explosive areas

à Ensure the proper use of the pumps (See Chapter

2.1 Proper use

Eliminate the possibility of improper use of the pumps (see Chapter 2.2

Improper use ).

Observe safety notices (Chapter 3 Safety

WARNING

Risk of pump head bursting due to excessive pressure increase

à Do not exceed the maximum permissible operating pressure (see

4 Technical data ).

à Monitor the pressure during operation.

à If the pressure exceeds the maximum permissible operating pressure of the pump: immediately switch off the pump and remedy the fault

(see Chapter Troubleshooting).

à Only throttle or regulate the air or gas quantity on the suction line to prevent the maximum permissible operating pressure from being exceeded.

à If the air quantity or gas quantity on the pressure line is throttled or regulated, make sure that the maximum permissible operating pressure at the pump is not exceeded.

à Ensure that the pump outlet is not closed or restricted.

WARNING

Risk of explosion from elevated ambient temperature

à Monitor the ambient temperature (compression heat, motor heat).

à Ensure sufficient cooling air supply.

WARNING

Risk of dangerous gas mixtures during pump operation if diaphragm breaks

If the diaphragm should break, the medium will mix with the air in the compressor housing or in the surroundings.

à Stop pump immediately.

à Replace the diaphragm prior to further operation (see Chapter

9 Servicing

Pump standstill

Because the diaphragm is a wear part, diaphragm breakage may occur at any time.

When the pump is at a standstill, establish normal atmospheric pressure in the lines.

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Operation

Vapors as medium

Diaphragm pump N0150 EX

à The service life of the diaphragm can be prolonged if condensation does not form in the pump. Therefore, only carry out work with saturated or near-saturated vapors while the pump is warm.

Operation with open suction-side gas connection can result in contaminants and objects being drawn in.

8.2 Information on switching the pump on and off

Switching on the pump

The pump must not be started up against pressure or vacuum during switch-on. This also applies during operation after a brief power failure.

Recommissioning

Inspecting the pump

à Ensure that there is normal atmospheric pressure in the lines when switching on.

Switching off the pump

à KNF recommends: When pumping corrosive media, flush the pump

before switching off (see Chapter 9.2.1 Flushing the pump

) to extend the service life of the diaphragm.

à Establish normal atmospheric pressure in the lines (relieve pump pneumatically).

à Before recommissioning, observe the applicable standards, guidelines, regulations and technical standards at the electrical connection.

à Inspect the pump periodically for external damage or leakage.

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Diaphragm pump N0150 EX Servicing

9 Servicing

NOTICE

Servicing the pump

Damage to the pumps can result from failure to observe the applicable legal regulations and procedures for the location or intervention by untrained or uninstructed personnel.

à Servicing may only be performed according to the legal regulations (e.g. work safety, environmental protection) and provisions.

à Servicing may only be performed by specialized personnel or trained and instructed personnel.

9.1 Servicing schedule

WARNING

Risk of explosion from wear

à Have the connecting rod bearing replaced by

KNF according to servicing schedule.

à Have the motor bearing replaced by KNF according to servicing schedule.

WARNING

Risk of explosion if genuine spare parts are not used.

If original parts are not used, the pump loses its explosion protection properties. Furthermore, the function of the pump and it safety are lost.

The validity of the CE conformity is rendered void if genuine spare parts are not used.

à Use only genuine spare parts from KNF when performing servicing work.

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Servicing Diaphragm pump N0150 EX

Component

Pump

Pump bearing

(on pump shaft and connecting rod)

Motor bearing

Gas connections

Coupling

Servicing interval

à Perform periodic inspections for external damage or leakage.

à Periodically check for noticeable changes to noises and vibrations.

à Replace after 34,000 operating hours or after no more than 48 months

à See the operating and installation instructions for the motor; inquire with the manufacturer of the motor if necessary

à Inspect the pump periodically for external damage or leakage

à Inspect coupling play periodically

à See operating instructions for coupling

Tab.19

The ball bearings installed in the pump and in the drive motor are lubricated for life. This means that the bearings are coated with a high-quality grease with a high degree of purity and an ideal fill level by the bearing manufacturer at the plant. These bearings cannot be relubricated. The prescribed bearing replacement periods can be found in Chapter

9.1 Servicing schedule .

The duration of use of the bearing grease depends on many highly individual factors. The prescribed bearing replacement periods were specified under the assumption of normal ambient conditions. Factors that can make early bearing replacement necessary include dust or dirt that may get into the bearing, aggressive gases or vapors that may change the lubricating properties of the bearing grease, etc. It is the operator's responsibility to assess these factors.

36 Translation of Original Operation and Installation Instruction, english, KNF 321729 11/22

Diaphragm pump N0150 EX Servicing

9.2 Cleaning

9.2.1 Flushing the pump

WARNING

Risk of explosion by flushing the pump with air

à In potentially explosive areas or when using the pump with explosive media, only permit specialist to flush the pump with inert gas.

WARNING

Risk of burns from hot pump parts and/or hot medium

Some pump parts may be hot during or after operation of the pump.

à Allow the pump to cool after operation.

à Take protective measures to protect against touching hot parts.

à Before switching off the pump under atmospheric conditions, flush for several minutes with inert gas.

If there is no risk of explosion, flushing can also be performed with air.

à Discharge the media safely.

9.2.2 Cleaning the pump

WARNING

Risk of explosion from electrostatic charging of the components

à Only clean the pump with a damp cloth.

Only clean the pump with a damp cloth and non-flammable cleaning agents.

à Only use solvents during cleaning if head materials are not corroded

(ensure resistance of the material).

à If compressed air is present, blow out the components.

Requirements

9.3 Changing diaphragm and reed valves

à Disconnect the drive from the mains and ensure that it is deenergized.

à Allow the pump and the drive to cool.

à Clean the pump and free the pump of hazardous materials.

à Remove the hoses/pipes from the pneumatic pump inlet and outlet.

With multi-headed pumps, parts of the various pump heads might become mixed up.

à Change the parts of the individual pump heads that are to be replaced one at a time.

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Servicing Diaphragm pump N0150 EX

WARNING

Risk of explosion from formation of potentially explosive atmosphere

Leaky connections can result in dangerous potentially explosive atmospheres.

à Make certain that all elastomer parts are undamaged, clean and correctly installed.

à Check the pneumatic connections of the pump for leaks.

à Work with care during service work.

à Replace defective parts immediately.

WARNING

Health hazard due to dangerous substances in the pump

Depending on the medium being transferred, caustic burns or poisoning is possible.

à Wear protective equipment if necessary, e.g., protective gloves, goggles.

à Clean the pump with suitable measures.

CAUTION

Risk of burns from hot pump parts

The pump head or motor may still be hot after operation of the pump.

à Allow the pump to cool after operation.

For two-headed pumps:

Servicing work should generally be performed on both heads at the same time.

Spare parts Spare part*

Diaphragm

Item designation**

(4)

Quantity

1 (per pump head)

O-ring

O-ring (only .13)

Reed valve, suction side

Reed valve, pressure side

(2)

(8)

(10)

(17)

(14)

2 (per pump head)

1 (per pump head)

Slotted cap screw (13) 4 (per pump head)

Tab.20 * According to spare parts list, Chapter 11.1 Spare parts

** According to Individual parts of the pump head

38 Translation of Original Operation and Installation Instruction, english, KNF 321729 11/22

Diaphragm pump N0150 EX Servicing

1 Head cover

2 O-ring

3 Intermediate plate

4 Diaphragm

5 Housing

6 Shim ring(s)

7 Connection rod

8 O-ring (only .13)

9 Conrod plate

10 O-ring (only . 13)

11 Retainer plate

12 Hexagon socket head cap screws

13 Slotted cap screw

14 Reed valve, pressure side

15 Valve stopper, pressure side

16 Hexagon socket head cap screws

17 Reed valve, suction side

18 Valve stopper, suction side

Tool and material Quantity

Tool/material

4 mm allen key with torque indicator

5 mm allen key with torque indicator

Screwdriver blade width 5.5 mm

#2 Phillips screwdriver (for fan assembly)

Adjustable face spanner wrench for nuts with two holes, pin diameter 4 mm, length approx. 160 mm (available as wrench for

retainer plate as KNF accessory, see 11.2 Accessories ).

Felt-tip pen

Hot air gun

1 Adhesive (Loctite 2400) or comparable product

Tab.21 *According to accessory list, Chapter 11.2 Accessories

Fig.14 Components of the pump head

The following item numbers refer to Individual parts of the pump head unless specified otherwise.

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Servicing

Union nut

Marking

Fig.15 Marking of the union nuts

Diaphragm pump N0150 EX

Removing the pump head

1. Accessing the fan blades:

Mark the motor fan cover with a continuous line made with a felt-tip pen

(for later reassembly) and then loosen the fastening screws of the motor fan cover (see Chapter

5 Product description and function

) and remove the cover.

2. For two-headed pumps only:

Remove the pneumatic connection between the pump heads; to do this, mark the union nuts according to Fig. 15 and loosen them.

3. Mark head plate (1), intermediate plate (3) and housing (5) with a continuous line made with a felt-tip pen. This helps to avoid incorrect assembly later.

4. Loosen the six hexagon socket head cap screws (12) as well as the two screws (16); remove head plate (1) and intermediate plate (3).

WARNING

Risk of explosion from damage

If the housing cover is bent or if the paint is damaged, there is no risk of explosion.

à Perform the work steps carefully and without the use of force.

5. For two-headed pumps:

Perform steps 3 and 4 for the second pump head.

Replacing the diaphragm

1. Heat the retainer plate (11) with a hot-air gun (T=approx. 400 °C) for approx. 5 minutes to approx. 100 °C.

WARNING

Risk of burns from hot parts

Burns may occur on skin contact with the hot retainer plate and countersunk screw or other heated pump parts.

à Wear protective gloves.

à Only loosen the retainer plate with face spanner wrench.

à Only place the retainer plate and countersunk screw on a heat-resistant surface.

2. Removing the retainer plate (11):

Loosen the retainer plate from the conrod plate (9) with the wrench for retainer plate by turning counterclockwise and remove it.

3. Remove the diaphragm (4).

4. Only .13:

Remove the O-ring (10) from the housing (5).

5. Only .13:

Remove the O-ring (8) from the conrod plate (9).

6. Check all parts for contamination and clean them if necessary.

There may be glue residue on the external thread of the retainer plate as well as on the internal thread of the conrod plate. Remove this.

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Diaphragm pump N0150 EX Servicing

Caution: Take care not to let the shim ring(s) fall into the pump housing.

When removing the conrod plate, remove and set the shim ring(s) aside for safe keeping.

When remounting, use the exact same number of shim ring(s).

7. Turn the fan blade to move the connection rod (7) with conrod plate (9) to the middle position.

8. Place the new diaphragm (4) on the conrod plate (9); make certain that the bulges around the outer circumference and around the inner circumference of the diaphragm lie in the grooves of the housing and conrod plate.

9. Only .13:

Insert the new O-ring (10) in the housing (5).

10. Only .13:

Insert the new O-ring (8) in the conrod plate (9).

11. Apply adhesive around the thread of the retainer plate (11) and in the threaded hole of the connecting rod (7) and screw the retainer plate into the connecting rod.

While screwing in, turn the retainer plate back one turn to allow the adhesive to spread onto both thread flanks (retainer plate and conrod plate).

Attention: Note the use-by-date for the adhesive.

The adhesive may lose its effectiveness after the use-by-date has passed.

12. Then securely tighten the retainer plate (11) with the wrench for retainer plate (tightening torque: 20 Nm).

Attention: Observe the hardening time for the adhesive before recommissioning the pump.

The hardening time for the adhesive is approx. 24 hours.

13. For two-headed pumps:

Perform steps 1 to 12 for the second pump head.

Changing reed valves

1. Remove the two O-rings (2) from the intermediate plate (3).

2. Use a felt-tip pen to mark the position of the valve limiter of the suction side (18) to the intermediate plate (3); Remove the valve limiter (18) and the reed valve of the suction side (17) after loosening the screw

(13).

3. Remove the valve limiter of the pressure side (15) and the reed valve of the pressure side (14) from the intermediate plate (3) after loosening the screws (13).

4. Mount the new reed valves on the suction side and the pressure side together with the valve limiters.

5. For two-headed pumps:

Perform steps 1 to 4 for the second pump head.

Fitting the pump head

1. Place the intermediate plate (3) on the housing (5) according to the felt-tip pen marking (diaphragm should be held in middle position by holding the fan blade).

2. Insert the two new O-rings (2) in the intermediate plate (3).

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Servicing

Diaphragm pump N0150 EX

3. Place the head plate (1) on the intermediate plate (3) according to the felt-tip pen marking.

4. Screw in the hexagon socket head cap screws (12) and (16) one to two threads.

5. Tighten the two hexagon socket head cap screws (16) (tightening torque: 6 Nm), then tighten the hexagon socket head cap screws (12) crosswise (tightening torque: 9 Nm).

6. Check the pump for smooth running by turning the fan.

7. For two-headed pumps:

Perform steps 1 to 6 for the second pump head.

8. Install the motor fan cover (see Chapter

5 Product description and function

) according to the felt-tip pen marking.

9. For two-headed pumps:

Mount the pneumatic connection between the pump heads. In doing so, retighten the union nuts to the original position (as marked during disassembly, see Fig. 15).

When fitting the motor fan cover, make sure that all of the screws are fitted again, the fan cover and the fan are undamaged, and the fan can rotate freely. To do this, perform a function test.

10. Function test

Perform a function test in an non-explosive atmosphere.

– Connect the suction and pressure sides to the pump.

– Electrically connect the pump.

– Test the functionality of the pump.

– Disconnect the pump electrically and pneumatically again.

11. Pump integrated in application

– Connect the suction and pressure sides to the pump.

– Electrically connect the pump.

– Test the functionality of the pump.

To ensure the required gas tightness of the pump following servicing, a leak test is to be performed.

WARNING

Risk of explosion from leaks

à Before recommissioning the pump, check the pump heads and pneumatic connections for leaks. Leaks may lead to a risk of explosion.

WARNING

Risk of injury and poisoning from leaks

à Before recommissioning the pump, check the pump heads and pneumatic connections for leaks. Leaks may lead to poisoning, chemical burns or similar injuries.

Before recommissioning, observe the applicable standards, guidelines, regulations and technical standards at the electrical connection.

Translation of Original Operation and Installation Instruction, english, KNF 321729 11/22

Diaphragm pump N0150 EX Servicing

Requirements

9.4 Checking and replacing sprocket on coupling

à Disconnect the motor from mains and ensure that it is voltage-free.

à Allow the pump and the motor to cool.

CAUTION

Risk of burns from hot pump parts

The pump head or motor may still be hot after operation of the pump.

à Allow the pump to cool after operation.

CAUTION

Personal injury and/or property damage due to incorrect or improper transport of the motor

In the event of incorrect or improper transport, the motor can fall down, be damaged or injure persons.

à Use suitable auxiliary means if necessary

(carrying strap, lifting gear, etc.).

à Where appropriate, wear suitable personal protective equipment (e.g., safety shoes, safety gloves).

Tool and material

Quantity

Tab.22

Spare parts

Spare part

Sprocket

Tab.23

Tool/material

Feeler gage 3 mm

Test adapter for coupling (see Chapter 11.2 Accessories

)

Open-end wrench 8 mm

Size 13 open-end wrench with torque indicator

Item designation

(4)

Quantity

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Servicing Diaphragm pump N0150 EX

1 Nut

2 Serrated washer

3 Motor

4 Sprocket

5 Motor-side coupling half

6 Pump-side coupling half

7 Compressor housing

8 Stud bolts

9 Motor fan cover

10 Fastening screw for motor fan cover

Fig.16 Lifting motor (depicted pump as an example)

Fig.17 Replacing sprocket (depicted pump as an example)

Removing the motor

1. Attach the lifting gear (see figure for lifting motor) to the motor ( 3 ).

2. Loosen the nuts ( 1 ) that connect the motor ( 3 ) to the compressor housing

( 7 ).

3. Remove the ribbed disks ( 2 ).

4. Remove the motor ( 3 ) from the compressor housing ( 7 ).

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Diaphragm pump N0150 EX Servicing

Checking the sprocket

Observe the intervals for the periodic inspection of the coupling play

(see operating instructions for the coupling).

1. Place the sprocket ( 4 ) on the motor-side coupling half ( 5 ).

2. Place the test adapter for the coupling on the motor-side coupling half ( 5 ).

3. Use the feeler gage to check the coupling play (see operating instructions for the coupling).

4. Replace the sprocket ( 4 ) if there is too much coupling play (see operating instructions for the motor).

5. Define the intervals for the periodic inspection of the coupling play (see operating instructions for the motor).

Replacing the sprocket

1. Remove the worn sprocket ( 4 ) from the motor-side ( 5 ) or pump-side coupling half ( 6 ).

2. Push the new sprocket ( 4 ) onto the pump-side coupling half ( 6 ).

The sprocket is symmetric and can be pushed on in both possible positions.

Installing the motor

1. Align the motor-side ( 5 ) and pump-side coupling halves ( 6 ) with one another.

2. Place the motor ( 3 ) on the compressor housing ( 7 ).

Centering is performed using the four stud bolts ( 8 ) in the flange of the compressor housing ( 7 ) as well as the previously inserted sprocket.

3. Check whether the flange surface of the motor ( 3 ) and the flange surface of the compressor housing ( 7 ) lie properly on top of one another.

4. Push the four ribbed disks ( 2 ) onto the stud bolts ( 8 ).

Make certain that the inner diameter of the ribbed disk ( 2 ) lies against the nut ( 1 ) and the outer diameter lies against the motor flange ( 3 ) (see

Fig. 18).

Fig.18 Alignment of the ribbed disk ( 2 )

Translation of Original Operation and Installation Instruction, english, KNF 321729 11/22 45

Servicing Diaphragm pump N0150 EX

5. Turn the four nuts ( 1 ) on the stud bolts ( 8 ) and tighten them crosswise

(tightening torque: 11 Nm).

Inspecting pumps

1. Mark the motor fan cover ( 9 ) with a continuous line made with a felt-tip pen.

2. Loosen the fastening screws ( 10 ) of the motor fan cover ( 9 ) and remove the motor fan cover ( 9 ).

3. Check the pump for smooth running by turning the fan.

4. Refit the motor fan cover ( 9 ) according to the marking.

5. Hand-tighten the fastening screws ( 10 ) again.

When fitting the motor fan cover, make sure that all of the screws are fitted again, the fan cover and the fan are undamaged, and the fan can rotate freely. To do this, perform a function test.

6. Function test

Perform a function test in an non-explosive atmosphere.

– Connect the suction and pressure sides to the pump.

– Electrically connect the pump.

– Test the functionality of the pump.

– Disconnect the pump electrically and pneumatically again.

7. Pump integrated in application

– Connect the suction and pressure sides to the pump.

– Electrically connect the pump.

– Test the functionality of the pump.

46 Translation of Original Operation and Installation Instruction, english, KNF 321729 11/22

Diaphragm pump N0150 EX Troubleshooting

10 Troubleshooting

DANGER

Danger: electric shock can be life-threatening.

à All work on the pump may only be performed by an authorized specialist.

à Before working on the pump: Disconnect the pump from the power supply.

à Check and ensure that no voltage is present.

à Allow the pump to cool before troubleshooting.

à Check the pump (see following tables).

Also observe the operating instructions for the drive when troubleshooting.

à Also observe the operating instructions for the coupling when troubleshooting.

Pump not pumping

Cause

Pump is not connected to the electrical mains.

No voltage in the electrical mains.

Troubleshooting

à Connect the pump to the electrical mains.

Pneumatic connections or lines are blocked.

à Check the circuit breaker for the room and switch it on if necessary.

à Check the pneumatic connections and lines.

à Remove the blockage.

à Check external valves and filters.

External valve is closed or filter clogged.

Condensation has collected in the pump head.

Diaphragm or reed valves/valve plate are worn.

Triggering device for PTC thermistor sensor tripped.

à Isolate the source of condensation from the pump.

à Flush the pump with air at atmospheric pressure for a few minutes (if necessary for safety reasons: with an inert gas).

Install the pump at the highest location in the system.

à Change the diaphragm and the reed valves/valve plate

(see Chapter

9 Servicing ).

Determine the cause.

à See operating instructions for motor.

Tab.24

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Troubleshooting Diaphragm pump N0150 EX

Flow rate, pressure or vacuum too low

The pump does not reach the output stated in the technical data or data sheet.

Cause Troubleshooting

Condensation has collected in the pump head.

à Isolate the source of condensation from the pump.

à Flush the pump with air at atmospheric pressure for a few minutes (if necessary for safety reasons: with an inert gas).

à Install the pump at the highest location in the system.

à Change the pneumatic conditions.

There is overpressure on the pressure side and at the same time vacuum or pressure above atmospheric pressure on the suction side.

Pneumatic lines or connection parts have insufficient cross section or are throttled.

à Disconnect the pump from the system to determine the output values.

à Correct any constriction (e,g. valve).

à If necessary, install lines or a connector component with a larger cross section.

à Eliminate the leaks.

Leaks occur at pneumatic connections, lines or pump head.

Pneumatic connections or lines are partially or completely blocked.

Head parts are soiled.

Diaphragm or reed valves/valve plate are worn.

Working diaphragm broken

Pump exhibiting changed running noises and vibrations.

à Check the pneumatic connections and lines.

à Remove any parts and particles that are causing the blockage.

à Clean the head components.

à Change the diaphragm and the reed valves/valve plate

(see Chapter

9 Servicing ).

à Stop the pump immediately.

à Contact KNF Customer Service.

Tab.25

Pump exhibiting changed running noises and vibrations.

Cause Troubleshooting

Pump bearing worn or defective.

Drive worn or defective.

Coupling worn or defective.

à Determine the cause.

à Contact KNF Customer Service.

à See operating instructions for the drive.

à See operating instructions for coupling.

Tab.26

48 Translation of Original Operation and Installation Instruction, english, KNF 321729 11/22

Diaphragm pump N0150 EX Troubleshooting

Fault cannot be rectified

If you are unable to identify any of the specified causes, send the pump to

KNF Customer Service (contact data: see www.knf.com).

1. Flush the pump with air for a few minutes (if necessary for safety reasons: with an inert gas) at atmospheric pressure in order to remove hazardous or aggressive gases from the pump head (see Chapter

9.2.1 Flushing the pump

2. Clean the pump (see Chapter 9.2.2 Cleaning the pump ).

3. Send the pump together with completed Health and Safety Clearance and Decontamination Form to KNF, stating the nature of the transferred medium.

Translation of Original Operation and Installation Instruction, english, KNF 321729 11/22 49

Spare parts and accessories Diaphragm pump N0150 EX

11 Spare parts and accessories

To order spare parts and accessories, please contact your KNF sales partner or KNF Customer Service (contact data: see www.knf.com).

11.1 Spare parts

Parts

Diaphragm

O-ring

Item number*

(4)

(2)

Quantity

N0150

O-ring (only .13)

(8)

(10)

Reed valve, suction side (17)

Reed valve, pressure side

(14)

Slotted cheese head screw

(13) 4

Tab.27 *see Chapter 9.3 Changing diaphragm and reed valves

Spare part set

N0150ST.9 EX

N0150.1.2ST.9 EX

N0150.3ST.9 EX

Tab.28

Order number

321947

321948

Quantity

N0150.3

Spare part

Sprocket for coupling

Tab.29

Order number

322095

11.2 Accessories

Accessories

Water cooling connection:

N0150S_

N0150.3S_

N0150.1.2S_

Suction filter G1/2

Face spanner wrench

Test adapter for coupling

Tab.30

Order number

305998

306765

316662

018816

322184

50 Translation of Original Operation and Installation Instruction, english, KNF 321729 11/22

Diaphragm pump N0150 EX Returns

12 Returns

Preparing for return

1. Flush the pump with air for a few minutes (if necessary for safety reasons: with inert gas) at atmospheric pressure to free the pump head of

dangerous or aggressive gases (see Chapter 9.2.1 Flushing the pump ).

Please contact your KNF sales partner if the pump cannot be flushed due to damage.

2. Remove the pump.

3. Clean the pump (see Chapter 9.2.2 Cleaning the pump ).

4. Send the pump together with the completed Health and Safety Clearance and Decontamination Form to KNF, stating the nature of the transferred medium.

5. Pack the device securely to prevent further damage to the product. If necessary, request original packaging for a fee.

Returns

KNF shall undertake to repair the pump only under the condition that the customer presents a certificate regarding the medium that is pumped and the cleaning of the pump. In this case too, old devices can be returned.

Please follow the instructions at knf.com/repairs here.

Contact your KNF sales partner directly if you require additional support for your return service.

Translation of Original Operation and Installation Instruction, english, KNF 321729 11/22 51

Appendix

13 Appendix

13.1 Declaration of Conformity

13.2 Motor

13.3 Coupling

13.1 Declaration of Conformity

For further information, see also

Konformitätserklärung N0150EX.pdf

Diaphragm pump N0150 EX

52 Translation of Original Operation and Installation Instruction, english, KNF 321729 11/22

Diaphragm pump N0150 EX

13.2 Motor

For further information, see also

Betriebsanleitung Motor.pdf

Konformitätserklärung Motor.pdf

Appendix

Translation of Original Operation and Installation Instruction, english, KNF 321729 11/22 57

Table of contents

2021-05-31

Operating manual

Electric motors Size 63 - 225

ATEX / IECEx

Doc-ID: 6316 Read the operating manual before starting all work.

GmbH & Co. KG

Goebenstr. 106

D-32051 Herford

Tel.: +49 (0) 5221 5904-0

Fax: +49 (0) 5221 5904-34

E-Mail: [email protected]

Internet: www.hew-hf.de

Release:

Created by:

Kothes!

Technische Kommunikation GmbH & Co. KG www.kothes.de

This issue replaces all previous issues. All previous issues are invalid. The date of issue (  footer) is authoritative.

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Electric motors Size 63 - 225 ATEX / IECEx

1 General information ............................................................... 5

1.1

Information on this operating manual ............................ 5

1.2

Explanation of symbols .................................................. 6

1.3

Limitation of liability ........................................................ 7

1.4

1.5

Spare parts .................................................................... 8

1.6

Warranty conditions ....................................................... 8

1.7

Customer service ........................................................... 8

2 Safety ...................................................................................... 9

2.1

Responsibility of the user ............................................... 9

2.2

Staff requirements ....................................................... 10

2.2.1

Qualifications ................................................ 10

2.2.2

Unauthorised parties .................................... 12

2.2.3

Training ......................................................... 12

2.3

Proper use ................................................................... 12

2.4

Personal safety equipment and clothing ...................... 13

2.5

Special hazards ........................................................... 14

2.6

Safety devices.............................................................. 17

2.7

Securing the machine to prevent it from being switched back on ......................................................... 17

2.8

How to act in case of hazards and accidents .............. 18

2.9

Environmental protection ............................................. 19

3 Technical data ...................................................................... 20

3.1

Operating conditions .................................................... 20

3.2

Type plate .................................................................... 20

3.3

Explosion protection marking ....................................... 21

4 Construction and function .................................................. 23

4.1

Overview of sizes 63 to 132 ......................................... 23

4.2

Overview of sizes 160 to 225 ....................................... 24

4.3

Connection, motor protection ....................................... 25

4.4

Obligations and conditions ........................................... 25

4.5

Operation on the frequency converter ......................... 26

5 Transportation, packaging and storage ............................ 27

5.1

Delivery inspection ....................................................... 28

5.2

Transportation .............................................................. 29

5.3

Packaging .................................................................... 30

5.4

Storage ........................................................................ 31

Electric motors Size 63 - 225 ATEX / IECEx

6 Installation and commissioning .........................................32

6.1

Safety ...........................................................................32

6.2

Installation ....................................................................34

6.2.1

Ventilation at the location for use .................34

6.2.2

Types of construction as per EN 60034-7 ....34

6.2.3

Erecting the machine ....................................37

6.2.4

Installation .....................................................37

6.3

Connecting to the energy supply .................................38

6.3.1

Screwed cable gland ....................................38

6.3.2

Voltage and circuit ........................................39

6.3.3

Checking the insulation resistance ...............40

6.4

Commissioning .............................................................40

7 Operations ............................................................................42

7.1

General information......................................................42

7.2

Shutting down in an emergency ...................................42

8 Faults .....................................................................................43

8.1

Safety ...........................................................................43

8.2

Fault table ....................................................................45

8.3

Commissioning after remedied fault ............................47

9 Maintenance ..........................................................................48

9.1

Safety ...........................................................................48

9.2

Cleaning .......................................................................50

9.3

Maintenance schedule .................................................50

9.4

Tightening torque values for screws ............................52

9.4.1

Tightening torque values for screws for electrical connections ...................................52

9.4.2

Screw connections, property class 8.8 and

A4-70 ............................................................53

9.4.3

Screw connections of property class 5.6 ......53

9.5

Measures on completion of maintenance ....................54

10 Removal.................................................................................55

10.1

Safety ...........................................................................55

10.2

Removal .......................................................................56

10.3

Disposal .......................................................................57

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General information

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1 General information

1.1 Information on this operating manual

This operating manual makes it possible to handle the machine safely and efficiently.

The manual is a component of the machine and must be kept in the direct vicinity of the plant and be accessible to staff at all times.

Staff must have carefully read and understood this manual before starting all work. Adherence to all the specified safety instructions and instructions for actions in this operating manual is a fundamental requirement for working safely.

The local regulations for the prevention of accidents and the general safety regulations for the location in which the machine is used also apply.

The illustrations in this operating manual are for purposes or general understanding and may differ from the actual machine version.

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1.2 Explanation of symbols

Safety instructions The safety instructions in this manual are indicated by symbols.

The safety instructions are introduced by signal words which express the extent of the risk.

It is imperative to adhere to safety instructions and act with caution in order to prevent accidents, personal injury and material damage.

DANGER!

... indicates an immediately dangerous situation which will lead to death or serious injuries if not avoided.

WARNING!

... indicates a possibly dangerous situation which may lead to death or serious injuries if not avoided.

CAUTION!

... indicates a possibly dangerous situation which may lead to minor or light injuries if not avoided.

CAUTION!

... indicates a possibly dangerous situation which may lead to material damage if not avoided.

Tips and recommendations

NOTE!

… draws attention to tips and recommendation and information for efficient, fault-free operation.

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Special safety instructions

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1.3 Limitation of liability

Electric motors Size 63 - 225 ATEX / IECEx

General information

The following symbols are used in safety instructions in order to point out particular hazards.

... indicates risks from electrical current. Failure to observe the safety instructions will result in the risk of serious or fatal injury.

EXPLOSION PROTECTION!

... indicates content and instructions in this operating manual which apply when using this machine in potentially explosive areas as per the

ATEX directive. Failure to observe this content and these instructions can lead to a loss of explosion protection.

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All the information and instructions in this manual have been complied in line with the valid standards and regulations, state-ofthe-art technology and our many years of experience and knowhow.

The manufacturer shall not be liable for damages caused by:

◼ Failure to observe the manual

◼ Improper use

◼ Employment of unqualified staff

◼ Arbitrary modifications

◼ Technical changes

◼ Use of non-approved spare parts

In case of special versions, the utilisation of additional order options or due to new technical changes, the actual scope of delivery may differ from the explanations described here and the illustrations.

The obligations agreed in the delivery contract, the General terms and Conditions and the Terms and Conditions of Delivery of the manufacturer, and the legal regulations valid at the point of completion of the contract apply.

We reserve the right to make technical changes within the scope of further development and improvement of the performance characteristics.

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General information

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1.4 Copyright

This operating manual is protected by copyright and for internal use only.

The manual must not be made available to third parties, reproduced in any way (including excerpts), its content must not be utilised and/or communicated without the written approval of the manufacturer, except for internal purposes.

Failure to comply will render the offender liable for damages. We reserve the right to further claims.

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1.5 Spare parts

Explosion protection

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EXPLOSION PROTECTION!

The use of incorrect or faulty spare parts can use to explosions in the potentially explosive area.

Therefore:

– Only use the manufacturer's original spare parts or spare parts expressly approved by the manufacturer.

– Always contact the manufacturer in case of any uncertainty.

Failure to adhere to these instructions will lead to a loss of the explosion protection.

Purchase spare parts from authorised dealers or directly from the manufacturer. See page 2 for the address.

The spare parts list can be found on pages 23-24.

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1.6 Warranty conditions

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The warranty conditions are included in the manufacturer's

General Terms and Conditions.

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1.7 Customer service

Our customer service department is available to provide technical information. See page 2 for contact details.

Furthermore our staff are always interested in receiving new information and hearing of new experiences gained from the use of our products which can be used to improve our products.

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Safety

2 Safety

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Failure to observe the instructions and safety instructions for actions in this operating manual can cause considerable risks.

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2.1 Responsibility of the user

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This section provides you with an overview of all important aspects of safety required for providing staff with optimum protection as well as safe, fault-free operation.

The machine is used in the commercial field. The user of the machine is therefore subject to the legal obligations for occupational safety.

In addition to the safety instructions in this manual, the regulations for safety, accident prevention and environmental protection which apply at the location for use of the machine must also be observed.

The following in particular applies:

◼ The user must fully acquaint himself with the valid occupational safety regulations and, in addition, carry out a risk assessment to determine the hazards which result from the particular working conditions at the location in which the machine is used.

The results must be implemented as a set of operating instructions for operation of the machine.

◼ The user must carry out checks during the entire period of its use to determine whether the operating instructions drawn up are in line with the current regulations and adjust them as necessary.

◼ The user must clearly set out the responsibilities for installation, operation, maintenance and cleaning.

◼ The user must make sure that all staff involved with work on the machine have read and understood the manual.

Furthermore, staff must be provided with regular training and information on the following points:

⚫ Fire and explosion hazards at the machine's location for use and the immediate vicinity.

⚫ Local fire and explosion protection measures.

⚫ Location and function of protective equipment.

⚫ The necessity of a ban on smoking.

⚫ The necessity of avoiding open fire.

⚫ Procedure for cleaning and maintenance work and repairs, including the tools, aids and cleaning agents to be used.

⚫ The necessity of wearing personal safety equipment and clothing which is suitable for the potentially explosive environment.

◼ The user must adhere to the further obligations of Directive

99/92/EC for the improvement of health and safety measures

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Safety

and the safety of employees who may be at risk from a potentially explosive atmosphere. This includes adherence to further organisational measures, such as:

⚫ marking potentially explosive areas.

⚫ drawing up an explosion protection document for each zone.

⚫ denying unauthorised parties access.

⚫ putting up clear signs indicating all restraints.

⚫ introduction of a permit procedure for carrying out dangerous work.

◼ The user must provide staff with the required safety clothing and equipment.

The user is also responsible for ensuring that the machine is kept in technically perfect condition. The following applies:

◼ The user must make sure that the maintenance intervals described in the operating manual are adhered to. Reduce the intervals accordingly in case of above average strain.

◼ The user must have all the safety devices checked regularly to make sure they are complete and fully functional.

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Loss of explosion protection

EXPLOSION PROTECTION!

On machines which are designed to be installed in plants for operation in potentially explosive areas, as defined by Directive 2014/34/EU, the user must make sure that the directive is adhered to for the entire plant.

Failure to comply will lead to a loss of the explosion protection.

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2.2 Staff requirements

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2.2.1 Qualifications

WARNING!

Risk of injuries in case of insufficiently qualified staff.

Improper use can cause considerable personal injury and material damage.

Therefore:

– Have all tasks performed by staff with the appropriate qualifications only.

The following levels of qualification are named in the operating manual for various ranges of tasks.

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Electric motors Size 63 - 225 ATEX / IECEx

Safety

◼ Trained person has been informed of the tasks with which he has been entrusted and the possible risks in case of incorrect behaviour in training measures provided by the user.

◼ Specialist staff are capable of carrying out the work with which they have been entrusted and recognising the potential risks independently because of their specialist qualifications, knowledge and experience, and knowledge of the valid regulations.

◼ Qualified electrician is capable of carrying out the work on electrical equipment and recognising and preventing the potential risks independently because of their specialist qualifications, knowledge and experience, and knowledge of the valid standards and regulations.

The qualified electrician is qualified to work in the specific area in which he works and is familiar with the relevant standards and regulations.

◼ Qualified specialist for the potentially explosive area is capable of carrying out the work on plants or components in the potentially explosive area and recognising the potential risks independently because of their specialist qualifications, knowledge and experience, and knowledge of the valid standards and regulations.

The qualified specialist has knowledge of the various ignition protection types, installation procedures and area classifications in potentially explosive spaces, and certification for the purported experience and knowledge.

The person is familiar with the relevant rules and regulations for the work and explosion protection, in particular but not exclusively, ATEX product directive 2014/34/EU and the pertaining EN 60079 standard as well as the IECEx standard

IEC 60079.

Staff should be made up exclusively of people who can be expected to carry out their work reliably. People who reactions are influenced, for instance, by drugs, alcohol or medication, must not be allowed.

◼ When selecting staff adhere to the valid local regulations relating to age and profession.

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Safety

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2.2.2 Unauthorised parties

WARNING!

Danger for unauthorised parties.

Unauthorised persons who do not meet with the requirements described here, are not familiar with the hazards in the working area.

Therefore:

– Keep unauthorised persons away from the working area.

– In case of doubt, approach these persons and instruct them to leave the working area.

– Stop work until any unauthorised parties have left the working area.

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2.2.3 Training

Date Name

Fig. 1

2.3 Proper use

Staff must be provided with regular training by the user. Training must be logged to keep better track.

Type of training Training provided by

Signature

The machine has been engineered and designed exclusively for the proper use described in this documentation.

The machine is only intended for use as a drive unit in low voltage industrial systems.

Proper use also includes adherence with all the stipulations of this manual.

Any other type of use, or use of the machine going beyond this use is considered improper use and can cause dangerous situations.

12 2021-05-31

Electric motors Size 63 - 225 ATEX / IECEx

Safety

WARNING!

Danger from improper use.

Improper use of the machine can cause dangerous situations.

Take particular care not to use the machine as follows:

– Operation beyond the original designated application.

– Operation of machines in potentially explosive areas which do not have explosion protection markings and are thus not suitable for use in a potentially explosive atmosphere (  Chapter

"Explosion protection marking").

Claims of any kind for damages caused by improper use are null and void.

The user carries sole liability for any damages in case of improper use.

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2.4 Personal safety equipment and clothing

Whilst work is being carried out, personal safety equipment and clothing must be worn in order to minimise health hazards.

◼ Always the safety clothing and equipment required for the respective task whilst working.

◼ Follow the instructions in the working area on personal safety equipment and clothing.

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To be worn for all work

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The following must be worn for all work:

Occupational safety clothing is close-fitting working clothing with a low tear strength, close-fitting sleeves and no protruding parts. It serves primarily as protection from entanglement in moving machine parts.

Do not wear rings, chains or other jewellery.

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Safety shoes to protect from heavy falling parts and from slipping on slippery surfaces.

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Safety

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To be worn for special tasks

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When carrying out special tasks, special safety equipment and clothing is required. Reference is made to this in the individual chapters of this manual. These special items of safety clothing and equipment are explained in the following:

Light breathing mask to protect from harmful dust.

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2.5 Special hazards

The following section points out residual risks which have been determined by a risk analysis.

◼ Adhere to the safety instructions listed here and the warnings in other chapters in order to reduce health hazards and prevent dangerous situations.

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Explosion protection

EXPLOSION PROTECTION!

The introduction of ignition sources such as sparks, open flames and hot surfaces can cause explosions in the potentially explosive area.

Therefore, when carrying out all work on the machine in the potentially explosive area:

– Do not start any work without a written permit.

– Only carry out work to the exclusion of a potentially explosive atmosphere.

– Only use tools which are approved for use in the potentially explosive area.

Failure to adhere to these instructions will lead to a loss of the explosion protection.

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Electrical current

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Moving parts

Electric motors Size 63 - 225 ATEX / IECEx

Safety

DANGER!

Danger to life from electrical current.

There is an immediate risk of fatal injury in case of contact with live parts. Damage to the insulation or individual components can mean danger to life.

Therefore:

– In case of damage to the insulation, switch off the power supply immediately and have repairs carried out.

– Have work on the electrical equipment carried out by qualified electricians only.

– When any work is carried out on the electrical equipment, disconnect it from the power and make sure it is free of voltage.

– Before carrying out maintenance, cleaning and repair work, switch off the power supply and secure it to prevent it from being switched back on.

– Do not jumper or disable any fuses or circuit breakers. When replacing fuses or circuit breakers make sure to adhere to the correct ampere rating.

– Keep moisture away from live parts. It can lead to a short circuit.

WARNING!

Risk of fatal injury from moving parts.

Rotating parts and/or parts which move linearly can cause serious injuries.

Therefore:

– Do not reach into moving parts or handle moving parts during operation.

– Do not open covers during operation.

– Adhere to the follow-up time:

Before opening covers make sure that none of the parts are still moving.

– In the danger area wear close-fitting protective clothing.

Electric motors Size 63 - 225 ATEX / IECEx

Safety

Pos : 2. 39 /KN 2006-SM /Sic her hei t/ 007 Besondere G ef ahr en/Heiß e O berfl äc hen_Vorsicht! @ 8\ mod_1143375956657_1.doc @ 81347

Hot surfaces

CAUTION!

Risk of burns from hot surfaces.

Contact with hot parts can cause burns.

Therefore:

– When working in the vicinity of hot parts always wear protective clothing and protective gloves.

– Before carrying out any work make sure that all components have cooled to ambient temperature.

Pos : 2.40 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75471

Pos : 2. 41 /KN 2006-SM /Sic her hei t/ 007 Besondere G ef ahr en/Schmutz und herumli egende Geg ens tände_Vorsic ht! @ 8\ mod_1143378670336_1. doc @ 81411

Soiling and objects lying around

CAUTION!

Risk of stumbling due to soiling and objects left lying around.

Soiling and objects left lying around are sources of slipping and stumbling ad can cause considerable injuries.

Therefore:

– Always keep the working area clean.

– Remove any objects which are no longer required.

– Mark any possible stumbling hazards with yellow and black marker tape.

Pos : 2.42 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75471

Pos : 2. 43 /KN 2006-SM /Sic her hei t/ 007 Besondere G ef ahr en/Scharf e Kant en, s pitz e Ec ken_Vorsic ht! @ 8\ mod_1143378164691_1. doc @ 81402

Sharp edges and corners

CAUTION!

Risk of injuries from edges and corners.

Sharp edges and corners can cause grazes and cuts on the skin.

Therefore:

– Proceed with caution when working in the vicinity of sharp edges and corners.

– If in doubt wear protective gloves.

Pos : 2.44 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75471

16 2021-05-31

Electric motors Size 63 - 225 ATEX / IECEx

Safety

Pos : 2. 45 /KN 2006-Pr ojekte/Herf order Elektromot oren-Wer ke/Sic herheit/ 008 1. 1 Sic her heit sei nricht ungen_Tit el @ 59 \ mod_1203337625484_1. doc @ 1037161

2.6 Safety devices

Pos : 2. 46 /KN 2006-SM /Sic her hei t/ 008 Sicherheits einric ht ungen/Kein eigener Not-Aus (M asc hine) @ 41\ mod_1183384960738_1.doc @ 503378

Integration into an emergency stop concept required

The machine is for use within a plant. It does not have its own control unit and does not have an independent emergency stop function.

Before the machine is put into operation install the emergency stop devices for the machine and integrate it into the plant control unit's safety chain.

Connect the emergency stop devices so that there is no chance that dangerous situations for people and objects of material value cannot arise if the energy supply is broken or the energy supply is activated after being broken.

The emergency stop devices must be freely accessible at all times.

Pos : 2.47 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75471

Pos : 2. 48 /KN 2006-SM /Ausgemust ert/ Sicher heit /009 1.1 Sic hern g egen Wieder einschalt en_Tit el+Text @ 9\ mod_1144435859202_1.doc @ 86859

2.7 Securing the machine to prevent it from being switched back on

DANGER!

Risk of death from switching on without authorisation!

When working in the danger area there is a risk that the energy supply will be switched on without authorisation. This puts the life of people in the danger area at risk.

Therefore:

– Adhere to the instructions on securing the machine to prevent it from being switched on in the chapters of this manual.

– Always adhere to the procedure described below to secure the machine to prevent it from being switched back on.

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Electric motors Size 63 - 225 ATEX / IECEx

Safety

Switch secured with a padlock on: …….. at ...... h.

DO NOT SWITCH ON

The padlock must only be removed by: ………………… once you have made sure that there is nobody in the danger area.

Fig. 2

Securing the machine to prevent it from being switched back on:

Switch off the energy supply.

If possible, secure the switch with a padlock and attach a clearly visible sign according to Fig. 2 to the switch.

Have the key kept safely by the member of staff named on the sign.

Switched off on: …….. at ...... h.

DO NOT SWITCH ON

Only to be switched on by: ………………… once you have made sure that there is nobody in the danger area.

If it is impossible to secure a switch with a padlock, erect a sign according to Fig. 3.

Once all work has been carried out, make sure that nobody is in the danger area.

Make sure that all safety devices and mechanisms are installed and fully functional.

Do not remove the sign until you have done so.

Fig. 3

Pos : 2.49 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75471

Pos: 2.50 /KN2006-SM/Sicherheit/010 1.1 Verhalten im Gefahrenfall und bei Unfällen @ 8\mod_1143382088320_1.doc @ 81515

2.8 How to act in case of hazards and accidents

Preventive measures ◼ Always be prepared for accidents or fires.

◼ Keep first aid facilities (first aid box, blankets etc.) and fire extinguishers accessible at all times.

◼ Familiarise staff with accident report, first aid and rescue facilities.

◼ Keep access routes for emergency vehicles clear.

Measures in case of accidents ◼ Trigger an emergency stop immediately.

◼ Instigate first aid measures.

◼ Remove any people from the danger zone.

◼ Inform the responsible party at the location.

◼ Notify emergency services.

◼ Clear access routes for emergency vehicles.

Pos : 2.51 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75471

18 2021-05-31

Electric motors Size 63 - 225 ATEX / IECEx

Safety

Pos : 2. 52 /KN 2006-SM /Sic her hei t/ 011 U mweltsc hutz/ 011 U mwelts chutz Tit el und Einf ührung @ 9\ mod_1143987199086_1. doc @ 84175

2.9 Environmental protection

Pos : 2. 53 /KN 2006-SM /Sic her hei t/ 011 U mweltsc hutz/ Sc hmierst of fe @ 9\ mod_1143987769095_1. doc @ 84196

Lubricants

CAUTION!

Risk of environmental damage in case of incorrect handling.

Incorrect handling of environmentally hazardous substances, in particular incorrect disposal, can cause considerable damage to the environment.

Therefore:

– Always adhere to the instructions below.

– If environmentally hazardous substances are accidentally released into the environment, take suitable measures immediately. In case of doubt inform the responsible local authority of the damage.

The following environmentally hazardous substances are used:

Lubricants such as grease and oils contain toxic substances. They must not be released into the environment. They must be disposed of by a specialist disposal company.

Pos : 2. 54 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\ mod_1141997892953_0.doc @ 75471

Pos : 2. 55 /KN 2006-Pr ojekte/Herf order Elektromot oren-Wer ke/Sic herheit/H INWEI S - R ohst offric htlini e @ 71\mod_1211355261046_1. doc @ 1184214

NOTE!

The motors comply with EC Directive 2011/65/EU for the limitation of the use of certain hazardous substances in electrical and electronic devices.

Pos : 2.56 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75471

Pos : 3. 1 / KN2006- SM/ nL.... ... ... Seit enumbr uc h . ... ... ... @ 8\ mod_1141998334703_0. doc @ 75489

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Electric motors Size 63 - 225 ATEX / IECEx

Technical data

Pos : 3. 2 / KN2006- SM/T echnisc he D aten/ 001 1 Tec hnisc he Dat en_Ti tel @ 8\ mod_1143124628960_1.doc @ 80561

3 Technical data

Pos : 3. 3 / KN2006- Proj ekt e/H erfor der El ektromot oren- Wer ke/T ec hnis che D at en/HIN WE IS - Die not wendigen t ec hnischen D at en @ 59\ mod_1203077215350_1.doc @ 1034411

NOTE!

The necessary technical data can be found on the respective type plates. This information is authoritative.

Further technical data can be taken from the catalogue.

Pos : 3. 4 / KN2006- SM/ nL---------- Abschnit tsende ---------- @ 8\ mod_1141997892953_0. doc @ 75471

Pos : 3. 5 / KN2006- SM/T echnisc he D aten/ 003 1.1 Betriebs beding ung en_Tit el @ 9 \ mod_1143989042992_1. doc @ 84238

3.1 Operating conditions

Pos : 3. 6 / KN2006- Proj ekt e/H erfor der El ektromot oren- Wer ke/T ec hnis che D at en/003 1.1.0 Betri ebs bedi ngungen @ 54 \mod_1196341403646_1. doc @ 832739

Environment

Pos : 3.7 /KN2006- SM/nL---------- Abschnittsende ---------- @ 8\mod_1141997892953_0.doc @ 75471

Pos : 3. 8 / KN2006- SM/T echnisc he D aten/ 008 1.1 T ypensc hild_Tit el @ 9\ mod_1144045129972_1. doc @ 84411

3.2 Type plate

Specification

Temperature range (standard)

Temperature range (optional)

Value Unit

20…+40 °C

-50 …+85 °C

Maximum installation height above sea level

1000 m

The ambient temperature range is only indicated on the type plate

if it deviates from the standard.

Pos : 3. 9 / KN2006- Proj ekt e/H erfor der El ektromot oren- Wer ke/T ec hnis che D at en/AT EX/008 1. 1. 0 Ex-T ypenschil d @ 62\ mod_1205227533086_1. doc @ 1061982

Fig.4: Example of a type plate

The type plate is situated on the motor housing and the information it contains includes:

◼ Explosion protection symbol

◼ Manufacturer/year of manufacture

◼ CE symbol

◼ ID of notified body

◼ Certificate number

◼ Motor identification (type), motor number (serial number)

◼ Weight

◼ Performance data

◼ Ambient temperatures deviating from the standard temperatures of – 20°C to + 40°C specified in the standard

NOTE!

The information on the type plate may vary depending on the type of motor.

20 2021-05-31

Electric motors Size 63 - 225 ATEX / IECEx

Technical data

3.3 Explosion protection marking

EXPLOSION PROTECTION! acc. to ATEX directive 2014/34/EU standard EN 60079 or IECEx / standard IEC 60079

Marking acc. to ATEX – size 63

II 2G Ex db IIC T4 – T6 Gb or Ex db e IIC T4 – T6 Gb

Oder II 2G Ex db IIC T4 – T6 Gb or Ex db eb IIC T4 – T6 Gb

II 2G Ex db IIB T4 – T6 Gb or Ex db e IIB T4 – T6 Gb

Oder II 2G Ex db IIB T4 – T6 Gb or Ex db eb IIB T4 – T6 Gb

II 2D Ex tb IIIC T 135 – 85°C Db

II 2D Ex tb IIIB T 135 – 85°C Db

Marking acc. to IECEx – size 63

Ex db IIC T4 – T6 Gb or Ex db e IIC T4 – T6 Gb

or Ex db IIC T4 – T6 Gb or Ex db eb IIC T4 – T6 Gb

Ex db IIB T4 – T6 Gb or Ex db e IIB T4 – T6 Gb

or Ex db IIB T4 – T6 Gb or Ex db eb IIB T4 – T6 Gb

Ex tb IIIC T 135 – 85°C Db

Ex tb IIIB T 135 – 85°C Db

Marking acc. to ATEX – sizes 71 -225

II 2G Ex db IIC T1 – T6 Gb or Ex db eb IIC T1 – T6 Gb

or II 2G Ex d IIC T1 – T6 Gb or Ex de IIC T1 – T6 Gb

II 2G Ex db IIB T1 – T6 Gb or Ex db eb IIB T1 – T6 Gb

or II 2G Ex d IIB T1 – T6 Gb or Ex de IIB T1 – T6 Gb

II 2D Ex tb IIIC T 200 – 85°C Db

Marking acc. to IECEx – sizes 71 -225

Ex db IIC T1 – T6 Gb or Ex db eb IIC T1 – T6 Gb

or Ex d IIC T1 – T6 Gb or Ex de IIC T1 – T6 Gb

Ex db IIB T1 – T6 Gb or Ex db eb IIB T1 – T6 Gb

or Ex d IIB T1 – T6 Gb or Ex de IIB T1 – T6 Gb

Ex tb IIIC T 200 – 85°C Db

2021-05-31 21

Ex d / db e / eb tb

IIC

IIB

IIIC

IIIB

T1 – T6

Electric motors Size 63 - 225 ATEX / IECEx

Technical data

Section Designation Significance

Explosion protection symbol Marking for protection from explosions

II Device group

4 Construction and function

Pos : 4. 3 / KN2006- Proj ekt e/H erfor der El ektromot oren- Wer ke/ Aufbau und F unktion/ AT EX/ 002 1.1.0 Übersicht @ 68\ mod_1209358678629_1. doc @ 1157152

4.1 Overview of sizes 63 to 132

Electric motors Size 63 - 225 ATEX / IECEx

Construction and function

2 3 4 5 13 14 15 16 17 18

Fig. 5: Overview of sizes 63 to 132

1 Flange rings

2 Sealing rings DS* 1

3 Rolling bearings DS* 1

4 Stator housing, complete

5 Motor foot

6 Terminal box seal

7 Lower terminal box section

8 Cable bushing

9 Terminal board

* 1 DS = Drive side

* 2 NS = Nondrive side

! For sizes 63 and 71 the terminal box is casted

10 Terminal box cover

11 Terminal box cover seal

12 Screwed cable gland

13 Rotor shaft, complete

14 Bearing cover NS* 2

15 Rolling bearings NS* 2

16 Sealing ring NS* 2

17 Fan blade

18 Ventilation hood (with optional safety cover)

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Electric motors Size 63 - 225 ATEX / IECEx

Construction and function

4.2 Overview of sizes 160 to 225

2 3 4 5 6

Fig. 6: Overview of sizes 160 to 225

1 Flange rings

2 Sealing rings DS* 1

3 Cover plate DS* 1

4 Rolling bearings DS* 1

5 Base flange

6 Stator housing, complete

7 Motor foot

8 Terminal box adapter

9 Cable bushing

10 Lower terminal box section

11 Terminal board

* 1 DS = Drive side

* 2 NS = Nondrive side

Pos : 4. 4 / KN2006- SM/ nL---------- Abschnit tsende ---------- @ 8\ mod_1141997892953_0. doc @ 75471

15 16 17 18 19 20 21

12 Terminal box cover seal

13 Terminal box cover

14 Screwed cable glands

15 Rotor shaft, complete

16 Bearing cover NS* 2

17 Rolling bearings NS* 2

18 Cover plate NS* 2

19 Sealing ring NS* 2

20 Fan blade

21 Ventilation hood (with optional safety cover)

2021-05-31

Electric motors Size 63 - 225 ATEX / IECEx

Construction and function

Pos : 4. 5 / KN2006- SM/Auf bau und F unktion/ 005 1. 1 Anschl üss e_Titel @ 9\ mod_1144394868217_1. doc @ 86353

4.3 Connection, motor protection

Pos : 4. 6 / KN2006- Proj ekt e/H erfor der El ektromot oren- Wer ke/ Aufbau und F unktion/ 005 1.1.0 Ansc hlüss e @ 54\ mod_1196341904624_1.doc @ 832892

Before connecting the explosion protected motor, check the following:

- do the ratings on the type plate match the mains voltage and frequency?

- does the explosion protection match the environment in which the motor is operated

(gas group, temperature class)?

The electrical connections are established using the terminal box. The connection diagram (wiring diagram) is inside the terminal box.

Optionally the motors can be supplied with a motor cable instead of with a terminal box (  catalogue).

Pos : 4. 7 / KN2006- SM/ nL---------- Abschnit tsende ---------- @ 8\ mod_1141997892953_0. doc @ 75471

If a standstill heating is present, the electrical controller has to ensure that the motor voltage and the heating voltage cannot be applied simultaneously.

The motor protection can be implemented with a motor protection switch or a thermal sensor (PTC, PTO,

PT100).

For self-ventilated, single-speed motors in S1 mains operation with low-load and infrequent starts not causing any significant heating, a motor protection switch is a sufficient measure to comply with explosion protection requirements (temperature class).

Exclusive protection by temperature monitoring with thermal sensor for all modes other than S1 is only permitted in connection with a certified triggering device. These triggering devices must have been certified and marked by a notified body according to directive 2014/34/EU (IECEx). The devices must be included in the regular monitoring by the operator.

Pos : 4. 5 / KN2006- SM/Auf bau und F unktion/ 005 1. 1 Anschl üss e_Titel @ 9\ mod_1144394868217_1. doc @ 86353

4.4 Obligations and conditions

Some gap lengths of the spark-proof gap of this equipment are greater, and some gap widths of the sparkproof gap are smaller than required in Table 3 of EN/IEC 60079-1:2014. For information regarding the dimensions, please contact the manufacturer.

To connect the pressure proof encapsulation, use screws with a yield point of at least 640 N/mm 2 .

Motors requiring direct temperature monitoring have to be monitored with a separately certified triggering device (see 4.3).

Make sure when operating a 3-phase motor with an external fan that the motor can only be run while the external fan is running. The external fan motor must comply with EPL Gb or Db.

Make sure not to exceed the permissible temperatures for the used components.

Only metal fan blades may be used if the temperature on the shaft journal in the fan blade area is >= 95°C during rated operation.

The manufacturer specifies the electrical parameters, the temperature class and the ambient temperature range of the respective version after a routine test.

Pos : 4.8 /KN2006- Proj ekte/H erfor der El ektromotoren- Wer ke/Aufbau und F unktion/1.1 Betrieb am Freq uenz umrichter @ 59\mod_1203343042775_1.doc @ 1037183

2021-05-31 25

Electric motors Size 63 - 225 ATEX / IECEx

Construction and function

4.5 Operation on the frequency converter

The motors of EX versions “pressure-proof encapsulation” Ex d(e) and “protection by housing” Ex t are approved for inverter operation. For approved versions, the possible frequency range must be obtained from the EU prototype test certificate.

The chart and the table below show and explain the most common curves for FI operation. The permissible torque at 50 Hz depends on the size, the number of poles and the performance; refer to the HEW catalogue

“Explosion protected electric motors” (Part 20).

Permissible torque curve

Frequency (Hz)

Characteristic curve

Frequency

Motor version

5 - 50 Hz 230/400 V

400/690V

5 - 50 Hz 230/400 V

Motor voltage / circuit

400 V Y

400 V



400 V Y

Inverter

U/f=constant

Ventilation internal fan external ventilation

Torque curve in frequency range acc. to Catalogue Part 20 reduced constant

400/690V 400V



U/f=constant

50 - 87Hz 230/400 V

400/690V

50 - 87Hz 230/400 V

400 V Y

400V



230V



U=constant

U/f=constant

When the frequency range is specified in the order, the motors come with an additional plate indicating the

FI operation data given on the right:

(Example: DCEx 112 M/4 K – 400 V 

50 Hz 4.0 kW) internal fan internal fan drops with 1/f

Field weakening operation constant

87 Hz curve

DCEx 112 M/4 K / Motor number

40 V 5 Hz 0.24 kW Tperm.= 16 Nm

400 V 50 Hz 4.0 kW Tperm.= 27 Nm

400 V 87 Hz 4.0 kW Tperm.= 16 Nm

Sections 4.3 and 4.4 describe the motor protection for frequency inverter operation.

Use shielded cables to prevent electromagnetic interference.

We recommend using insulated bearings for motors of size 250 and greater.

Further information can be requested from the HEW headquarters in Herford at any time.

Pos : 5. 1 / KN2006- SM/ nL.... ... ... Seit enumbr uc h . ... ... ... @ 8\ mod_1141998334703_0. doc @ 75489

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Electric motors Size 63 - 225 ATEX / IECEx

Transportation, packaging and storage

Pos: 5.2 /KN2006-SM/Transport, Verpackung und Lagerung/001 1 Transport, Verpackung und Lagerung_Titel @ 9\mod_1144048567385_1.doc @ 84502

5 Transportation, packaging and storage

Pos : 5. 3 / KN2006- SM/Trans por t, Ver pac kung und Lag erung/002 1. 1. 0 War nung! Lebensgef ahr durch sc hwebende Las ten @ 9\ mod_1144048709603_1.doc @ 84516

Suspended loads

WARNING!

Risk of fatal injury from suspended loads.

When lifting loads there is a risk of fatal injuries from falling parts or parts swinging uncontrolledly.

Therefore:

– Never stand under suspended loads.

– Only use the stipulated fastening points.

– Do not fasten lifting gear to protruding machine parts or the lugs on attached parts. Make sure the fastening equipment is securely fastened.

– Only use approved lifting gear and fastening equipment with sufficient load bearing capacity.

– Do not use any torn or frayed ropes or belts.

– Do not attach ropes and belts to sharp edges and corners. Do not knot or twist them.

Pos : 5.4 /KN2006- SM/nL---------- Abschnittsende ---------- @ 8\mod_1141997892953_0.doc @ 75471

Pos : 5. 5 / KN2006- SM/Trans por t, Ver pac kung und Lag erung/002 1. 1. 0 A uß ermi ttiger Sc hwer punkt _War nung! @ 9\ mod_1144502588366_1.doc @ 87473

Off-centre centre of gravity

WARNING!

Risk of falling due to an off-centre centre of gravity.

Packages may have an off-centre centre of gravity.

If fastened incorrectly the package may tilt and cause potentially fatal injury.

Therefore:

– Adhere to the markings on the packages.

– Attach the crane hook so that it is directly above the centre of gravity.

– Lift cautiously and observe whether the load tilts. If necessary change the fastening.

Pos : 5. 6 / KN2006- SM/ nL---------- Abschnit tsende ---------- @ 8\ mod_1141997892953_0. doc @ 75471

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Electric motors Size 63 - 225 ATEX / IECEx

Transportation, packaging and storage

Pos : 5. 7 / KN2006- SM/Trans por t, Ver pac kung und Lag erung/002 1. 1. 0 Vorsic ht Tr ansportsc häden bei unsac hgemäß em Trans por t_Vorsic ht! Sac hsc haden @ 9\ mod_1144051344560_1.doc @ 84538

Improper transportation

CAUTION!

Risk of damage in case of improper transportation.

Improper transportation can cause considerable material damage.

Therefore:

– When unloading delivered packages and when transporting on the premises, proceed with caution and adhere to the symbols and instructions on the packaging.

– Only use the fastening points provided.

– Do not remove the packaging until shortly before installation.

Pos : 5. 8 / KN2006- SM/ nL---------- Abschnit tsende ---------- @ 8\ mod_1141997892953_0. doc @ 75471

Pos : 5. 9 / KN2006- SM/Trans por t, Ver pac kung und Lag erung/004 1. 1 Trans por tins pektion_Tit el @ 9\ mod_1144054094956_1. doc @ 84692

5.1 Delivery inspection

Pos : 5. 10 /KN 2006-SM /Transport , Verpac kung und Lager ung/ 004 1.1.0 Transporti nspektion - I nhalt , Kurz for m @ 9\ mod_1144054141858_1.doc @ 84699

Inspect the delivery for damage and to make sure it is complete immediately after receiving it.

Proceed as follows in case of visual external damage:

◼ Refuse delivery or accept delivery provisionally.

◼ Make a note of the extent of damage in the shipping documents or on the carrier's delivery note.

◼ Make a claim.

NOTE!

Make a claim for every discrepancy as soon as it is discovered. Claims for compensation can only be asserted within the valid claims periods.

Pos : 5. 11 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\ mod_1141997892953_0.doc @ 75471

Pos : 5. 12 /KN 2006-Pr ojekte/Herf order Elektromot oren-Wer ke/Trans port /AT EX/ 004 1. 1. 0 Trans portins pekti on EX-SCHUTZ @ 60\ mod_1203497791228_1.doc @ 1039774

Explosion protection

EXPLOSION PROTECTION!

Transport damage can cause a loss of the explosion protection.

– Do not put the machine into operation in case of visible transport damage. Contact the manufacturer.

Failure to adhere to these instructions will lead to a loss of the explosion protection.

Pos : 5. 13 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\ mod_1141997892953_0.doc @ 75471

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Electric motors Size 63 - 225 ATEX / IECEx

Transportation, packaging and storage

Pos : 5. 14 /KN 2006-SM /Transport , Verpac kung und Lager ung/ 006 1.1 Transport _Tit el @ 9 \ mod_1145448098995_1. doc @ 90988

5.2 Transportation

Pos : 5. 15 /KN 2006-Pr ojekte/Herf order Elektromot oren-Wer ke/Trans port /005 1. 1. 0 Ansc hl agpunkte @ 54\ mod_1196342213558_1.doc @ 832949

Fastening points ◼ Use suitable lifting gear.

◼ Use the lifting eyebolts provided on the motor.

◼ To transport machine sets (e.g. gear units, fan attachments etc.) only use the lifting eyebolts and lugs provided. Machine sets must not be lifted by the individual machines.

◼ Remove any transport safety devices which protect from bearing damage before commissioning.

Pos : 5.16 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75471

Pos : 5. 17 /KN 2006-SM /Transport , Verpac kung und Lager ung/ 006 1.1.0 Transport von Pac kst üc ken mit dem Kr an @ 9\ mod_1144393009755_1. doc @ 86326

Transporting packages by crane

Fig. 7

Pos : 5.18 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75471

Pos : 5. 19 /KN 2006-SM /Transport , Verpac kung und Lager ung/ 006 1.1.0 Transport von Pal et ten mit dem Kran @ 9 \ mod_1144391982978_1. doc @ 86312

Transporting pallets by crane

Packages which have fastening eyebolts can be transported directly by crane on the following conditions:

◼ The crane and lifting gear must be designed for the weight of the packages.

◼ The operator must be authorised to operate the crane.

Fastening:

Fasten ropes, belts or multiple-point suspension gear according to Fig. 7.

Make sure that the package hangs straight, paying attention to the off-centre centre of gravity as necessary.

Begin transportation.

Packages which are fastened to pallets can be transported by crane under the following conditions:

◼ The crane and lifting gear must be designed for the weight of the packages.

◼ The operator must be authorised to operate the crane.

Fastening:

Fasten ropes, belts or multiple-point suspension gear to the pallet according to Fig. 8.

Check that the packages are not damaged by the fastening equipment. If necessary use other fastening equipment.

Begin transportation.

Fig. 8

Pos : 5.20 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75471

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Electric motors Size 63 - 225 ATEX / IECEx

Transportation, packaging and storage

Pos : 5. 21 /KN 2006-SM /Transport , Verpac kung und Lager ung/ 006 1.1.0 Transport von Pal et ten mit dem Gabels tapl er @ 9\ mod_1144392667613_1. doc @ 86319

Transporting pallets by forklift

Fig. 9

Packages which are fastened to pallets can be transported by forklift under the following conditions:

◼ The forklift must be designed for the weight of the units for transportation.

◼ The driver must be authorised to drive the forklift.

Fastening:

Drive the forklift with the forks between or underneath the beams of the pallet.

Insert the forks so that they protrude on the opposite side.

Make sure that the pallet cannot tilt in case it has an off-centre centre of gravity.

Raise the package and begin transportation.

Pos : 5. 22 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\ mod_1141997892953_0.doc @ 75471

Pos : 5. 23 /KN 2006-SM /Transport , Verpac kung und Lager ung/ 005 1.1 Verpac kung _Tit el @ 9\ mod_1144054971395_1. doc @ 84770

5.3 Packaging

Pos : 5. 24 /KN 2006-SM /Transport , Verpac kung und Lager ung/ 005 1.1.0 Zur Ver pac kung @ 9 \ mod_1144055345537_1. doc @ 84784

Information on packaging The individual packages are packaged appropriately for the expected transportation conditions. Only environmentally friendly materials have been used for packaging.

The packaging is designed to protect the individual parts from transport damage, corrosion and other damage up until they are installed. You must therefore not destroy the packaging and not remove it until shortly before installation.

Pos : 5. 25 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\ mod_1141997892953_0.doc @ 75471

Pos : 5. 26 /KN 2006-SM /Transport , Verpac kung und Lager ung/ 005 1.1.0 U mg ang mit Verpac kung smat erialien @ 9\ mod_1144055030585_1.doc @ 84777

Handling packaging materials Dispose of packaging material in accordance with the respective valid laws and local regulations.

CAUTION!

Risk of environmental damage due to incorrect disposal.

Packaging materials are valuable raw materials and can be re-used in many cases or treated and recycled.

Therefore:

– Dispose of packaging material in an environmentally friendly manner.

– Adhere to the valid local regulations for disposal. Contract a specialist company to carry out disposal as necessary.

Pos : 5.27 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75471

30 2021-05-31

Pos : 5. 28 /KN 2006-SM /Transport , Verpac kung und Lager ung/ 007 1.1 Lagerung_Ti tel @ 38 \ mod_1179315679426_1. doc @ 471241

5.4 Storage

Pos : 5. 29 /KN 2006-Pr ojekte/Herf order Elektromot oren-Wer ke/Trans port /007 1. 1. 0 Lager ung der Pac ks tüc ke @ 59\ mod_1203074612840_1.doc @ 1034278

Storing packages

Electric motors Size 63 - 225 ATEX / IECEx

Transportation, packaging and storage

Store the packages under the following conditions:

◼ Do not store in the open.

◼ Keep in a dry and dust-free environment.

◼ Do not expose to any corrosive media.

◼ Protect from sunlight.

◼ Make sure to store in a low-vibration environment

(v eff

≤ 0.2 mm/s)

◼ Avoid large fluctuations in storage temperature.

◼ Relative humidity: max. 60 %.

◼ Check the insulation resistance as necessary

(  chapter "Checking the insulation resistance").

◼ Grease or replace the rolling bearings as necessary

(  chapter "Maintenance").

◼ When storing for longer than 3 months, regularly check the general condition of all parts and the packaging. If necessary, replenish or replace the conservation.

NOTE!

In some cases there will be instructions for storage on the packages informing you of further requirements going beyond those listed here.

Adhere to these instructions accordingly.

Pos : 6. 1 / KN2006- SM/ nL.... ... ... Seit enumbr uc h . ... ... ... @ 8\ mod_1141998334703_0. doc @ 75489

2021-05-31 31

Electric motors Size 63 - 225 ATEX / IECEx

Installation and commissioning

Pos : 6. 2 / KN2006- SM/I nst allation & I nbetri ebnahme/ 001 1 Ins tall ati on und Ers tinbetriebnahme_Tit el @ 9\ mod_1144393592402_1. doc @ 86332

6 Installation and commissioning

Pos : 6. 3 / KN2006- Proj ekt e/H erfor der El ektromot oren- Wer ke/I ns tall ation & Inbetriebnahme/ AT EX/HIN WEIS - Nor men, Ric htlini en Ex- Ber eich @ 60\ mod_1203665634793_1.doc @ 1043962

NOTE!

When installing and commissioning adhere to the current standards and directive for electrical apparatus for explosive gas atmospheres.

Pos : 6.4 /KN2006- SM/nL---------- Abschnittsende ---------- @ 8\mod_1141997892953_0.doc @ 75471

Pos : 6. 5 / KN2006- SM/I nst allation & I nbetri ebnahme/ 002 1. 1 Sic her heit _Tit el @ 9 \ mod_1144395122392_1. doc @ 86367

6.1 Safety

Pos: 6.6 /KN2006-SM/Installation & Inbetriebnahme/003 1.1.0 Personal --> Standard --> ggf. anpassen @ 9\mod_1144395266192_1.doc @ 86374

Staff ◼ Installation and commissioning must only be performed by specialist staff with the appropriate qualifications.

◼ Work on the electrical equipment must only be carried out by qualified electricians.

Pos : 6. 7 / KN2006- SM/ nL---------- Abschnit tsende ---------- @ 8\ mod_1141997892953_0. doc @ 75471

Pos : 6. 8 / KN2006- Proj ekt e/H erfor der El ektromot oren- Wer ke/I ns tall ation & Inbetriebnahme/ 003 1.1.0 Persönliche Sc hutzausr üst ung @ 54\ mod_1196342349679_1.doc @ 832968

Personal safety equipment and clothing

Wear the following safety equipment and clothing for all installation and commissioning work:

◼ Occupational safety clothing

◼ Safety shoes

Pos : 6.9 /KN2006- SM/nL---------- Abschnittsende ---------- @ 8\mod_1141997892953_0.doc @ 75471

Pos : 6. 10 /KN 2006-Pr ojekte/Herf order Elektromot oren-Wer ke/I nst allation & I nbetri ebnahme/ ATEX/ 003 1. 1. 0 M ontag ear bei ten EX- SCHUTZ @ 60\ mod_1203498686471_1. doc @ 1039833

Explosion protection

EXPLOSION PROTECTION!

The introduction of ignition sources such as sparks, open flames and hot surfaces can cause explosions in the potentially explosive area.

Therefore, when carrying out all installation work on the machine in the potentially explosive area:

– Do not start any installation work without a written permit.

– Only carry out installation work to the exclusion of a potentially explosive atmosphere.

– Only use tools which are approved for use in the potentially explosive area.

Failure to adhere to these instructions will lead to a loss of the explosion protection.

Pos : 6. 11 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\ mod_1141997892953_0.doc @ 75471

32 2021-05-31

Pos : 6. 12 /KN 2006-SM /I nst allati on & I nbetriebnahme/003 1. 1. 0 El ektrisc he Anl age_G ef ahr! @ 9\ mod_1144397463440_1. doc @ 86395

Electrical equipment

Pos : 6.13 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75471

Pos : 6. 14 /KN 2006-SM /I nst allati on & I nbetriebnahme/003 1. 1. 0 Sic hern g egen Wiedereinschalt en @ 9 \mod_1144397709746_1. doc @ 86412

Securing the machine to prevent it from being switched back on

Pos : 6.15 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75471

Pos : 6. 16 /KN 2006-SM /I nst allati on & I nbetriebnahme/003 1. 1. 0 Gr undl egendes _Warn ung! @ 9\ mod_1144396463455_1. doc @ 86388

Improper installation and commissioning

Electric motors Size 63 - 225 ATEX / IECEx

Installation and commissioning

DANGER!

Danger to life from electrical current.

There is a risk of fatal injury from contact with live parts. Electrical components which are switched on can carry out uncontrolled movements and cause serious injuries.

Therefore:

– Before starting work switch off the electrical power supply and secure it to prevent it from being switched back on.

DANGER!

Risk of death from switching on without authorisation!

When performing installation there is a risk that the energy supply will be switched on without authorisation. This puts the life of people in the danger area at risk.

Therefore:

– Before beginning all work shut off all energy supplies and secure them to prevent them from being switched back on.

WARNING!

Risk of injuries from improper installation and commissioning.

Improper installation and commissioning can cause serious personal injury and material damage.

Therefore:

– Before starting work make sure there is sufficient space for performing the installation work.

– Handle open, sharp-edged parts with care.

– Keep the installation area clean and tidy. Loose parts and tools stacked on top of each other or parts and tools left lying around are potential sources of accidents.

– Fit parts properly. Adhere to the stipulated tightening torque values for screws.

– Secure parts to prevent them from falling or toppling.

Pos : 6.17 /KN 2006-SM /nL.......... Sei tenumbr uch .. ........ @ 8\mod_1141998334703_0.doc @ 75489

2021-05-31 33

Electric motors Size 63 - 225 ATEX / IECEx

Installation and commissioning

Pos : 6. 18 /KN 2006-SM /I nst allati on & I nbetriebnahme/005 1. 1 I nst allation_Titel @ 9\ mod_1144401700720_1. doc @ 86426

6.2 Installation

Pos : 6. 19 /KN 2006-Pr ojekte/Herf order Elektromot oren-Wer ke/I nst allation & I nbetri ebnahme/ 1. 1. 1 Bel üft ung am Einsatzort @ 59\ mod_1203072994994_1.doc @ 1034256

6.2.1 Ventilation at the location for use

The ventilation for the motor must not be obstructed.

You must therefore adhere to the following points:

◼ Makes rue that there is sufficient space between the motor fan and the walls and other similar obstructions.

◼ The clearance to obstructions must be at least d/4

(d = diameter of the motor).

◼ Make sure that the exhaust air is not sucked directly back in.

◼ In case of heavy soiling clean the air ways regularly.

Pos : 6. 20 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\ mod_1141997892953_0.doc @ 75471

Pos : 6. 21 /KN 2006-Pr ojekte/Herf order Elektromot oren-Wer ke/I nst allation & I nbetri ebnahme/ ATEX/ 1. 1. 1 Bauf or men nach DIN EN 60034- 7 ATEX @ 60\ mod_1203513321369_1. doc @ 1040516

6.2.2 Types of construction as per EN 60034-7

Type of construction and IM code (international mounting) of the most frequently used versions.

Type of construction

Symbol Explanation

IM B3

IM 1001

◼ 2 bearing covers

◼ with feet

IM V5

IM 1011

◼ 2 bearing covers

◼ with feet

◼ Shaft end bottom

◼ Fastening on the wall

IM V6

IM 1031

◼ 2 bearing covers

◼ with feet

◼ Shaft end top

◼ Fastening on the wall

IM B6

IM 1051

◼ 2 bearing covers

◼ with feet

◼ Construction type IM B3

◼ Fastening on the wall

◼ Feet left, viewed from drive side

34 2021-05-31

IM B8

IM 1071

IM B35

IM 2001

IM B34

IM 2101

IM B5

IM 3001

IM V1

IM 3011

Type of construction

IM B7

IM 1061

Symbol

IM V3

IM 3031

IM B14

IM 3601

Electric motors Size 63 - 225 ATEX / IECEx

Installation and commissioning

Explanation

◼ 2 bearing covers

◼ with feet

◼ Construction type IM B3

◼ Fastening on the wall

◼ Feet right, viewed from drive side

◼ 2 bearing covers

◼ with feet

◼ Construction type IM B3

◼ Fastening on the ceiling

◼ 2 bearing covers

◼ with feet

◼ Securing flange type A

◼ 2 bearing covers

◼ with feet

◼ Securing flange type C

◼ 2 bearing covers

◼ without feet

◼ Securing flange type A

◼ 2 bearing covers

◼ without feet

◼ Shaft end bottom

◼ Securing flange type A

◼ 2 bearing covers

◼ without feet

◼ Shaft end top

◼ Securing flange type A

◼ 2 bearing covers

◼ without feet

◼ Securing flange type C

2021-05-31 35

Electric motors Size 63 - 225 ATEX / IECEx

Installation and commissioning

Symbol Type of construction

IM V18

IM 3611

IM V19

IM 3631

IM V6/IM V19

IM V36

IM 2031

IM V5/IM V18

IM V15

IM 2011

Explanation

◼ 2 bearing covers

◼ without feet

◼ Shaft end bottom

◼ Securing flange type C

◼ 2 bearing covers

◼ without feet

◼ Shaft end top

◼ Securing flange type C

◼ 2 bearing covers

◼ with feet

◼ Shaft end top

◼ Securing flange type C

◼ 2 bearing covers

◼ with feet

◼ Shaft end top

◼ Securing flange type A

◼ 2 bearing covers

◼ with feet

◼ Shaft end bottom

◼ Securing flange type C

◼ 2 bearing covers

◼ with feet

◼ Shaft end bottom

◼ Securing flange type A

Pos : 6. 22 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\ mod_1141997892953_0.doc @ 75471

36 2021-05-31

Pos : 6. 23 /KN 2006-Pr ojekte/Herf order Elektromot oren-Wer ke/I nst allation & I nbetri ebnahme/ 1. 1. 1 M aschi nenaufst ellung @ 59\ mod_1203075619986_1. doc @ 1034390

6.2.3 Erecting the machine

Electric motors Size 63 - 225 ATEX / IECEx

Installation and commissioning

DANGER!

Risk of death due to insufficient protection classes.

Insufficient protection classes can lead to considerable material damage, serious personal injury or even death.

Therefore:

– Do not erect machines of protection class

≤ IP23 in the open.

In order to ensure that the machine runs quietly and with low vibrations make sure of the following when erecting the machine:

◼ the foundation must be stable

◼ the foundation's natural frequency with the machine must be sufficiently different to the rotary frequency and the double mains frequency

◼ the motors must be aligned accurately

◼ the drive machines must be well balanced

Pos : 6. 24 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\ mod_1141997892953_0.doc @ 75471

Pos : 6. 25 /KN 2006-Pr ojekte/Herf order Elektromot oren-Wer ke/I nst allation & I nbetri ebnahme/ 005 1. 1. 1 M ontag e @ 54\ mod_1196342352100_1. doc @ 832987

6.2.4 Installation

Installation varies depending on the construction type. In case you have any doubts contact the service department (  page 2).

When installing, always pay attention to the following points:

◼ All connection elements (walls, ceilings etc.) must be of sufficient size.

◼ The rotor is dynamically balanced with a half feather key. Take this into account when balancing the drive element.

◼ Avoid incorrect belt tension (  catalogue). Cover couplings and belt pulleys with a guard to protect accidental contact.

◼ Fit and remove drive elements (couplings, belt pulley, toothed wheels etc.) with the suitable devices.

◼ Tighten all screw connections with the appropriate tightening torque (  chapter "Tightening torque values for screws").

◼ Fit construction types with the shaft ends at the bottom with a cover to prevent foreign bodies from falling into the motor's fan.

◼ Any condensation drain holes must be positioned at the lowest point of the motor when installed and cleaned of any impurities.

◼ Take generally required measures for preventing accidental contacts between drive elements

2021-05-31 37

Electric motors Size 63 - 225 ATEX / IECEx

Installation and commissioning

6.3 Connecting to the energy supply

Pos : 6. 28 /KN 2006-SM /Sic her hei t/ 007 Besondere G ef ahr en/El ektrisc her Strom_G ef ahr! @ 8\ mod_1143366795746_1. doc @ 81188

Electrical current

DANGER!

Danger to life from electrical current.

There is an immediate risk of fatal injury in case of contact with live parts. Damage to the insulation or individual components can mean danger to life.

Therefore:

– In case of damage to the insulation, switch off the power supply immediately and have repairs carried out.

– Have work on the electrical equipment carried out by qualified electricians only.

– When any work is carried out on the electrical equipment, disconnect it from the power and make sure it is free of voltage.

– Before carrying out maintenance, cleaning and repair work, switch off the power supply and secure it to prevent it from being switched back on.

– Do not jumper or disable any fuses or circuit breakers. When replacing fuses or circuit breakers make sure to adhere to the correct ampere rating.

– Keep moisture away from live parts. It can lead to a short circuit.

Pos : 6.29 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75471

Pos : 6. 30 /KN 2006-Pr ojekte/Herf order Elektromot oren-Wer ke/I nst allation & I nbetri ebnahme/ ATEX/ 1. 1. 1 Kabel versc hraubung @ 60\ mod_1203664041040_1.doc @ 1043941

6.3.1 Screwed cable gland

NOTE!

Type Ex de motors are equipped with EEx e screwed cable glands. For type EEx d motors, the cable glands are not included in the scope of delivery. These must be adapted to the cable diameter on site.

NOTE!

Unused cable bushing openings must be sealed off with certified plugs with the matching IP protection type as shown on the type plate.

38 2021-05-31

Ex d motors

Ex de motors

Pos : 6. 31 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\ mod_1141997892953_0.doc @ 75471

Pos : 6. 32 /KN 2006-Pr ojekte/Herf order Elektromot oren-Wer ke/I nst allation & I nbetri ebnahme/ 1. 1. 1 Spannung und Sc hal tung @ 59\ mod_1203082128766_1. doc @ 1035016

6.3.2 Voltage and circuit

Electric motors Size 63 - 225 ATEX / IECEx

Installation and commissioning

Connection to the terminal box with these motors is implemented with a standard connection.

You must take great care when selecting the cable connection. It is imperative that the version is approved and approved for at least the protection class of the motor.

The type and dimensions of the cable connections must match the cable type and cable cross section.

Strictly adhere to the directives and standards which apply to the terminal box connections of these motors. The type of cable connection must be approved.

2. Make sure that the supply cable is connected in line with the instructions of the wiring diagram in the terminal box.

Properly insert the seals on the terminal box into the grooves provided.

Creepage paths and air gaps must comply with EN 60079-7.

◼ Adhere to the wiring specification on the type plate and wiring diagram in the terminal box.

◼ Compare the operating voltages and supply voltages.

◼ Motor rated voltages and the supply voltage must not differ

± 5 %; ± 2 % is permitted for the rated frequency.

Pos : 6. 33 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\ mod_1141997892953_0.doc @ 75471

2021-05-31 39

Electric motors Size 63 - 225 ATEX / IECEx

Installation and commissioning

Pos : 6. 34 /KN 2006-Pr ojekte/Herf order Elektromot oren-Wer ke/I nst allation & I nbetri ebnahme/ 1. 1. 1 Is ol ations wi ders tand pr üf en @ 59\ mod_1203315508128_1.doc @ 1036431

6.3.3 Checking the insulation resistance

◼ To be performed by a qualified electrician only

DANGER!

Risk of death due to uncontrolled fault currents.

Insulation faults can call potentially fatal fault currents.

Therefore:

– The value of the insulation resistance must be higher than the critical value of 0.5 MΩ.

– In case the value drops below the critical insulation resistance, take the motor out of operation and shut it down immediately.

DANGER!

Danger to life from electrical current.

When measuring and immediately afterwards the terminals carry partly dangerous voltages.

Therefore:

– Do not touch the terminals.

– Discharge after measuring.

Before commissioning the motor, after a longer period of storage or without use, the insulation resistance of the coils has to be determined again. When doing so, adhere to the valid standards and directives.

Pos : 6. 35 /KN 2006-SM /nL.. ... ... .. Sei tenumbr uch .. ... ... .. @ 8\ mod_1141998334703_0.doc @ 75489

Pos : 6. 36 /KN 2006-SM /I nst allati on & I nbetriebnahme/007 1. 1 Ers tinbetriebnahme_Tit el @ 9 \ mod_1144401802375_1. doc @ 86433

6.4 Commissioning

Pos : 6.37 /KN 2006-Pr ojekte/Herforder Elektromotoren-Wer ke/Installation & Inbetri ebnahme/Gefahr! Elektrischer Strom @ 59\mod_1203336144609_1.doc @ 1037099

DANGER!

Danger to life from electrical current.

There is an immediate risk of fatal injury in case of contact with live parts.

Therefore:

– Only carry out work with the plant free of voltage.

– Secure the plant to prevent it from being switched back on.

Pos : 6.38 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75471

40 2021-05-31

Pos : 6. 39 /KN 2006-Pr ojekte/Herf order Elektromot oren-Wer ke/I nst allation & I nbetri ebnahme/ VOR SICHT - Her ausg esc hleudert e Pas sf eder @ 59\ mod_1203079038551_1. doc @ 1034432

Pos : 6.40 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75471

Pos : 6. 41 /KN 2006-Pr ojekte/Herf order Elektromot oren-Wer ke/I nst allation & I nbetri ebnahme/ Vor Inbetriebnahme pr üf en @ 59\ mod_1203079708164_1.doc @ 1034523

Electric motors Size 63 - 225 ATEX / IECEx

Installation and commissioning

CAUTION!

Risk of personal injury and/or material damage from feather keys ejected at speed.

When commissioning a motor without drive elements the feather keys may be ejected at speed.

Therefore:

– Before commissioning motors without drive elements remove or secure the feather keys beforehand.

Before commissioning make sure that:

◼ the minimum insulation resistance values are adhered to

(  chapter "Checking the insulation resistance").

◼ the protective earth conductor connection is properly established and, where necessary, a potential equalisation has been established (see DIN EN 60079-14, chapter 6.3)

◼ the rotor can be turned without rubbing.

◼ the motor is properly fitted and aligned.

◼ the drive elements have the right settings (e.g. belt tension for belt drive etc.)

◼ the drives are suitable for the conditions of use.

◼ all electrical connections, fastening screws and fastening elements are the right type and are tightened properly.

◼ measures to prevent accidental contacts for mowing and live parts have been taken.

NOTE!

Commissioning is performed using the overall plant control unit (



Operating manual for the complete plant).

Pos : 7. 1 / KN2006- SM/ nL.... ... ... Seit enumbr uc h . ... ... ... @ 8\ mod_1141998334703_0. doc @ 75489

2021-05-31 41

Electric motors Size 63 - 225 ATEX / IECEx

Operations

Pos : 7. 2 / KN2006- SM/Bedienung/ 001 1 Bedi enung _Tit el @ 9\mod_1144402040153_1. doc @ 86490

7 Operations

Pos : 7. 3 / KN2006- Proj ekt e/H erfor der El ektromot oren- Wer ke/ Bedienung/ 1. 1 Allgemei nes @ 59\ mod_1203412166172_1. doc @ 1038421

7.1 General information

During operation no staff are required in the machine area or in the direct vicinity to operate it.

Operation is performed using the overall plant control unit

(  Operating manual for the complete plant).

Pos : 7. 4 / KN2006- SM/ nL---------- Abschnit tsende ---------- @ 8\ mod_1141997892953_0. doc @ 75471

Pos : 7. 5 / KN2006- SM/Bedienung/ 007 1. 1 Stillsetz en im Notf all_Tit el @ 9 \ mod_1144405047456_1. doc @ 86610

7.2 Shutting down in an emergency

Pos : 7. 6 / KN2006- SM/Bedienung/ 007 1. 1 Stillsetz en im Notf all --> Anl age und größ ere M asc hine @ 9\ mod_1144432835796_1.doc @ 86788

In danger situations machine movements must be stopped as quickly as possible and the energy supply has to be switched off.

Shutting down in an emergency

After emergency measures

In case of danger proceed as follows:

Trigger an emergency stop immediately.

Remove any people from the danger zone and administer first aid.

3. Alert a doctor and the fire services.

Inform the responsible party at the location.

Switch off the master switch and secure it to prevent it from being switched back on.

Keep access routes for emergency vehicles clear.

If the seriousness of the emergency requires it, inform the respective authorities.

Have specialist staff remedy the fault.

WARNING!

Risk of death from switching on prematurely.

When switching back on there is a risk of fatal injury for all people in the danger area.

Therefore:

– Before switching back on make sure that there is nobody in the danger area.

Before re-starting check the plant and make sure that all safety devices are installed and fully functional.

Pos : 8.1 /F I/.......... Seitenumbr uch .......... @ 0\mod272_1.doc @ 1522

42 2021-05-31

Electric motors Size 63 - 225 ATEX / IECEx

Faults

Pos : 8. 2 / KN2006- SM/Stör ung en/001 1 Stör ung en_Tit el+Text @ 9\ mod_1144439647801_1.doc @ 86957

8 Faults

The following chapter describes possible causes of faults and the work to eradicate them.

In case of faults which occur several times, reduce the maintenance interval accordingly to suit the actual strain.

In case of faults which cannot be cleared using the following instructions, contact the manufacturer, see service address on page 2.

Pos : 8. 3 / KN2006- SM/Stör ung en/002 1.1 Sic herheit _Titel @ 9\ mod_1144439648502_1. doc @ 86964

8.1 Safety

Pos: 8.4 /KN2006-Projekte/Herforder Elektromotoren-Werke/Störungen/003 1.1.0 Personal @ 64\mod_1206009264903_1.doc @ 1073732

Staff ◼ Some tasks can only be carried out by specialist staff with special qualifications or exclusively by the manufacturer. The description of the respective individual fault makes reference to this in each case.

◼ Work on the electrical equipment must only be carried out by qualified electricians.

Pos : 8. 5 / KN2006- SM/ nL---------- Abschnit tsende ---------- @ 8\ mod_1141997892953_0. doc @ 75471

Pos : 8. 6 / KN2006- Proj ekt e/H erfor der El ektromot oren- Wer ke/ St örungen/ 003 1. 1. 0 Pers önlic he Schutz ausrüs tung @ 54 \ mod_1196342589631_1. doc @ 833025

Personal safety equipment and clothing

Wear the following safety equipment and clothing for all faults work:

◼ Occupational safety clothing

◼ Safety shoes

Pos : 8. 7 / KN2006- SM/ nL---------- Abschnit tsende ---------- @ 8\ mod_1141997892953_0. doc @ 75471

Pos : 8. 8 / KN2006- Proj ekt e/H erfor der El ektromot oren- Wer ke/ St örungen/ ATEX/ 003 1. 1. 0 Arbeit en zur St örungsbes eitigung EX-SCHUTZ @ 60\ mod_1203499429928_1.doc @ 1039989

Explosion protection

EXPLOSION PROTECTION!

The introduction of ignition sources such as sparks, open flames and hot surfaces can cause explosions in the potentially explosive area.

Therefore, when carrying out all work to remedy faults in the potentially explosive area:

– Do not start any work without a written permit.

– Only carry out work to remedy faults to the exclusion of a potentially explosive atmosphere.

– Only use tools which are approved for use in the potentially explosive area.

Failure to adhere to these instructions will lead to a loss of the explosion protection.

Pos : 8.9 /KN2006- SM/nL---------- Abschnittsende ---------- @ 8\mod_1141997892953_0.doc @ 75471

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Electric motors Size 63 - 225 ATEX / IECEx

Faults

Pos : 8. 10 /KN 2006-SM /St örungen/ 003 1. 1. 0 Elektrisc he Anlage_Gef ahr! @ 9\ mod_1144439649994_1.doc @ 86978

Electrical equipment

DANGER!

Danger to life from electrical current.

There is a risk of fatal injury from contact with live parts. Electrical components which are switched on can carry out uncontrolled movements and cause serious injuries.

Therefore:

– Before starting work switch off the electrical power supply and secure it to prevent it from being switched back on.

Pos : 8.11 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75471

Pos : 8. 12 /KN 2006-SM /St örungen/ 003 1. 1. 0 Sic her n geg en Wi ederei nsc halten_G ef ahr! @ 9\ mod_1144439652427_1. doc @ 86999

Securing the machine to prevent it from being switched back on

DANGER!

Risk of death from switching on without authorisation!

When working to remedy faults there is a risk that the energy supply will be switched on without authorisation. This puts the life of people in the danger area at risk.

Therefore:

– Before beginning all work shut off all energy supplies and secure them to prevent them from being switched back on.

Pos : 8.13 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75471

Pos : 8. 14 /KN 2006-SM /St örungen/ 003 1. 1. 0 Grundlegendes _Warnung! @ 9\ mod_1144439650705_1. doc @ 86985

Improper eradication of faults

WARNING!

Risk of injuries from incorrectly eradicating faults.

Eradicating faults incorrectly can cause serious personal injury and material damage.

Therefore:

– Before starting work make sure there is sufficient space for performing the installation work.

– Keep the installation area clean and tidy. Loose parts and tools stacked on top of each other or parts and tools left lying around are potential sources of accidents.

– If parts have been removed, make sure they are installed properly, re-install all fastening elements and adhere to the tightening torque values for screws.

Pos : 8. 15 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\ mod_1141997892953_0.doc @ 75471

44 2021-05-31

Pos : 8. 16 /KN 2006-SM /St örungen/ 003 1. 1. 0 Verhalten bei Stör ung en (Ger ät) @ 9\ mod_1144441786782_1.doc @ 87239

How to act in case of faults

Electric motors Size 63 - 225 ATEX / IECEx

Faults

The following basic instructions apply:

In case of faults which pose an immediate risk to people or objects of material value, activate the emergency stop function immediately.

Determine the cause of the fault.

If eradicating the fault requires work in the danger area, switch off the plant and secure it to prevent it from being switched back on.

Inform the responsible party at the location of the fault immediately.

Depending on the type of fault, have it remedied by specialist staff or remedy it yourself.

NOTE!

The following fault table provides information on who is authorised to remedy the fault.

Pos : 8. 17 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\ mod_1141997892953_0.doc @ 75471

Pos : 8. 18 /KN 2006-SM /St örungen/ 005 1. 1 St örungst abelle_Tit el @ 9\ mod_1144442349705_1. doc @ 87246

8.2 Fault table

Pos : 8. 19 /KN 2006-Pr ojekte/Herf order Elektromot oren-Wer ke/Stör ung en/005 1.1.0 Stör ungst abell e @ 54\ mod_1196342592303_1. doc @ 833044

Fault

◼ Bearing is too warm

◼ Motor is not running smoothly

◼ Bearing is too warm

◼ Bearing noises

◼ Bearing is too warm

◼ Bearing noises

◼ Motor is not running smoothly

Possible cause

Too much grease in the bearing

Bearing is soiled

Belt tension too high

Remedy To be remedied by

Remove excessive grease Qualified specialist

Replace the bearing Manufacturer

Reduce belt tension Qualified specialist

Bearing grease dark in colour

Coupling forces are pulling or pushing

Check for bearing currents Qualified specialist

Align the motor exactly, adjust the coupling

Qualified specialist

Not enough grease in the bearing

Lubricate as stipulated

Motor erected incorrectly Check the motor construction type

Qualified specialist

2021-05-31 45

Electric motors Size 63 - 225 ATEX / IECEx

Faults

Fault Possible cause Remedy To be remedied by

Manufacturer ◼ Bearing noises

◼ Motor is not running smoothly

◼ Motor does not start up

◼ Considerable drop in speed

Scoring on inner bearing ring, e.g. from motor starting up with bearing locked

Imbalance due to belt pulley or coupling

Machine fastening insufficient

Load moment too high

Supply voltage too low

◼ Motor does not start up

◼ Considerable drop in speed

◼ Safety device is triggered

Phase interrupted

◼ Motor does not start up

◼ Motor is too warm

◼ Considerable drop in speed

◼ Safety device is triggered

Incorrect circuit

◼ Motor is too warm

◼ Considerable drop in speed

◼ Safety device is triggered

Overload

◼ Motor is too warm

◼ Safety device is triggered

Too many switching actuations

◼ Motor is too warm Ventilation insufficient

◼ Safety device is triggered

Replace bearing, avoid vibrations when at a standstill

Balance exactly Manufacturer

Check machine fastening Qualified specialist

Check motor torque and load moment

Qualified electrician

Check power supply conditions

Check the mains connection

Qualified electrician

Adhere to wiring diagram and type plate

Adhere to stipulations on type plate

Observe rated operating mode

Qualified electrician

Check cooling air routes, check direction of rotation

Qualified electrician

Ventilation ducts soiled

Coil or terminal short circuit

Clean the ventilation ducts Qualified specialist

Measure the insulation resistance

The start-up time has been exceeded

Check the start-up conditions

Qualified electrician

Pos : 8.20 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75471

46 2021-05-31

Electric motors Size 63 - 225 ATEX / IECEx

Faults

Pos: 8.21 /KN2006-SM/Störungen/007 1.1 Inbetriebnahme nach behobener Störung_Titel @ 9\mod_1144442691882_1.doc @ 87274

8.3 Commissioning after remedied fault

Pos : 8. 22 /KN 2006-SM /St örungen/ 007 1. 1. 0 Inbetriebnahme nac h behobener St örung --> St andard --> ggf. anpass en @ 9\ mod_1144442763671_1. doc @ 87281

After remedying the fault carry out the following steps for recommissioning:

1. Reset the emergency stop devices.

Acknowledge the fault on the control unit.

Make sure that there is nobody in the danger area.

Start by following the instructions in the chapter "Operation".

Pos : 8. 23 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\ mod_1141997892953_0.doc @ 75471

Pos : 8. 24 /KN 2006-Pr ojekte/Herf order Elektromot oren-Wer ke/Stör ung en/AT EX/007 1.1.0 Pot ential ausgleich und Er dung anbring en EX-SCHUTZ @ 60\ mod_1203499601815_1.doc @ 1040010

Explosion protection

EXPLOSION PROTECTION!

Introducing ignition sources such as sparks in the potentially explosive area can cause explosions.

Therefore, after carrying out all work to remedy faults in the potentially explosive area:

– Make sure that all aggregates are connected to each other with potential equalisation of sufficient dimensions. To be performed by a qualified electrician only.

– Make sure that the motor is earthed to prevent static charging. To be performed by a qualified electrician only.

Failure to adhere to these instructions will lead to a loss of the explosion protection.

Pos : 9.1 /KN2006- SM/nL.......... Seitenumbr uc h .......... @ 8\mod_1141998334703_0.doc @ 75489

2021-05-31 47

Electric motors Size 63 - 225 ATEX / IECEx

Maintenance

Pos : 9. 2 / KN2006- SM/ War tung/001 1 Wart ung_Tit el @ 9\ mod_1144434830143_1.doc @ 86796

9 Maintenance

Pos : 9. 3 / KN2006- SM/ War tung/002 1. 1 Sic herheit _Titel @ 9\ mod_1144434831619_1. doc @ 86810

9.1 Safety

Pos: 9.4 /KN2006-SM/Wartung/003 1.1.0 Personal --> Standard --> ggf. anpassen @ 9\mod_1144434832402_1.doc @ 86817

Staff ◼ The maintenance work described here can be carried out by the operator unless otherwise stated.

◼ Some maintenance tasks can only be carried out by specialist staff with special qualifications or exclusively by the manufacturer. The description of the respective individual maintenance task makes reference to this in each case.

◼ Work on the electrical equipment must only be carried out by qualified electricians.

Pos : 9.5 /KN2006- SM/nL---------- Abschnittsende ---------- @ 8\mod_1141997892953_0.doc @ 75471

Pos : 9. 6 / KN2006- Proj ekt e/H erfor der El ektromot oren- Wer ke/ Wartung/ 003 1. 1. 0 Pers önlic he Schutz ausrüs tung @ 54\ mod_1196342705414_1. doc @ 833082

Personal safety equipment and clothing

Wear the following safety equipment and clothing for all maintenance work:

◼ Occupational safety clothing

◼ Safety shoes

Pos : 9.7 /KN2006- SM/nL---------- Abschnittsende ---------- @ 8\mod_1141997892953_0.doc @ 75471

Pos : 9. 8 / KN2006- Proj ekt e/H erfor der El ektromot oren- Wer ke/ Wartung/ ATEX/ 003 1. 1. 0 Wartungsar bei ten EX- SCHUTZ @ 60\ mod_1203499811448_1. doc @ 1040084

Explosion protection

EXPLOSION PROTECTION!

The introduction of ignition sources such as sparks, open flames and hot surfaces can cause explosions in the potentially explosive area.

Therefore, when carrying out all maintenance work on the machine in the potentially explosive area:

– Do not start any maintenance work without a written permit.

– Only carry out maintenance work to the exclusion of a potentially explosive atmosphere.

– Only use tools which are approved for use in the potentially explosive area.

Failure to adhere to these instructions will lead to a loss of the explosion protection.

Pos : 9.9 /KN2006- SM/nL---------- Abschnittsende ---------- @ 8\mod_1141997892953_0.doc @ 75471

48 2021-05-31

Electric motors Size 63 - 225 ATEX / IECEx

Maintenance

Pos : 9. 10 /KN 2006-SM /Wart ung/ 003 1.1. 0 Elektrisc he Anlage @ 9\mod_1144434833265_1. doc @ 86824

Electrical equipment

DANGER!

Danger to life from electrical current.

There is a risk of fatal injury from contact with live parts. Electrical components which are switched on can carry out uncontrolled movements and cause serious injuries.

Therefore:

– Before starting work switch off the electrical power supply and secure it to prevent it from being switched back on.

Pos : 9.11 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75471

Pos : 9. 12 /KN 2006-SM /Wart ung/ 003 1.1. 0 Sic her n geg en Wi eder einsc halten @ 9\ mod_1144434835685_1.doc @ 86845

Securing the machine to prevent it from being switched back on

DANGER!

Risk of death from switching on without authorisation!

When performing maintenance there is a risk that the energy supply will be switched on without authorisation. This puts the life of people in the danger area at risk.

Therefore:

– Before beginning all work shut off all energy supplies and secure them to prevent them from being switched back on.

Pos : 9.13 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75471

Pos : 9. 14 /KN 2006-SM /Wart ung/ 003 1.1. 0 Grundlegendes @ 9\ mod_1144434834059_1. doc @ 86831

Improperly performed maintenance work

Pos : 9. 15 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\ mod_1141997892953_0.doc @ 75471

Pos : 9. 16 /KN 2006-SM /Wart ung/ 004 1.1. 0 U mwelts chutz _Tit el @ 9\ mod_1144436206520_1. doc @ 86865

Environmental protection

Pos : 9.17 /KN 2006-SM /Wartung/004 1.1.0.0 Ents orgung F ett @ 9\mod_1144436328140_1.doc @ 86872

WARNING!

Risk of injury due to improperly performed maintenance work.

Performing maintenance incorrectly can cause serious personal injury and material damage.

Therefore:

– Before starting work make sure there is sufficient space for performing the installation work.

– Keep the installation area clean and tidy. Loose parts and tools stacked on top of each other or parts and tools left lying around are potential sources of accidents.

– If parts have been removed, make sure they are installed properly, re-install all fastening elements and adhere to the tightening torque values for screws.

Adhere to the following instructions on environmental protection when performing maintenance work:

2021-05-31 49

Electric motors Size 63 - 225 ATEX / IECEx

Maintenance

Pos : 9. 18 /KN 2006-SM /Wart ung/ 004 1.1. 0. 0 Ents orgung Öl @ 9\ mod_1144439240623_1. doc @ 86943

◼ At all lubricating points which are supplied with lubricant by hand, remove the expelled, used or excess grease and dispose of it in accordance with the local regulations.

◼ Collect replaced oil in suitable containers and dispose of it in accordance with the local regulations.

Pos : 9. 19 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\ mod_1141997892953_0.doc @ 75471

Pos : 9. 20 /KN 2006-SM /Wart ung/ 005 1.1 Rei nigung _Tit el @ 9\ mod_1144436963247_1. doc @ 86879

9.2 Cleaning

Pos : 9. 21 /KN 2006-Pr ojekte/Herf order Elektromot oren-Wer ke/ Wart ung/AT EX/005 1. 1 Rei nigung EX-SCHUTZ @ 60\ mod_1203501156710_1.doc @ 1040105

Explosion protection

◼ Additionally required safety equipment and clothing:

⚫ Light breathing mask

EXPLOSION PROTECTION!

Swirled up deposits of dust can form potentially explosive dust/air mixtures and when ignition sources are introduced, such as sparks, open flames and hot surfaces, can cause explosions in the potentially explosive area.

Therefore:

– Prevent layers of dust deposits from exceeding a thickness of 5 mm by regularly cleaning the location.

– Only carry out cleaning work to the exclusion of a potentially explosive atmosphere.

– Only use cleaning implements which are approved for use in the potentially explosive area.

– Wear personal safety equipment and clothing.

Failure to adhere to these instructions will lead to a loss of the explosion protection.

Pos : 9.22 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75471

Pos : 9. 23 /KN 2006-Pr ojekte/Herf order Elektromot oren-Wer ke/ Wart ung/1.1.0 Rei nigung @ 59\ mod_1203075291752_1. doc @ 1034369

◼ Do not spray electrical machines with water or other liquids.

◼ Check the entire route for cooling air for soiling at least once a year.

Pos : 9. 24 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\ mod_1141997892953_0.doc @ 75471

Pos : 9. 25 /KN 2006-SM /Wart ung/ 006 1.1 Wart ungs plan_Titel (Anleit ung) @ 9\ mod_1144437014193_1.doc @ 86886

9.3 Maintenance schedule

The next sections describe maintenance work which is required to ensure optimum and fault-free operation.

If during regular checks increased wear is identified, shorten the required maintenance intervals to match the actual signs of wear.

50 2021-05-31

Electric motors Size 63 - 225 ATEX / IECEx

Maintenance

In case you have any questions on maintenance work and intervals, contact the manufacturer, see service address on page 2.

The standard version motors are fitted with permanently lubricated bearings.

Motors from construction type 160 and above can be fitted with lubricating equipment. The lubricating intervals depend on many influence factors. The values in the table below apply under normal operating conditions.

Before lubricating, remove the plug screw on the side opposite the grease nipple and screw it back in when finished.

NOTE!

In case of questions on lubrication, contact the manufacturer.

See page 2 for contact details.

Lubricating the ball bearings - intervals in operating hours

Size Quantity of grease [g]

Speed [min -1 ]

3600 3000 1800 1500 1000 500

160 25 7000 9500 14000 17000 21000 24000

180

200

225

6000

4000

3000

8000

6000

5000

13500

11000

10000

16000

13000

12500

20000

17000

16500

23000

21000

20000

2021-05-31 51

Electric motors Size 63 - 225 ATEX / IECEx

Maintenance

Pos : 9. 29 /KN 2006-Pr ojekte/Herf order Elektromot oren-Wer ke/ Wart ung/1.1 Sc hraubenanz ugsdr ehmomente @ 67 \ mod_1208937207889_1. doc @ 1150009

9.4 Tightening torque values for screws

Explosion protection

EXPLOSION PROTECTION!

The introduction of ignition sources such as sparks, open flames and hot surfaces can cause explosions in the potentially explosive area.

Therefore, when carrying out all maintenance work on the machine in the potentially explosive area:

– Do not start any maintenance work without a written permit.

– Only carry out maintenance work to the exclusion of a potentially explosive atmosphere.

– Only use tools which are approved for use in the potentially explosive area.

Failure to adhere to these instructions will lead to a loss of the explosion protection.

NOTE!

Strength class 8.8 screws must be used for all screwed connections which are used to seal

the pressure-resistant space.

Replace screws which can no longer be used with new screws of the same type and strength class.

If not otherwise stated, the following tightening torque values apply for screw connections.

9.4.1 Tightening torque values for screws for electrical connections

Thread Tightening torque value [Nm]

M 4

M 5

M 6

M 8

M 10

1.2

M 12

M 16

M 20

M 24

M 30

15.5

150

52 2021-05-31

Electric motors Size 63 - 225 ATEX / IECEx

Maintenance

9.4.2 Screw connections, property class 8.8 and A4-70

NOTE!

Only use tightening torque values for screws of property class 8.8 and A4-70 (A4-80) in highstrength parts (e.g. grey cast iron, steel).

Thread

M 4

M 5

M 6

M 8

M 10

Tightening torque value [Nm]

Thread

2.3 M 14

4.6

7.9

M 16

M 20

M 24

M 12 66

9.4.3 Screw connections of property class 5.6

M 30

M 36

Tightening torque value [Nm]

105

160

330

560

1100

1900

NOTE!

Only use tightening torque values for screws of property class 5.6, 4.6 A2 or for screws in lowstrength parts (e.g. aluminium).

Thread

M 4

M 5

M 6

M 8

M 10

M 12

3.7

8.9

Tightening torque value [Nm]

Thread

1.1

2.1

M 14

M 16

M 20

M 24

M 30

M 36

150

260

520

920

Tightening torque value [Nm]

Pos : 9. 30 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\ mod_1141997892953_0.doc @ 75471

2021-05-31 53

Electric motors Size 63 - 225 ATEX / IECEx

Maintenance

Pos : 9. 31 /KN 2006-SM /Wart ung/ 009 1.1 M aß nahmen nac h erfolgt er Wart ung_Tit el @ 9 \ mod_1144438930025_1. doc @ 86928

9.5 Measures on completion of maintenance

Pos : 9. 32 /KN 2006-Pr ojekte/Herf order Elektromot oren-Wer ke/ Wart ung/AT EX/007 1. 1.0 Pot ential ausgleich und Erdung anbring en EX-SCHUTZ @ 60\ mod_1203501310249_1.doc @ 1040296

Explosion protection

EXPLOSION PROTECTION!

Introducing ignition sources such as sparks in the potentially explosive area can cause explosions.

Therefore, after carrying out all maintenance work on the machine in the potentially explosive area:

– Make sure that all aggregates are connected to each other with potential equalisation of sufficient dimensions. To be performed by a qualified electrician only.

– Make sure that the motor is earthed to prevent static charging. To be performed by a qualified electrician only.

Failure to adhere to these instructions will lead to a loss of the explosion protection.

Pos : 9.33 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75471

Pos : 9. 34 /KN 2006-SM /Wart ung/ 009 1.1. 0 M aß nahmen nac h erfolgt er Wart ung --> St andard @ 9\ mod_1144438981309_1. doc @ 86935

On completion of maintenance work, carry out the following steps before switching on:

Check that all screw connections which have been unfastened are fastened securely again.

Check whether all the safety devices and covers which have been removed have been properly re-installed.

Make sure that all tools, materials and other equipment which have been used, have been removed from the working area.

Clean the working area and remove any substances, e.g. liquids, processing material etc.

Make sure that all the plant's safety devices are in perfect working order.

Pos : 10.1 /KN 2006-SM /nL.. ... ... .. Sei tenumbr uch .. ... ... .. @ 8\ mod_1141998334703_0.doc @ 75489

54 2021-05-31

Electric motors Size 63 - 225 ATEX / IECEx

Removal

Pos : 10.2 /KN 2006-SM /Demontag e/ 001 1 D emont age_Tit el @ 9\ mod_1144501489239_1. doc @ 87445

10 Removal

Pos : 10.3 /KN 2006-SM /Demontag e/ 001 1. 0 N ac hdem das G ebrauchsende erreic ht ist. ..(Mas chi ne) @ 41 \ mod_1183385607485_1. doc @ 503412

Once the period of use has expired, the machine must be removed and disposed of in an environmentally friendly manner.

Pos : 10.4 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\ mod_1141997892953_0.doc @ 75471

Pos : 10.5 /KN 2006-SM /Demontag e/ 002 1 Sicherheit _Tit el @ 9\ mod_1144870285363_1. doc @ 89612

10.1 Safety

Pos: 10.6 /KN2006-SM/Demontage/003 1.1.0 Personal --> Standard --> ggf. anpassen @ 9\mod_1144870288160_1.doc @ 89633

Staff ◼ The machine must only be removed by qualified specialist staff with the appropriate qualifications.

◼ Work on the electrical equipment must only be carried out by qualified electricians.

Pos : 10.7 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\ mod_1141997892953_0.doc @ 75471

Pos : 10.8 /KN 2006-Pr ojekte/Herf order Elektromot oren-Wer ke/Demont age/ ATEX/ 003 1. 1. 0 D emontagear beit en EX-SCHUT Z @ 60\ mod_1203501579116_1. doc @ 1040381

Explosion protection

EXPLOSION PROTECTION!

The introduction of ignition sources such as sparks, open flames and hot surfaces can cause explosions in the potentially explosive area.

Therefore, when carrying out all removal work on the machine in the potentially explosive area:

– Do not start any removal work without a written permit.

– Only carry out removal work to the exclusion of a potentially explosive atmosphere.

– Only use tools which are approved for use in the potentially explosive area.

Failure to adhere to these instructions will lead to a loss of the explosion protection.

Pos : 10.9 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75471

Pos : 10.10 / KN 2006-SM/D emont age/003 1.1.0 El ektrisc he Anlag e @ 9\ mod_1144870286332_1. doc @ 89619

Electrical equipment

DANGER!

Danger to life from electrical current.

There is a risk of fatal injury from contact with live parts. Electrical components which are switched on can carry out uncontrolled movements and cause serious injuries.

Therefore:

– Before starting removal work switch off the electrical supply and disconnect it permanently.

Pos : 10.11 /KN 2006-SM/nL---------- Absc hnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75471

2021-05-31 55

Electric motors Size 63 - 225 ATEX / IECEx

Removal

Pos : 10.12 / KN 2006-SM/D emont age/003 1.1.0 Gr undleg endes @ 9\ mod_1144870287285_1. doc @ 89626

Improper removal

WARNING!

Risk of injury from improper removal.

Stored residual energy, sharp parts, points and corners on and in the device or on the required tools can cause injuries.

Therefore:

– Before starting work make sure there is sufficient space.

– Handle open, sharp-edged parts with care.

– Keep the working area clean and tidy. Loose parts and tools stacked on top of each other or parts and tools left lying around are potential sources of accidents.

– Remove parts properly. Be aware that some parts have a heavy dead weight. Use lifting gear as necessary.

– Secure parts to prevent them from falling or toppling.

– In case of doubt, contact the manufacturer.

Pos : 10.13 /KN 2006-SM/nL---------- Absc hnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75471

Pos : 10.14 / KN 2006-SM/D emont age/008 1.1 Demont age --> Maschi ne --> ggf. anpas sen! (Masc hine) @ 41\ mod_1183386016255_1. doc @ 503426

10.2 Removal

Before starting removal:

◼ Switch off the machine and secure it to prevent it from being switched back on.

◼ Physically disconnect the entire energy supply and discharge stored residual energy.

◼ Remove fuels and consumables and residual processing materials and dispose of them in an environmentally friendly manner.

Then clean assembly groups and parts properly and dismantle then in accordance with the local regulations for occupational safety and environmental protection.

Pos : 10.15 / KN 2006-SM/ nL---------- Absc hnit ts ende ---------- @ 8\ mod_1141997892953_0. doc @ 75471

56 2021-05-31

Pos : 10.16 / KN 2006-SM/D emont age/009 1.1 Ents orgung --> Standar d --> ggf. anpas sen! @ 8\ mod_1142093514566_1. doc @ 75855

10.3 Disposal

Electric motors Size 63 - 225 ATEX / IECEx

Removal

If no agreements have been made for return or disposal, have the dismantled components recycled:

◼ Have metals scrapped.

◼ Hand over plastic elements for recycling.

◼ Sort and dispose of other components according to the material properties.

CAUTION!

Risk of environmental damage due to incorrect disposal.

Electrical scrap, electronic components, lubricants and consumables require special waste treatment and must only be disposed of by approved specialist companies.

The local authorities or specialist disposal companies can provide information on environmentally friendly disposal.

2021-05-31 57

EC / EU – declaration of conformity

HERFORDER ELEKTROMOTOREN-WERKE GmbH & Co. KG

– 32051 Herford Goebenstraße 106 Tel.: 05221 59040 [email protected]

– 32008 Herford post office box 1852

Electrical operating equipment:

Explosion-proof three phase asynchronous motors ( flame-proof encapsulation ) with squirrel cage

Typ

DCEx 63

DBEx 63

DDEx 63

DCEx 71 - 225

DBEx 71 - 225 marking gas

II 2G Ex db e IIC T4-T6 Gb oder II 2G Ex db IIC T4-T6 Gb marking dust

II 2G Ex db e IIB T4-T6 Gb oder II 2G Ex db IIB T4-T6 Gb

II 2G Ex db e IIC T4-T6 Gb oder II 2G Ex db IIC T4-T6 Gb

II 2G Ex db eb IIC T4-T6 Gb oder II 2G Ex db IIC T4-T6 Gb

II 2G Ex db eb IIB T4-T6 Gb oder II 2G Ex db IIB T4-T6 Gb

II 2D Ex tb IIIC T135°C - 85°C Db

DDEx 71 - 225 II 2G Ex db eb IIC T4-T6 Gb oder II 2G Ex db IIC T4-T6 Gb II 2D Ex tb IIIC T135°C - 85°C Db

DCEx 250 and DCEx 280 II 2G Ex db eb IIC T4-T6 Gb oder II 2G Ex db IIC T4-T6 Gb

DBEx 250 and DBEx 280 II 2G Ex db eb IIB T4-T6 Gb oder II 2G Ex db IIB T4-T6 Gb

DDEx 250 and DDEx 280 II 2G Ex db eb IIC T4-T6 Gb oder II 2G Ex db IIC T4-T6 Gb II 2D Ex tb IIIC T135°C - 85°C Db

DEx 315 II 2G Ex de IIC T4-T6 oder II 2G Ex d IIC T4-T6 are conform to the regulations of the following European directives:

EMV- directive 2014/30/EU

ATEX- directive

RoHS- directive

2014/34/EU

2011/65/EU and (Amendment Annex II (EU) 2015/863)

Electric motor Regulation

Machinery directive

2019/1781/EU

2006/42/EC

The compliance with the provisions of the directives is proved by the following series of standards with all relevant parts according to the current date:

DIN EN 60034

DIN EN 60079-0:2018, 60079-1:2014, 60079-7:2015 + A1:2018, 60079-31:2014

The following EG/EU-type examination certificate is valid:

D_Ex 63: SIQ 16 ATEX 142 X 0158 DEKRA DTC Gmbh

D_Ex 71

– 225: BVS 14 ATEX E 114 X

0158 DEKRA DTC Gmbh

D_Ex 250:

D_Ex 280:

BVS 19 ATEX E 005 X

BVS 19 ATEX E 006 X

0158 DEKRA DTC Gmbh

DEx 315: PTB 10 ATEX 1047 X 0158 DEKRA DTC Gmbh

The designated product is to be seen as a component for installation into a machine or system.

Commissioning is prohibited until the conformity of the final product to the directive 2006/42/EC is established.

( M. Scheidt ) Managing Director date 30.06.2021

The safety instructions of the product documentation must be duly observed.

This declaration of conformity is no warranty of the characteristics in the sense of product liability.

Appendix

13.3 Coupling

For further information, see also

Rotex-BA.pdf

Diaphragm pump N0150 EX

116 Translation of Original Operation and Installation Instruction, english, KNF 321729 11/22

ROTEX ®

Operating/Assembly instructions

ROTEX

®

Torsionally flexible jaw couplings type

No. 001 - shaft coupling,

No. 018 - DKM, with taper clamping sleeve and their combinations according to directive 2014/34/EU

KTR-N

Sheet:

Edition:

40210 EN

1 of 27

Type No. 001 - shaft coupling

Type No. 018 - DKM double-cardanic coupling

Please observe protection note ISO 16016.

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Type with taper clamping sleeve

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KTR-N dated 2017-09-06

ROTEX ®

Operating/Assembly instructions

KTR-N

Sheet:

Edition:

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2 of 27

ROTEX ®

is a torsionally flexible jaw coupling. It is able to compensate for shaft misalignment, for example caused by manufacturing inaccuracies, thermal expansion, etc.

Table of contents

1 Technical data

2 Advice

2.1 General advice

2.2 Safety and advice symbols

2.3 General hazard warnings

2.4 Intended use

2.5 Coupling selection

2.6 Reference to EC Machinery Directive 2006/42/EC

3 Storage, transport and packaging

3.1 Storage

3.2 Transport and packaging

4 Assembly

4.1 Components of the coupling

4.2 Advice for finish bore

4.3 Assembly of the hubs

4.4 Assembly of taper clamping sleeve

4.5 Displacements - alignment of the couplings

5 Start-up

6 Breakdowns, causes and elimination

7 Disposal

8 Maintenance and service

9 Spares inventory, customer service addresses

10 Enclosure A

7

8

9

10

11

12

13

14

Advice and instructions regarding the use in potentially explosive atmospheres 20

10.1 Intended use in potentially explosive atmospheres

10.2 Inspection intervals for couplings in

10.3 Standard values of wear

potentially explosive atmospheres

10.4 marking of coupling for potentially explosive atmospheres

10.5 EU Certificate of conformity

21

22

24

25

27

Please observe protection note ISO 16016.

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1 Technical data

ROTEX ®

Operating/Assembly instructions

KTR-N

Sheet:

Edition:

40210 EN

3 of 27

Illustration 1: ROTEX ® (material: powder metal, Al-D and Al-H)

Table 1: Material powder metal steel (Sint)

Size

Component

Spider

(component 2)

Rated torque [Nm]

92 ShA 98 ShA 64 ShD

7.5

12.5

Finish bore 2) d (min-max)

6 - 16

6 - 24

9 - 28

Dimensions [mm] 3) b

General s D

4) d

L l

, l

35 11 13 10 1.5 30

66 25 16 12 2.0 40

78 30 18 14 2.0 56

Table 2: Material aluminium diecast (Al-D) - no approval for ATEX

Size

Component

Spider 1) (component 2)

Rated torque [Nm]

92 ShA 98 ShA 64 ShD

160

Table 3: Material aluminium (Al-H)

Finish bore 2) d (min-max)

6 - 19

19 - 24

9 - 24

22 - 28

10 - 28

28 - 38

L l

, l

Dimensions [mm]

General b s D

4) d

66 25 16 12 2.0 41

78 30 18 14 2.0 56

90 35 20 15 2.5 67

Size

Component

Spider

(component 2)

Rated torque [Nm]

92 ShA 98 ShA 64 ShD

0.5

1.2

3.0

5.0

7.5

190

265

310

0.9

2.0

5.0

9.0

12.5

160

325

450

525

2.4

6.0

200

405

560

655

Finish bore 2) d (min-max)

0 - 6

0 - 7

0 - 11

0 - 12

0 - 16

0 - 24

0 - 28

0 - 38

0 - 45

0 - 55

0 - 62

L l

, l

Dimensions [mm] 3) b

General s D

4) d

15 5

22 7

4 0.5 10

6 1.0 14

30 10 10 8 1.0 20

34 11 12 10 1.0 25

35 11 13 10 1.5 30

66 25 16 12 2.0 40

78 30 18 14 2.0 55

90 35 20 15 2.5 65

114 45 24 18 3.0 80

126 50 26 20 3.0 95

140 56 28 21 3.0 105

7.2

8.5

- 10.5 -

- 18 -

1) Maximum torque of the coupling T

Kmax.

= rated torque of the coupling T

K rated

x 2

2) Bores H7 with keyway to DIN 6885 sheet 1 [JS9] and setscrew

3) For dimensions G and t see table 8; there is a setscrew on the keyway (only with Al-D opposite the keyway)

4) D

= internal diameter of housing

Please observe protection note ISO 16016.

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1 Technical data

ROTEX ®

Operating/Assembly instructions

KTR-N

Sheet:

Edition:

40210 EN

4 of 27

Illustration 2: ROTEX ® (material: GJL/GJS)

Table 4: Material cast iron (GJL)/nodular iron (GJS)

Size

Component

Spider

(component 2)

Rated torque [Nm]

92 ShA 98 ShA 64 ShD

190

265

310

410

625

1280

2400

325

450

525

685

940

1920

3600

405

560

655

825

1175

2400

4500

Finish bore 2) d (min-max) L l

, l

Dimensions [mm] 3)

General b s D

4) d

D, D

12 - 40

38 - 48

12 - 48

14 - 45

42 - 55

14 - 55

15 - 52

48 - 62

15 - 62

20 - 60

55 - 74

22 - 70

30 - 80

40 - 97

Cast iron (GJL)

114 45

24 18 3.0 80 - - 38

164 70

126 50

26 20 3.0 95 - - 46

176 75

140 56

28 21 3.5 105 - - 51

104

188 80

160 65 30 22 4.0 120 -

185 75 35 26 4.5 135 -

118

68 115

210 85 40 30 5.0 160 - - 80 135

245 100 45 34 5.5 200 218 230 100 160

Nodular iron (GJS)

50 - 115

60 - 125

60 - 145

270

295

340

110

120

140

6.0

6.5

7.0

225

255

290

246

276

315

260

290

330

113

127

147

180

200

230

112

60 - 160

80 - 185

85 - 200

375

425

475

155

175

185

7.5

9.0

320

370

10.5 420

345

400

450

360

415

465

165

190

220

255

290

325

124

140

156

100

110

125

140

160

180

3300

4800

6650

4950

7200

6185

9000

10000 12500

8550 12800 16000

12800 19200 24000

18650 28000 35000

1) Maximum torque of the coupling T

Kmax.

= rated torque of the coupling T

K rated

x 2

2) Bores H7 with keyway to DIN 6885 sheet 1 [JS9] and setscrew

3) For dimensions G and t see table 8; there is a setscrew on the keyway

4) D

= internal diameter of housing

Please observe protection note ISO 16016.

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1 Technical data

ROTEX ®

Operating/Assembly instructions

KTR-N

Sheet:

Edition:

40210 EN

5 of 27

Illustration 3: ROTEX ® (material: steel)

Table 5: Material steel

Size

Component

Spider 1) (component 2)

Rated torque [Nm]

92 ShA 98 ShA 64 ShD

Finish bore 2) d (min-max)

100

110

125

140

160

180

7.5

190

265

310

410

625

1280

2400

12.5

160

325

450

525

685

940

1920

3600

200

405

560

655

825

1175

2400

4500

3300

4800

6650

8550

4950

7200

10000

12800

6185

9000

12500

16000

12800 19200 24000

18650 28000 35000

0 - 16

0 - 25

0 - 35

0 - 40

0 - 48

0 - 55

0 - 62

0 - 75

0 - 80

0 - 95

0 - 110

0 - 115

0 - 125

60 - 145

60 - 160

80 - 185

85 - 200

1) Maximum torque of the coupling T

Kmax.

= rated torque of the coupling T

K rated

x 2

2) Bores H7 with keyway to DIN 6885 sheet 1 [JS9] and setscrew

3) For dimensions G and t see table 8; there is a setscrew on the keyway

4) D

= internal diameter of housing

L l

, l

Dimensions [mm]

3) b

General s D

4) d

D N

35 11

50 18.5

66 25

90 37

78 30

118 50

90 35

140 60

114 45

164 70

126 50

176 75

140 56

188 80

160 65

210 90

1.5

2.0

2.5

3.0

3.5

4.0

105

120

70 27

80 -

85 28

95 -

95 32

105 -

110 37

120 -

185 75

235 100

210 85

260 110

4.5

5.0

135

160

115 47

135 -

135 53

160 -

245 100

295 125

45 34 5.5 200 218 230 100

160 62

200 -

270 110 50 38 6.0 225 246 260 113 180 89

295 120 55 42 6.5 255 276 290 127 200 96

340 140 60 46 7.0 290 315 330 147 230 112

375 155 65 50 7.5 320 345 360 165 255 124

425 175 75 57 9.0 370 400 415 190 290 140

475 195 85 64 10.5 420 450 465 220 325 156

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1 Technical data

ROTEX ®

Operating/Assembly instructions

KTR-N

Sheet:

Edition:

40210 EN

6 of 27

Illustration 4: ROTEX ® type DKM

Table 6: Type DKM 5)

Size

Spider

(component 2)

Rated torque [Nm]

92 ShA 98 ShA

190

265

310

410

625

1280

2400

160

325

450

525

685

940

1920

3600

Dimensions d, D, D

DKM

112

128

158

174

192

218

252

286

330 l

, l

100

Dimensions [mm] 3) b

General s

2.0

2.5

3.0

3.5

4.0

4.5

5.0

5.5

1) Maximum torque of the coupling T

Kmax.

= rated torque of the coupling T

K rated

x 2

2) Bores H7 with keyway to DIN 6885 sheet 1 [JS9] and setscrew

3) For dimensions G and t see table 8; there is a setscrew on the keyway (only with Al-D opposite the keyway)

105

120

135

160

200

Please observe protection note ISO 16016.

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Replaced by: d

100 l11

KTR-N dated 2017-09-06 l12

102

116

130

1 Technical data

ROTEX ®

Operating/Assembly instructions

KTR-N

Sheet:

Edition:

40210 EN

7 of 27

Coupling design:

TB1 Screwing on cam side

TB2 Screwing on collar side

Different combinations of types TB1 and TB2 are possible.

100

125

Illustration 5: ROTEX ® type with taper clamping sleeve

Table 7: Type with taper clamping sleeve

Size

Component

Spider

(component 2)

Rated torque [Nm]

92 ShA 98 ShA

190

265

310

410

625

160

325

450

525

685

940

1280

2400

3300

6650

1920

3600

4950

10000

Finish bore d (min-max)

10 - 25

14 - 25

14 - 40

14 - 50

16 - 60

25 - 75

35 - 90

55 - 110

Dimensions [mm]

General

L l

, l

E b s D

2) d

64 23 18 14 2.0 55 -

66 23 20 15 2.5 65 -

70 23 24 18 3.0 80 -

78 26 26 20 3.0 95 -

106 39 28 21 3.5 105 -

96 33 30 22 4.0 120 -

101 33 35 26 4.5 135 -

104

118

115

144 52 40 30 5.0 160 - - 80 158 36

149 52 45 34 5.5 200 218 230 100 160 14

230 90 50 38 6.0 225 246 260 113 180 69

288 114 60 46 7.0 290 315 330 147 230 86

Taper clamping sleeve

1008

1108

1610

1615

2012

2517

3020 3)

3020

3535

4545

1) Maximum torque of the coupling T

Kmax.

= rated torque of the coupling T

K rated

x 2

2) D

= internal diameter of housing

3) Available for type TB2 only

ROTEX ® couplings with attachments that can generate heat, sparks and static charging

(e. g. combinations with brake drums, brake disks, overload systems such as torque limiters, fan impellers etc.) are not permitted for the use in potentially explosive atmospheres.

A separate analysis must be performed.

2 Advice

2.1 General advice

Please read through these operating/assembly instructions carefully before you start up the coupling.

Please pay special attention to the safety instructions!

The ROTEX ® coupling is suitable and approved for the use in potentially explosive atmospheres.

When using the coupling in potentially explosive atmospheres, observe the special advice and instructions regarding safety in enclosure A.

The operating/assembly instructions are part of your product. Please store them carefully and close to the coupling. The copyright for these operating/assembly instructions remains with KTR.

Please observe protection note ISO 16016.

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ROTEX ®

Operating/Assembly instructions

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Edition:

40210 EN

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2 Advice

2.2 Safety and advice symbols

Warning of potentially explosive atmospheres

This symbol indicates notes which may contribute to preventing bodily injuries or serious bodily injuries that may result in death caused by explosion.

STOP Warning of personal injury

This symbol indicates notes which may contribute to preventing bodily injuries or serious bodily injuries that may result in death.

Warning of product damages !



General advice

This symbol indicates notes which may contribute to preventing material or machine damage.

This symbol indicates notes which may contribute to preventing adverse results or conditions.

Warning of hot surfaces

This symbol indicates notes which may contribute to preventing burns with hot surfaces resulting in light to serious bodily injuries.

2.3 General hazard warnings

STOP

With assembly, operation and maintenance of the coupling it has to be made sure that the entire drive train is secured against accidental switch-on. You may be seriously hurt by rotating parts. Please make absolutely sure to read through and observe the following safety indications.

•

All operations on and with the coupling have to be performed taking into account "safety first".

•

Please make sure to switch off the power pack before you perform your work on the coupling.

•

Secure the power pack against accidental switch-on, e. g. by providing warning signs at the place of switch-on or removing the fuse for current supply.

•

Do not reach into the operating area of the coupling as long as it is in operation.

•

Please secure the coupling against accidental contact. Please provide for the necessary protection devices and covers.

2.4 Intended use

You may only assemble, operate and maintain the coupling if you

•

have carefully read through the operating/assembly instructions and understood them

•

are technically qualified and specifically trained (e. g. safety, environment, logistics)

•

are authorized by your company

The coupling may only be used in accordance with the technical data (see chapter 1). Unauthorized modifications on the coupling design are not admissible. We will not assume liability for any damage that may arise. In the interest of further development we reserve the right for technical modifications.

The ROTEX ® described in here corresponds to the technical status at the time of printing of these operating/assembly instructions.

Please observe protection note ISO 16016.

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ROTEX ®

Operating/Assembly instructions

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Sheet:

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2 Advice

2.5 Coupling selection

For a permanent and failure-free operation of the coupling it must be selected according to the selection instructions (according to DIN 740 part 2) for the particular application (see catalogue drive technology "ROTEX ® ").

If the operating conditions (performance, speed, modifications on engine and machine) change, the coupling selection must imperatively be reviewed.

Please make sure that the technical data regarding torque refer to the spider only. The transmittable torque of the shaft-hub-connection must be reviewed by the customer and is subject to his responsibility.

For drives subject to torsional vibrations (drives with cyclic stress due to torsional vibrations) it is necessary to perform a torsional vibration calculation to ensure a reliable selection. Typical drives subject to torsional vibrations are e. g. drives with diesel engines, piston pumps, piston compressors etc. If requested, KTR will perform the coupling selection and the torsional vibration calculation.

2.6 Reference to EC Machinery Directive 2006/42/EC

The couplings supplied by KTR should be considered as components, not machines or partly completed machines according to EC Machinery Directive 2006/42/EC. Consequently KTR does not have to issue a declaration of incorporation. For details about safe assembly, start-up and safe operation refer to the present operating/assembly instructions considering the warnings.

3 Storage, transport and packaging

3.1 Storage

The coupling hubs are supplied in preserved condition and can be stored at a dry and roofed place for 6 - 9 months.

The features of the coupling spiders (elastomers) remain unchanged for up to 5 years with favourable storage conditions.

The storage rooms must not include any ozone-generating devices like e. g. fluorescent light sources, mercury-vapour lamps or electrical high-voltage appliances.

Humid storage rooms are not suitable.

Please make sure that condensation is not generated. The best relative air humidity is less than 65 %.

3.2 Transport and packaging

In order to avoid any injuries and any kind of damage always make use of proper transport and lifting equipment.

The couplings are packed differently each depending on size, number and kind of transport. Unless otherwise contractually agreed, packaging will follow the in-house packaging specifications of KTR.

Please observe protection note ISO 16016.

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ROTEX ®

Operating/Assembly instructions

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Sheet:

Edition:

40210 EN

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4 Assembly

The coupling is generally supplied in individual parts. Before assembly the coupling has to be inspected for completeness.

4.1 Components of the coupling

Components of ROTEX ® , shaft coupling type No. 001

Component Number

1 2

5 2)

4 2

Description

Hub

Spider 1)

DZ elements 1)

Setscrews

DIN EN ISO 4029

1) Optionally spider or DZ elements

2) With size 180 the number is 6.

Illustration 6: ROTEX ®

Components of ROTEX ® type DKM 1)

Component Number Description

Hub

Spider

DKM spacer

Setscrews

DIN EN ISO 4029

1) Type DKM not available with DZ elements.

Components of ROTEX ® type with taper clamping sleeve

Illustration 7: ROTEX ® type DKM

Component Number Description

TB1/TB2

5 2)

Hub for taper clamping sleeve

Taper clamping sleeve

Spider 1)

DZ elements 1)

Setscrews

DIN EN ISO 4029

1) Optionally spider or DZ elements

2) With size 180 the number is 6.

Please observe protection note ISO 16016.

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ROTEX ®

Operating/Assembly instructions

4 Assembly

4.1 Components of the coupling

Features of standard spiders

Spider hardness

(Shore)

92 Shore A

T-PUR ®

(orange)

PUR

(yellow)

98 Shore A

T-PUR ®

(purple)

PUR

(red)

KTR-N

Sheet:

Edition:

40210 EN

11 of 27

T-PUR ®

64 Shore D

(light green)

PUR

(natural white 1) )

Marking

(colour)

1) Natural white with green marking of teeth

4.2 Advice for finish bore

STOP

The maximum permissible bore diameters d (see chapter

1 - technical data) must not be exceeded. If these figures are disregarded, the coupling may tear. Rotating particles may cause danger to life.

•

Hub bores machined by the customer have to observe concentricity or axial runout, respectively

(see illustration 9).

•

Make absolutely sure to observe the figures for Ø d max

•

Carefully align the hubs when the finish bores are drilled.

•

Provide for a setscrew according to DIN EN ISO 4029 with a cup point or an end plate to fasten the hubs axially.

Illustration 9: Concentricity and axial run-out

The customer bears the sole responsibility for all machining processes performed subsequently on unbored or pilot bored as well as finish machined coupling components and spare parts. KTR does not assume any warranty claims resulting from insufficient remachining.

KTR supplies unbored or pilot bored coupling components and spare parts only upon explicit request of the customer. These parts are additionally marked with the symbol .

Reference to unbored resp. pilot bored coupling components with explosion protection marking:

Basically the company KTR supplies couplings resp. coupling hubs with explosion protection marking as an unbored or pilot bored type only on explicit request of the customer. The prerequisite is a declaration of exemption submitted by the customer assuming any responsibility and liability for remachining performed properly.

Table 8: Setscrew DIN EN ISO 4029

Size

Dimension G

Dimension t

Tightening torque T

[Nm]

14 19 24 28 38 42 48 55 65 75 90 100 110 125 140 160 180

M4 M5 M5 M8 M8 M8 M8 M10 M10 M10 M12 M12 M16 M16 M20 M20 M20

5 10 10 15 15 20 20 20 20 25 30 30 35 40 45 50 50

1.5 2 2 10 10 10 10 17 17 17 40 40 80 80 140 140 140

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ROTEX ®

Operating/Assembly instructions

4 Assembly

4.2 Advice for finish bore

Table 9: Recommended fit pairs acc. to DIN 748-1

KTR-N

Sheet:

Edition:

40210 EN

12 of 27

Bore [mm] up to

Shaft tolerance Bore tolerance above

50 k6 m6

(KTR standard)

If a feather keyway is intended to be used in the hub, it should correspond to the tolerance ISO JS9 (KTR standard) with standard operating conditions or ISO P9 with complicated operating conditions (frequently alternating torsional direction, shock loads, etc.). The keyway should preferably be located between the cams.

With axial fastening via setscrew the tapped hole should be positioned on the keyway except for Al-D which should be positioned opposite the keyway.

The transmittable torque of the shaft-hub-connection must be reviewed by the customer and is subject to his responsibility.

4.3 Assembly of the hubs

 We recommend to inspect bores, shaft, keyway and feather key for dimensional accuracy before assembly.

Heating the hubs lightly (approx. 80 °C) allows for an easier mounting on the shaft.

Please pay attention to the ignition risk in potentially explosive atmospheres!

Touching the heated hubs causes burns.

STOP Please wear safety gloves.

With the assembly make sure that the distance dimension E (see table 1 to 7) is observed to allow for axial clearance of the spider when in operation.

Disregarding this advice may cause damage to the coupling.

If used in potentially explosive atmospheres the setscrews to fasten the hubs as well as all screw connections must be secured against working loose additionally, e. g. conglutinating with Loctite (average strength).

•

Mount the hubs on the shaft of driving and driven side (see illustration 10).

•

Insert the spider or DZ elements into the cam section of the hub on the driving or driven side.

•

Shift the power packs in axial direction until the distance dimension E is achieved (see illustration 11).

•

If the power packs are already firmly assembled, shifting the hubs axially on the shafts allows for setting the distance dimension E.

•

Fasten the hubs by tightening the setscrews DIN EN ISO 4029 with a cup point (tightening torques see table 8).

 If the shaft diameters with inserted feather key are smaller than dimension d

(see table 1 to

7) of the spider, one or two shaft ends may protude into the spider.

Please observe protection note ISO 16016.

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4 Assembly

4.3 Assembly of the hubs

ROTEX ®

Operating/Assembly instructions

KTR-N

Sheet:

Edition:

40210 EN

13 of 27

Illustration 10: Assembly of the hubs

4.4 Assembly of taper clamping sleeve

Assembly of taper clamping sleeve:

Illustration 11: Assembly of coupling

Clean the contact surfaces of the taper clamping sleeves and of shaft and hub and afterwards apply thin fluid oil lightly (e. g. Ballistol Universal oil or Klüber Quietsch-Ex).

The taper clamping sleeves have got axially parallel, cylindrical and smooth tapped blind holes. Only half of these holes are located in the material of the sleeve. The other half located in the hub has got threads.

Fit the coupling element and the taper clamping sleeve into each other, make sure that the bores cover each other and tighten the setscrews lightly. Fit the coupling element along with the taper clamping sleeve on the shaft and tighten the setscrews at the tightening torque specified in table 10.

During the screwing operation the hub is mounted onto the taper sleeve and thus the sleeve is pressed onto the shaft. By light blows of the hammer the taper clamping sleeve must be pushed further into the taper bore by means of a suitable sleeve. Afterwards re-tighten the setscrews at the tightening torque specified in table 10. This process must be performed at least once.

After operation under load of the drive for a short while please inspect if the setscrews have unscrewed.

Axial fixing of the Taper Lock hub (coupling hub with taper clamping sleeve) is obtained by proper assembly only.

If used in potentially explosive atmospheres the setscrews to fasten the taper clamping

! sleeves have to be secured against working loose additionally, e. g. conglutinating with

Loctite (average strength).

Taper clamping sleeves used without a feather key are not permitted in potentially explosive atmospheres and are thus not provided with a respective explosion protection marking.

Oils and greases with molybdenum disulphide or high-pressure additives, additives of

Teflon and silicone as well as internal lubricants reducing the coefficient of friction significantly must not be used.

Illustration 12: ROTEX ® type with taper clamping sleeve

Please observe protection note ISO 16016.

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ROTEX ®

Operating/Assembly instructions

4 Assembly

4.4 Assembly of taper clamping sleeve

Disassembly of taper clamping sleeve:

KTR-N

Sheet:

Edition:

40210 EN

14 of 27

The taper clamping sleeve is released by removing the setscrews. Afterwards one of the setscrews used as forcing screw is screwed in the thread of the sleeve and tightened.

The coupling hub untightened that way can be manually removed from the shaft with the taper clamping sleeve.

Table 10:

Taper clamping sleeve

1008

1108

1610

1615

2012

2517

3020

3535

4545

[inch]

1/4

3/8

7/16

1/2

5/8

1/2

3/4

Screw dimensions

L SW

[inch] [mm]

1/2

5/8

7/8

1 1/4

1 1/2

1 3/4

[Nm]

5.7

115

170

Number

Illustration 13: Withworth setscrew (BSW)

4.5 Displacements - alignment of the couplings

The displacement figures specified in tables 11 to 13 provide for sufficient safety to compensate for external influences like, for example, heat expansion or foundation settling.

In order to ensure a long service life of the coupling and avoid risks with the use in potentially explosive atmospheres, the shaft ends must be accurately aligned.

Please absolutely observe the displacement figures indicated (see table 11 to 13). If the figures are exceeded, the coupling will be damaged.

The more accurate the alignment of the coupling, the longer is its service life.

If used in potentially explosive atmospheres for explosion group IIC, only half of the

Please note: displacement figures (see table 11 to 13) are permissible.

•

The displacement figures specified in table 11 to 13 are maximum figures which must not arise in parallel. If radial and angular displacements arise at the same time, the permissible displacement values may only be used proportionally (see illustration 15).

•

Please inspect with a dial gauge, ruler or feeler whether the permissible displacement figures of tables 11 to

13 can be observed.

Angular displacements



K w

= L

1max.

- L

1min.

[mm]

Please observe protection note ISO 16016.

Drawn:

Verified:

Radial displacements

Illustration 14: Displacements

2019-07-02 Pz/Wb

2019-07-23 Pz

Replacing:

Replaced by:

Axial displacements

L max

= L +



K a

[mm]

KTR-N dated 2017-09-06

ROTEX ®

Operating/Assembly instructions

4 Assembly

4.5 Displacements - alignment of the couplings

Examples of the displacement combinations specified in illustration 15:

Example 1:



K r



K w

= 30 %

= 70 %

Example 2:



K r w

= 60 %

= 40 %

Illustration 15:

Combinations of displacement

KTR-N

Sheet:

Edition:

40210 EN

15 of 27



K total



K r



K w



100 %

Table 11: Displacement figures for 92 and 98 Shore A

Size

Max. axial displacement



K a

[mm]

14 19 24 28 38 42 48 55 65 75 90 100 110 125 140 160

-0.5 -0.5 -0.5 -0.7 -0.7 -1.0 -1.0 -1.0 -1.0 -1.5 -1.5 -1.5 -2.0 -2.0 -2.0 -2.5

180

-3.0

+1.0 +1.2 +1.4 +1.5 +1.8 +2.0 +2.1 +2.2 +2.6 +3.0 +3.4 +3.8 +4.2 +4.6 +5.0 +5.7 +6.4

Max. radial displacement



K r

[mm] with

1500 rpm 0.17 0.20 0.22 0.25 0.28 0.32 0.36 0.38 0.42 0.48 0.50 0.52 0.55 0.60 0.62 0.64 0.68

3000 rpm



K w

[degree]

0.11 0.13 0.15 0.17 0.19 0.21 0.25 0.26 0.28 0.32 0.34 0.36 0.38

1.2 1.2 0.9 0.9 1.0 1.0 1.1 1.1 1.2 1.2 1.2 1.2 1.3

1.3

1.2

1.2 max. angular displacement with n=1500 rpm



K w

[mm]



K w

[degree] max. angular displacement with n=3000 rpm



K w

[mm]

0.67 0.82 0.85 1.05 1.35 1.70 2.00 2.30 2.70 3.30 4.30 4.80 5.60 6.50 6.60 7.60 9.00

1.1 1.1 0.8 0.8 0.9 0.9 1.0 1.0 1.1 1.1 1.1 1.1 1.2

0.60 0.70 0.75 0.85 1.10 1.40 1.60 2.00 2.30 2.90 3.80 4.20 5.00

Table 12: Displacement figures for 64 Shore D

Size 14 19 24 28 38 42 48 55 65 75 90 100 110 125 140 160 180

Max. axial displacement



K a

[mm]

-0.5 -0.5 -0.5 -0.7 -0.7 -1.0 -1.0 -1.0 -1.0 -1.5 -1.5 -1.5 -2.0 -2.0 -2.0 -2.5 -3.0

+1.0 +1.2 +1.4 +1.5 +1.8 +2.0 +2.1 +2.2 +2.6 +3.0 +3.4 +3.8 +4.2 +4.6 +5.0 +5.7 +6.4

Max. radial displacement



K r

[mm] with

1500 rpm 0.11 0.13 0.15 0.18 0.21 0.23 0.25 0.27 0.30 0.34 0.36 0.37 0.40 0.43 0.45 0.46 0.49

3000 rpm



K w

[degree]

0.08 0.09 0.10 0.13 0.15 0.16 0.18 0.19 0.21 0.24 0.25 0.26 0.28

1.1 1.1 0.8 0.8 0.9 0.9 1.0 1.0 1.1 1.1 1.1 1.1 1.2

1.2

1.1

1.1 max. angular displacement with n=1500 rpm



K w

[mm]



K w

[degree] max. angular displacement with n=3000 rpm



K w

[mm]

0.57 0.77 0.77 0.90 1.25 1.40 1.80 2.00 2.50 3.00 3.80 4.30 5.30 6.00 6.10 7.10 8.00

1.0 1.0 0.7 0.7 0.8 0.8 0.9 0.9 1.0 1.0 1.0 1.0 1.1

0.52 0.70 0.67 0.80 1.00 1.30 1.60 1.80 2.20 2.70 3.50 4.00 4.90

Table 13: Displacement figures for type DKM only

Size

Max. axial displacement



K a

[mm]

Max. radial displacement



K r

[mm] with n =



K w

[degree] max. angular displacement with n =

1500 rpm

3000 rpm

1500 rpm

3000 rpm

19 24 28 38 42 48 55 65 75 90

+1.2 +1.4 +1.5 +1.8 +2.0 +2.1 +2.2 +2.6 +3.0 +3.4

-1.0 -1.0 -1.4 -1.4 -2.0 -2.0 -2.0 -2.0 -3.0 -3.0

0.45 0.59 0.66 0.77 0.84 0.91 1.01 1.17 1.33 1.48

0.40 0.53 0.60 0.70 0.75 0.82 0.81 1.05 1.19 1.33

1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0

0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.9

Please observe protection note ISO 16016.

Drawn:

Verified:

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2019-07-23 Pz

Replacing:

Replaced by:

KTR-N dated 2017-09-06

ROTEX ®

Operating/Assembly instructions

KTR-N

Sheet:

Edition:

40210 EN

16 of 27

5 Start-up

Before start-up of the coupling, inspect the tightening of setscrews in the hubs, the alignment and the distance dimension E and adjust, if necessary, and also inspect all screw connections for the tightening torques specified.

Finally the coupling protection against accidental contact must be fitted. It is required in accordance with

DIN EN ISO 12100 (Safety of Machinery) and directive 2014/34/EU and must protect against

•

access with the little finger

•

falling down of solid foreign objects.

The cover may provide for openings intended for necessary heat dissipation. These openings have to comply with

DIN EN ISO 13857.

The cover must be electrically conductive and included in the equipotential bonding. Bellhousings (magnesium share below 7.5 %) made of aluminium and damping rings (NBR) can be used as connecting element between pump and electric motor. The cover may only be taken off with standstill of the unit.

If the couplings are used in locations subject to dust explosion and in mining the user must make sure that there is no accumulation of dust in a dangerous volume between the cover and the coupling. The coupling must not operate in an accumulation of dust.

For covers with unlocked openings on the top face no light metals must be used if the couplings are used as equipment of equipment group ll (if possible, made of stainless

steel).

If the couplings are used in mining (equipment group l M2), the cover must not be made of light metal. In addition, it must be resistant to higher mechanical loads than with use as equipment of equipment group ll.

During operation of the coupling, please pay attention to

•

different operating noise

•

vibrations occurring.

If you note any irregularities with the coupling during operation, the drive unit must be switched off immediately. The cause of the breakdown must be specified by means of the table „Breakdowns“ and, if possible, be eliminated according to the proposals. The potential breakdowns specified can be hints only. To find out the cause all operating factors and machine components must be considered.

Coating of coupling:

If coated (priming, paintings, etc.) couplings are used in potentially explosive atmospheres, the requirements on conductibility and coating thickness must be considered. With paintings up to 200 µm electrostatic load does not have to be expected. Paintings and coatings exceeding a thickness of 200 µm are generally impermissible for potentially explosive atmospheres. This also applies for multiple coatings exceeding an overall thickness of 200 µm. Make sure with painting or coating that the coupling components are conductively connected with the device/devices to be connected so that the equipotential bonding is not impeded by the paint or coat applied. In addition, make sure that the marking of the coupling remains legible. Painting or coating of the spider is generally not admitted.

Please observe protection note ISO 16016.

Drawn:

Verified:

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2019-07-23 Pz

Replacing:

Replaced by:

KTR-N dated 2017-09-06

ROTEX ®

Operating/Assembly instructions

KTR-N

Sheet:

Edition:

40210 EN

17 of 27

6 Breakdowns, causes and elimination

The below-mentioned failures can lead to a use of the ROTEX ® coupling other than intended. In addition to the specifications given in these operating/assembly instructions make sure to avoid such failures.

The errors listed can only be clues to search for the failures. When searching for the failure the adjacent components must generally be considered.

If used other than intended the coupling can become a source of ignition.

EU directive 2014/34/EU requires special care by the manufacturer and the user.

General failures with use other than intended:

•

Important data for the coupling selection are not forwarded.

•

The calculation of the shaft-hub-connection is not considered.

•

Coupling components with damage occurred during transport are assembled.

•

If the heated hubs are assembled, the permissible temperature is exceeded.

•

The clearance of the components to be assembled is not coordinated with one another.

•

Tightening torques have been fallen below/exceeded.

•

Components are mixed up by mistake/assembled incorrectly.

•

A wrong or no spider/DZ elements are inserted in the coupling.

•

No original KTR components (purchased parts) are used.

•

Old/ spiders/DZ elements already worn off or spiders/DZ elements stored for too long are used.

•

Maintenance intervals are not observed.

Breakdowns Causes

Hazard notes for potentially explosive atmospheres

Elimination

Different operating noise and/or vibrations occuring

Misalignment

Wear of spider, shortterm torque transmission due to metal contact

Screws for axial fastening of hubs working loose

Increased temperature on the spider surface; ignition risk by hot surfaces

Ignition risk due to sparking

Ignition risk due to hot surfaces and sparking

1) Set the unit out of operation

2) Eliminate the reason for the misalignment

(e. g. loose foundation bolts, breaking of the engine mount, heat expansion of unit components, modification of the installation dimension E of the coupling)

3) For inspection of wear see chapter 10.2

1) Set the unit out of operation

2) Disassemble the coupling and remove residues of the spider

3) Inspect coupling components and replace coupling components that have been damaged

4) Insert spider, assemble coupling components

5) Inspect alignment, adjust if necessary

1) Set the unit out of operation

2) Inspect alignment of coupling

3) Tighten the screws to fasten the hubs and secure against working loose

4) For inspection of wear see chapter 10.2

Breaking of cams

Wear of spider, torque transmission due to metal contact

Breaking of the cams due to high impact energy/overload

Ignition risk due to sparking

1) Set the unit out of operation

2) Replace complete coupling

3) Inspect alignment

1) Set the unit out of operation

2) Replace complete coupling

3) Inspect alignment

4) Find out the reason for overload

Please observe protection note ISO 16016.

Drawn:

Verified:

2019-07-02 Pz/Wb

2019-07-23 Pz

Replacing:

Replaced by:

KTR-N dated 2017-09-06

ROTEX ®

Operating/Assembly instructions

KTR-N

Sheet:

Edition:

40210 EN

18 of 27

6 Breakdowns, causes and elimination

Breakdowns Causes

Hazard notes for potentially explosive atmospheres

Breaking of cams

Early wear of spider

(liquefaction of material inside the spider cam)

Operating parameters do not meet with the performance of the coupling

Operating error of the unit

Misalignment e. g. contact with aggressive liquids/oils, ozone influence, too high/low ambient temperatures etc. causing physical modification of the spider

Ambient/contact temperatures which are too high for the spider, max. permissible

-30 °C/+90 °C

Vibrations of drive

Elimination

Ignition risk due to sparking

Increased temperature on the spider surface; ignition risk by hot surfaces

Ignition risk due to sparking with metallic contact of the cams

1) Set the unit out of operation

2) Review the operating parameters and select a bigger coupling (consider mounting space)

3) Assemble new coupling size

4) Inspect alignment

1) Set the unit out of operation

2) Replace complete coupling

3) Inspect alignment

4) Instruct and train the service staff

1) Set the unit out of operation

2) Eliminate the reason for the misalignment

(e. g. loose foundation bolts, breaking of the engine mount, heat expansion of unit components, modification of the installation dimension E of the coupling)

3) For inspection of wear see chapter 10.2

1) Set the unit out of operation

2) Disassemble the coupling and remove residues of the spider

3) Inspect coupling components and replace coupling components that have been damaged

4) Insert spider, assemble coupling components

5) Inspect alignment, adjust if necessary

6) Make sure that further physical modifications of the spider are excluded

1) Set the unit out of operation

2) Disassemble the coupling and remove residues of the spider

3) Inspect coupling components and replace coupling components that have been damaged

4) Insert spider, assemble coupling components

5) Inspect alignment, adjust if necessary

6) Inspect and adjust ambient/contact temperature (correct by using other spider materials, if necessary)

1) Set the unit out of operation

2) Disassemble the coupling and remove residues of the spider

3) Inspect coupling components and replace coupling components that have been damaged

4) Insert spider, assemble coupling components

5) Inspect alignment, adjust if necessary

6) Find out the reason for the vibrations

(correct by spider with lower or higher Shore hardness, if necessary)

When operating with a worn spider (see chapter 10.3) proper operation is not ensured.

Please observe protection note ISO 16016.

Drawn:

Verified:

2019-07-02 Pz/Wb

2019-07-23 Pz

Replacing:

Replaced by:

KTR-N dated 2017-09-06

ROTEX ®

Operating/Assembly instructions

KTR-N

Sheet:

Edition:

40210 EN

19 of 27

7 Disposal

In respect of environmental protection we would ask you to dispose of the packaging resp. products on termination of their service life in accordance with the legal regulations and standards that apply.

•

Metal

Any metal components have to be cleaned and disposed of by scrap metal.

•

Nylon materials

Nylon materials have to be collected and disposed of by a waste disposal company.

8 Maintenance and service

ROTEX ® is a low-maintenance coupling. We recommend to perform a visual inspection on the coupling at least once a year . Please pay special attention to the condition of the coupling spiders.

•

Since the flexible machine bearings of the driving and driven side settle during the course of load, inspect the alignment of the coupling and re-align the coupling, if necessary.

•

The coupling components have to be inspected for damages.

•

The screw connections have to be visually inspected.

Having started up the coupling the tightening torques of the screws have to be inspected

! during the usual inspection intervals.

With the use in potentially explosive atmospheres observe chapter 10.2 "Inspection intervals for couplings in potentially explosive atmospheres".

9 Spares inventory, customer service addresses

We recommend to store major spare parts on site to ensure the readiness for use of the machine in case if a coupling fails.

Contact addresses of the KTR partners for spare parts and orders can be obtained from the KTR homepage at www.ktr.com.

 KTR does not assume any liability or warranty for the use of spare parts and accessories which are not provided by KTR and for the damages which may incur as a result.

Please observe protection note ISO 16016.

Drawn:

Verified:

2019-07-02 Pz/Wb

2019-07-23 Pz

Replacing:

Replaced by:

KTR-N dated 2017-09-06

ROTEX ®

Operating/Assembly instructions

KTR-N

Sheet:

Edition:

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20 of 27

10 Enclosure A

Advice and instructions regarding the use in potentially explosive atmospheres

Applicable hub designs/types: a) Hubs that may be used in group II, category 2 and 3 :

(hubs with feather keyway and hubs with CLAMPEX ® clamping set or clamping ring hubs)

•

1.0 Hub with feather keyway and setscrew

•

1.3 Hub with spline

•

1.4 Hub with feather keyway, without setscrew

•

2.1 Clamping hub single slot with feather keyway

•

2.3 Clamping hub single slot with spline

•

2.6 Clamping hub double slot with feather keyway

•

4.0 Hub with CLAMPEX ® clamping set KTR 150

•

4.1 Hub with CLAMPEX ® clamping set KTR 200

•

4.2 Hub with CLAMPEX ® clamping set KTR 250

•

4.3 Hub with CLAMPEX ® clamping set KTR 400

•

4.4 Hub with CLAMPEX ® clamping set KTR 401

•

6.0 Clamping ring hub

•

6.5 Clamping ring hub (hub type as 6.0, but external clamping screws only)

•

7.6 Half shell hub (DH) with feather keyway

•

7.9 Half shell hub (H) with feather keyway

Type standard, AFN, BFN, CF, CFN, DF, DFN, DKM, ZS-DKM, ZS-DKM-H, SP and TB with hubs corresponding to the specifications above b) Hubs which may be used in group II, category 3 only: hubs without feather keyway

•

2.0 Clamping hub single slot without feather keyway

•

2.5 Clamping hub double slot without feather keyway

•

2.8 Clamping hub with axial slot without feather keyway

7.5 Half shell hub (DH) without feather keyway

•

7.8 Half shell hub (H) without feather keyway

•

Type standard, AFN, BFN, CF, CFN, DKM, ZS-DKM, ZS-DKM-H and SP with hubs corresponding to the specifications above

ROTEX ® DKM and ROTEX ® ZS-DKM only with spacer made of steel or aluminium semi-finished products with a yield point of R p0.2

≥ 250 N/mm 2 .

Hubs, clamping hubs or similar types without feather keyways may be used in category 3 only and are marked with category 3 accordingly.

The hubs types 1.1 and 1.2 are not approved for potentially explosive atmospheres!

Please observe protection note ISO 16016.

Drawn:

Verified:

2019-07-02 Pz/Wb

2019-07-23 Pz

Replacing:

Replaced by:

KTR-N dated 2017-09-06

ROTEX ®

Operating/Assembly instructions

10 Enclosure A

Advice and instructions regarding the use in

KTR-N

Sheet:

Edition:

40210 EN

21 of 27

potentially explosive atmospheres

10.1 Intended use in potentially explosive atmospheres

Conditions of operation in potentially explosive atmospheres

ROTEX ® couplings are suitable for the use according to EU directive 2014/34/EU.

1. Industry (with the exception of mining)

•

Equipment group II of category 2 and 3 ( coupling is not approved/not suitable for equipment group 1 )

•

Substance group G ( gases, fogs, vapours ), zone 1 and 2 ( coupling is not approved/not suitable for zone 0 )

•

Substance group D ( dusts ), zone 21 and 22 ( coupling is not approved/not suitable for zone 20 )

•

Explosion group IIC ( gases, fogs, vapours ) (explosion group IIA and IIB are included in IIC) and explosion group IIIC ( dusts ) (explosion group IIIA and IIIB are included in IIIC)

Temperature class:

Temperature class

PUR / T-PUR ®

Ambient or operating temperature T a

-30 °C to +90 °C

-30 °C to +75 °C

-30 °C to +60 °C

Max. surface temperature 2)

+110 °C

+95 °C

+80 °C

Explanation:

The maximum surface temperatures each result from the maximum permissible ambient or operating temperature T a

plus the maximum temperature increase



T of 20 K to be considered. For the temperature class a safety margin subject to standard of 5 K is added.

1) The ambient or operating temperature T a

is limited to +90 °C due to the permissible permanent operating temperature of the elastomers used.

2) The maximum surface temperature of +110 °C applies for the use in locations which are potentially subject to dust explosion.

In potentially explosive atmospheres

•

the ignition temperature of dusts generated must at least be 1.5 times the surface temperature to be considered

•

the glow temperature must at least be the surface temperature to be considered plus a safety distance of 75 K.

•

the gases and vapours generated must amount to the temperature class specified.

2. Mining

Equipment group I of category M2 (coupling is not approved/not suitable for equipment group M1).

Permissible ambient temperature -30 °C to +90 °C.

Please observe protection note ISO 16016.

Drawn:

Verified:

2019-07-02 Pz/Wb

2019-07-23 Pz

Replacing:

Replaced by:

KTR-N dated 2017-09-06

ROTEX ®

Operating/Assembly instructions

10 Enclosure A

Advice and instructions regarding the use in

KTR-N

Sheet:

Edition:

40210 EN

22 of 27

potentially explosive atmospheres

10.2 Inspection intervals for couplings in potentially explosive atmospheres

Equipment category Inspection intervals

No gases and vapours of explosion group IIC

Gases and vapours of explosion group IIC

For couplings operated in zone 2 or zone 22 the inspection and maintenance intervals of the usual operating/assembly instructions for standard operation apply. During the standard operation which has to be taken as a basis of the ignition risk analysis the couplings are free from any ignition source. For gases, vapours and dusts generated the permissible glow and ignition temperatures specified in chapter 10.1 have to be considered and observed.

An inspection of the torsional backlash and a visual inspection of the flexible spider/DZ elements must be performed after 3,000 operating hours for the first time, at the latest after 6 months after start-up of the coupling.

If you note insignificant or no wear on the spider/DZ elements upon this initial inspection, further inspections can each be performed after 6,000 operating hours or at the latest after 18 months, provided that the operating parameters remain the same.

If you note significant wear during the initial inspection so that it would be recommendable to replace the spider/DZ elements, find out the cause according to the table „Breakdowns“, if possible.

The maintenance intervals must be adjusted to the modified operating parameters without fail.

An inspection of the torsional backlash and a visual inspection of the flexible spider/DZ elements must be performed after 2,000 operating hours for the first time, at the latest after 3 months after start-up of the coupling.

If you note insignificant or no wear on the spider/DZ elements upon this initial inspection, further inspections can each be performed after 4,000 operating hours or at the latest after 12 months, provided that the operating parameters remain the same.

The maintenance intervals must be adjusted to the modified operating parameters without fail.

Hubs, clamping hubs or similar types without feather keyways may be used in category 3 only and are marked with category 3 accordingly.

Please observe protection note ISO 16016.

Drawn:

Verified:

2019-07-02 Pz/Wb

2019-07-23 Pz

Replacing:

Replaced by:

KTR-N dated 2017-09-06

ROTEX ®

Operating/Assembly instructions

10 Enclosure A

Advice and instructions regarding the use in

KTR-N

Sheet:

Edition:

40210 EN

23 of 27

potentially explosive atmospheres

10.2 Inspection intervals for couplings in potentially explosive atmospheres

ROTEX ® coupling

Illustration 17.1:

ROTEX ® DZ elements

Illustration 17.2:

ROTEX ® spider

Illustration 16: ROTEX ® coupling

Here the backlash between the cams of the coupling and the flexible spider/DZ element must be inspected by means of a feeler gauge.

When reaching the wear limit maximum wear , the spider/DZ element must be replaced immediately, irrespective of the inspection intervals.

Please observe protection note ISO 16016.

Drawn:

Verified:

2019-07-02 Pz/Wb

2019-07-23 Pz

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Replaced by:

KTR-N dated 2017-09-06

ROTEX ®

Operating/Assembly instructions

KTR-N

Sheet:

Edition:

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24 of 27

10 Enclosure A

Advice and instructions regarding the use in

10.3 Standard values of wear

potentially explosive atmospheres

In case of backlash > X mm, the flexible spider/DZ elements must be replaced.

The general condition of the coupling can both be monitored at standstill and during operation. If the coupling is tested during operation, the operator must ensure an appropriate and proven test procedure (e. g. stroboscopic lamp, high-speed camera, etc.) which is definitely comparable to testing at standstill. Should any distinctive features arise, testing must be performed with the machine at standstill.

Reaching the limits for replacing depends on the operating conditions and the existing operating parameters.

In order to ensure a long service life of the coupling and avoid risks with the use in

! potentially explosive atmospheres, the shaft ends must be accurately aligned.

Please absolutely observe the displacement figures indicated (see table 11 to 13). If the figures are exceeded, the coupling will be damaged.

Table 14:

Illustration 18: Inspection of the limit of wear

Size

Limits of wear (friction)

X max.

[mm]

Please observe protection note ISO 16016.

Drawn:

Verified:

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2019-07-23 Pz

Size

100

110

125

140

160

180

Illustration 19: Wear of spider

Replacing:

Replaced by:

Limits of wear (friction)

X max.

[mm]

KTR-N dated 2017-09-06

ROTEX ®

Operating/Assembly instructions

10 Enclosure A

Advice and instructions regarding the use in

KTR-N

Sheet:

Edition:

40210 EN

25 of 27

potentially explosive atmospheres

10.4 marking of coupling for potentially explosive atmospheres

The ATEX marking of the ROTEX ® coupling is applied on the outer sheath or on the front side.

The flexible spider resp. DZ element is not marked.

For the complete marking refer to the operating/assembly instructions and/or the delivery note/package.

The following marking applies for the products:

•

Hubs resp. spacer without aluminium

Category 2 (hubs resp. clamping hubs with feather keyway)

ROTEX ®

<Year>

I M2 Ex h I

II 2G Ex h IIC T6

… T4

II 2D Ex h IIIC T80 °C … T110 °C Db

30 °C ≤ T a

≤ +60 °C … +90 °C

KTR Systems GmbH, Carl-Zeiss-Straße 25, D-48432 Rheine

•

Hubs resp. spacer without aluminium

Category 3 (hubs resp. clamping hubs without feather keyway)

ROTEX ®

<Year>

I M2 Ex h I Mb

II 3G Ex h IIC T6 … T4 Gc

II 3D Ex h IIIC T80 °C

… T110 °C Dc

30 °C ≤ T a

≤ +60 °C … +90 °C

KTR Systems GmbH, Carl-Zeiss-Straße 25, D-48432 Rheine

•

Hubs resp. spacer made of aluminium only

Category 2 (hubs resp. clamping hubs with feather keyway)

ROTEX ®

<Year>

II 2G Ex h IIC T6 … T4 Gb

II 2D Ex h IIIC T80 °C … T110 °C Db

30 °C ≤ T a

≤ +60 °C … +90 °C

KTR Systems GmbH, Carl-Zeiss-Straße 25, D-48432 Rheine

•

Hubs resp. spacer made of aluminium only

Category 3 (hubs resp. clamping hubs without feather keyway)

ROTEX ®

<Year>

II 3G Ex h IIC T6 … T4 Gc

II 3D Ex h IIIC T80 °C

… T110 °C Dc

30 °C ≤ T a

≤ +60 °C … +90 °C

KTR Systems GmbH, Carl-Zeiss-Straße 25, D-48432 Rheine

Short marking:

(A short marking is only made if there is no other option for reason of space or functioning.)

ROTEX

<Year>

Please observe protection note ISO 16016.

Drawn:

Verified:

2019-07-02 Pz/Wb

2019-07-23 Pz

Replacing:

Replaced by:

KTR-N dated 2017-09-06

ROTEX ®

Operating/Assembly instructions

10 Enclosure A

Advice and instructions regarding the use in

KTR-N

Sheet:

Edition:

40210 EN

26 of 27

potentially explosive atmospheres

10.4 marking of coupling for potentially explosive atmospheres

Deviating marking applies until 31st October 2019:

Short marking:

II 2GD c IIC T X/I M2 c X

Complete marking:

(valid for T-PUR ® only)

II 2G c IIC T6, T5, T4 resp. T3 -50 °C



T a



+65 °C, +80 °C,

+115 °C resp. +120 °C

II 2D c T 140 °C/I M2 c -50 °C



T a



+120 °C

Complete marking:

(valid for PUR only)

II 2G c IIC T6, T5 resp. T4 -30 °C



T a



+65 °C, +80 °C resp.

+90 °C

II 2D c T 110 °C/I M2 c -30 °C



T a



+90 °C

Substance group - gases, fogs and vapours:

The marking with explosion group llC includes explosion groups llA and llB.

Substance group - dusts:

The marking with explosion group lIlC includes explosion groups lIlA and lIlB.

If the symbol was punched in addition to marking , the coupling component was supplied by KTR as an unbored or pilot bored version (see chapter 4.2 of the present operating/assembly instructions).

Please observe protection note ISO 16016.

Drawn:

Verified:

2019-07-02 Pz/Wb

2019-07-23 Pz

Replacing:

Replaced by:

KTR-N dated 2017-09-06

ROTEX ®

Operating/Assembly instructions

KTR-N

Sheet:

Edition:

40210 EN

27 of 27

10 Enclosure A

Advice and instructions regarding the use in

10.5 EU Certificate of conformity

potentially explosive atmospheres

EU Certificate of conformity

corresponding to EU directive 2014/34/EU dated 26 February 2014 and to the legal regulations

The manufacturer - KTR Systems GmbH, D-48432 Rheine - states that the flexible ROTEX ® couplings in an explosion-proof design described in the present operating/assembly instructions are devices corresponding to article 2, 1. of directive 2014/34/EU and comply with the general safety and health requirements according to enclosure II of directive 2014/34/EU.

The coupling described in here complies with the specifications of the following standards/rules:

DIN EN ISO 80079-36

DIN EN ISO 80079-37

DIN EN ISO 80079-38

IEC/TS 60079-32-1

The ROTEX ® is in accordance with the specifications of directive 2014/34/EU.

According to article 13 (1) b) ii) of directive 2014/34/EU the technical documentation is deposited with the notified body (type examination certificate IBExU13ATEXB016 X):

IBExU

Institut für Sicherheitstechnik GmbH

Identification number: 0637

Fuchsmühlenweg 7

09599 Freiberg

Rheine,

Place

2019-07-02

Date i. V.

Reinhard Wibbeling

Engineering/R&D i. V.

Michael Brüning