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KNF 325089 11/22 ATEX N630.12 EX TRANSLATION OF ORIGINAL OPERATION AND INSTALLATION INSTRUCTION ENGLISH DIAPHRAGM PUMP Notice! Before operating the pump and accessories, read and observe the operating and installation instructions as well as the safety information! KNF Neuberger GmbH Alter Weg 3 79112 Freiburg Germany Tel. +49 (0)7664/5909-0 Fax. +49 (0)7664/5909-99 www.knf.com Index 1 About this document ......................................................... 3 1.1 Using the operating and installation instructions....... 3 1.2 Exclusion of liability................................................... 3 1.3 Symbols and markings.............................................. 4 2 Use.................................................................................... 6 2.1 Proper use ................................................................ 6 2.2 Improper use............................................................. 7 2.3 Use in potentially explosive areas............................. 7 2.4 Explanations of the explosion protection designation .................................................................................. 8 3 Safety .............................................................................. 12 4 Technical data................................................................. 14 4.1 Technical data......................................................... 14 5 Product description and function..................................... 17 6 Transport......................................................................... 20 General ................................................................... 20 Transport with carrying strap .................................. 21 Transporting with lifting eyebolt .............................. 22 7 Installation and connection.............................................. 24 7.1 Installing the pump.................................................. 24 7.2 Electrical connection ............................................... 27 7.3 Pneumatic connection............................................. 28 7.4 Installing monitoring device and monitoring diaphragm innerspace ............................................... 30 7.5 Connecting water cooling (optional)........................ 30 8 Operation ........................................................................ 34 8.1 General ................................................................... 34 8.2 Information on switching the pump on and off ........ 36 9 Servicing ......................................................................... 37 9.1 Servicing schedule.................................................. 37 9.2 Cleaning.................................................................. 39 9.3 Changing diaphragm and reed valves .................... 39 9.4 Checking and replacing sprocket on coupling ........ 45 10 Troubleshooting .............................................................. 49 11 Spare parts and accessories........................................... 52 11.1 Spare parts ............................................................. 52 11.2 Accessories............................................................. 52 12 Returns............................................................................ 53 13 Appendix ......................................................................... 54 13.1 Declaration of Conformity ....................................... 54 13.2 Motor....................................................................... 59 13.3 Coupling................................................................ 118 Diaphragm pump N630.12 EX About this document 1 About this document 1.1 Using the operating and installation instructions The operating and installation instructions are part of the pump. 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. à 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. 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. Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 3 About this document Diaphragm pump N630.12 EX 1.3 Symbols and markings Warning notice A notice that warns you of danger is located here. WARNING 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 Consequences if not observed warns of immediate Death or serious injury danger or serious damage will result. warns of possible dan- Death, serious injury or ger serious damage is possible. warns of a possibly Minor injury or damage dangerous situation is possible. warns of possible dam- Damage is possible. age 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. 4 Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 Diaphragm pump N630.12 EX About this document Explanations of pictograms Pictogram Meaning General warning symbol 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 Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 5 Use Diaphragm pump N630.12 EX 2 Use 2.1 Proper use The pumps are intended exclusively for transferring gases and vapors. Responsibility of the owner Operating parameters and Only install and operate the pumps in accordance with the operating paconditions rameters and conditions described in Chapter 4 Technical dataand Chapter 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. Protect the compressors with a pressure relief device between the pressure side of the compressor and the first shut-off valve. 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. Requirements on the transferred Before transferring a medium, check whether the medium can be transmedium ferred danger-free in the specific application. When doing so, take note of any change in the condition of the aggregate (condensation, crystallization). 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 the working diaphragm breaks: Depending on the medium being transferred, breakage of the working diaphragm can result in a dangerous mixture if the medium mixes with the air in the innerspace between the working diaphragm and the safety diaphragm: § KNF recommends monitoring the innerspace between the working diaphragm and the safety diaphragm (see item 5 in Fig. 4) through the hole(s) in the intermediate ring for a change in pressure. If the pressure changes in the innerspace, the pump is to be stopped immediately. § After breakage of the working diaphragm, the pump must be stopped immediately. Replace the working diaphragm and safety diaphragm prior to further operation (see Chapter 9 Servicing). § If pressure or flow rate changes without apparent reason, switch off the pump immediately and check the pump for damage. 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). 6 Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 Diaphragm pump N630.12 EX Use 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. 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 II 2/2G 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) Ex h IIB + H2 T3 Gb 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". Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 7 Use Diaphragm pump N630.12 EX 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. 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 cat- Description egory 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. 1D 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. 2G 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. 2/2G 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. 2/-G Devices that extract from zone 1 but are not designed for installation in a potentially explosive atmosphere (zone). 2D 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. 3G 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. 3/-G Devices that extract from zone 2 but are not designed for installation in a potentially explosive atmosphere (zone). 3D 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 8 Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 Diaphragm pump N630.12 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. T1 I Methane IIA Acetone Ethane Ethyl acetate Ammonia Ethyl chloride Benzene Acetic acid Carbon monoxide T2 T3 – – i-amyl acGasoline etate Diesel fuel n-butane Jet fuel n-butyl alco- Heating oils hol n-hexane Cyclohexanone 1,2dichloroetha ne Acetic anhydride Methane Methanol Methyl chloride Naphthalene Phenol Propane Toluene IIB Town gas Ethylene Hydrogen Ethyl alcohol sulfide IIC Hydrogen Acetylene – T4 – 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. Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 9 Use Diaphragm pump N630.12 EX 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 T1 T2 T3 T4 T5 T6 Max. surface temperature [°C] 450 300 200 135 100 85 Ignition temperature [°C] > 450 > 300 > 200 > 135 > 100 > 85 Tab.6 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 Description Constructional safety "c" Ignition source monitoring "b" Liquid immersion "k" Tab.7 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". 10 Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 Diaphragm pump N630.12 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 Ga Gb Gc Description* Constructional safety Devices with very high protection level Very high 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. Devices with high protection level for High 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. Device with increased protection level Increased 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 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. Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 11 Safety Diaphragm pump N630.12 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. Make sure that the personnel have read and understood the operating instructions, particularly the chapter on safety. Working in a safety conscious Observe the regulations on accident prevention and safety during all work manner 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. 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. Double diaphragm system For pump models with a double diaphragm system, a second diaphragm is located below the working diaphragm. This safety diaphragm is under less strain during pump operation, i.e. it is under significantly less tension than the working diaphragm. In the event of a defect to the working diaphragm, no gas can escape from the pump. The closed safety space between the two diaphragms can be monitored to immediately detect damage to the working diaphragm. In such a case, the pump must be brought to a standstill within 24 hours by the system owner and the working and safety diaphragm must be replaced. Classification of a pump When classifying a pump environment in a potentially explosive area environment (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. Use in potentially explosive The following applies for use in a potentially explosive environment conenvironment sisting 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. 12 Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 Diaphragm pump N630.12 EX Safety 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. § Only use tools and lifting gear that are approved for use in potentially explosive atmospheres. Handling of hazardous media Upon breakage of the working diaphragm and/or leaks, the transferred medium mixes with the air in the innerspace between the working diaphragm and the safety diaphragm and/or with the air in the surroundings. 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. Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 13 Technical data Diaphragm pump N630.12 EX 4 Technical data 4.1 Technical data Pump materials N630ST.12E EX N630.1.2.ST12E EX N630.3.ST12E EX Assembly Head plate, intermediate plate Intermediate ring Working diaphragm Safety diaphragm Valves Valve limiter Slotted cap screw O-rings Conrod plate Retainer plate Retainer plate screw Connection (only N630.1.2.12, N630.3.12) Material Stainless steel Aluminum PTFE-coated EPDM Stainless steel Stainless steel Stainless steel FPM Aluminum Stainless steel Stainless steel Stainless steel Tab.9 Pneumatic values Parameter Value N630.12 Max. permissible oper- 3 ating pressure [bar rel*] -Continuous operation Ultimate vacuum [mbar 120 abs.] Flow rate at atm. pressure [l/min]** -50 Hz 30 -60 Hz 35 Value N630.1.2.12 3 Value N630.3.12 0.5 120 25 58 68 30 35 Tab.10 *Bar rel related to 1013 hPa **Liters in standard state (1013 hPa, 20 °C) Pneumatic connections Pump type N630.12, N630.3.12 N630.1.2.12 Value Thread size G 1/4* For hose Ø 10 Tab.11 *Acc. to ISO 228 14 Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 Diaphragm pump N630.12 EX Technical data Connection for water cooling Pump type Value N630.12 Thread size G 1/4* N630.1.2.12 Thread size G 1/4* N630.3.12 Thread size G 1/4* Hole for pressure monitoring of the Thread size G 1/8* inner space between the working diaphragm and safety diaphragm (see 7.4 Installing monitoring device and monitoring diaphragm innerspace) Tab.12 *Acc. to ISO 228 Other parameters Parameter Permissible ambient temperature [°C] Permissible media temperature [°C] Dimensions N630.12 EX N630.1.2.12 EX N630.3.12 EX Gas tightness* of the pump head Protection class of pump Noise*** Value +5 to +40 +5 to +40 See Fig. 9, Kapitel 7.1 Installing the pump See Fig. 11, Kapitel 7.1 Installing the pump See Fig. 10, Chapter 7.1 Installing the pump < 5 x 10-5 mbar l/s** IP 20 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 **Values apply for helium leak test ***Max. emission sound pressure level over the entire pressure range with gas connections attached Electrical data Parameter Voltage [V] Frequency [Hz] Power P1 [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 Frequency converter suitability (speed range) Max. permissible line voltage fluctu- See operating instructions for drive ations Relative air humidity 80% for temperatures to 31 °C, decreasing linearly to 50% at 40 °C (non-condensing). Max. installation altitude See operating instructions for drive Tab.14 Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 15 Technical data Diaphragm pump N630.12 EX Weight Pump type N630.12 N630.1.2.12 N630.3.12 Value [kg] Approx. 41 Approx. 49 Approx. 49 Tab.15 Start-up against pressure/ vacuum Please contact KNF Customer Service. Coupling Parameter EX-designation Size Value II 2G h IIC T6…T4 Gb 24 Tab.16 16 Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 Diaphragm pump N630.12 EX Product description and function 5 Product description and function Design 1 Connection for water cooling 2 Pneumatic pump outlet 3 Pneumatic pump inlet 4 Electrical terminal box 5 Motor fan cover 6 Motor 7 Screw plug of the hole for pressure monitoring of the diaphragm innerspace (2x per head) 31 12 4 5 7 6 Fig.1 Design N630.12 EX 1 Union nut 2 Connection for water cooling 3 Pneumatic connection 4 Pneumatic pump inlet 5 Motor 6 Motor fan cover 7 Electrical terminal box 8 Screw plug of the hole for pressure monitoring of the diaphragm innerspace (1x per head) 9 Pneumatic pump outlet 2 1 2 1 3 6 7 9 4 8 5 Fig.2 Design N630.3.12 EX Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 17 Product description and function 1 Union nut 2 Connection for water cooling 3 Pneumatic connection 4 Pneumatic pump inlet 5 Motor 6 Motor fan cover 7 Electrical terminal box 8 Screw plug of the hole for pressure monitoring of the diaphragm innerspace (1x per head) 9 Pneumatic pump outlet Diaphragm pump N630.12 EX 2 1 2 3 1 7 6 9 8 4 5 Fig.3 Design N630.1.2.12 EX 18 Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 Diaphragm pump N630.12 EX Product description and function Function of double diaphragm pump 1 Outlet valve 2 Inlet valve 3 Transfer chamber 4 Working diaphragm 5 Innerspace 6 Hole for pressure monitoring of the innerspace (5) 7 Safety diaphragm 8 Eccentric 9 Connecting rod 2 3 4 5 1 6 7 8 9 Fig.4 Function principle of double diaphragm pump Double diaphragm pumps transfer, compress (depending on the version) and evacuate gases and vapors. The elastic working diaphragm (4) is moved up and down by the eccentric (8) and the connecting rod (9). In the downwards stroke, it aspirates the gas to be transferred via the inlet valve (2). In the upwards stroke, the working 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 working diaphragm. Located below the working diaphragm is a second diaphragm (safety diaphragm (7)), which is under less mechanical stress during pump operation. Should the working diaphragm be damaged, no gas can escape from the pump. The closed innerspace (5) between the two diaphragms can be monitored for pressure change with the help of the hole(s) (6) provided for this purpose. Damage to the working diaphragm and safety diaphragm can thereby be detected immediately. Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 19 Transport Diaphragm pump N630.12 EX 6 Transport General Personal injury and/or property damage due to incorrect or improper transport of the pump CAUTION 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). Risk of injury from sharp edges on the packaging CAUTION 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: Personal injury and/or property damage due to incorrect or improper transport of the pump CAUTION 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. 20 Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 Diaphragm pump N630.12 EX Transport Parameter Parameter Value Storage temperature [°C] + 5 to + 40 Transport temperature [°C] - 10 to + 60 Permissible humidity (non-condens- 30 to 85 ing) [%] Max. storage period 48 (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.5 Position of carrying strap (example) 1. Pull the carrying strap under the pump (see Fig. 5). Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 21 Transport Diaphragm pump N630.12 EX Fig.6 Fastening the carrying strap (pump shown as an example) 2. Fasten the carrying strap between compressor housing and motor (Fig. 1, see Fig. 6). 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). 1 M12 screw Fig.7 Loosen the M12 screw (pump illustrated as an example) 22 Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 Diaphragm pump N630.12 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.8 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. Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 23 Installation and connection Diaphragm pump N630.12 EX 7 Installation and connection The pumps are only to be installed in accordance with the operating parameters and conditions described in Chapter 4 Technical data. à Observe the safety notices (see Chapter Safety). Risk of dangerous gas mixtures during pump operation DANGER 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. 7.1 Installing the pump à Store the pump at the installation site prior to installation to bring it up to the ambient temperature. Mounting dimensions à For mounting dimensions, see following figures: Fig.9 Mounting dimensions N630.12 EX 24 Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 Diaphragm pump N630.12 EX Installation and connection Fig.10 Mounting dimensions N630.3.12 EX Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 25 Installation and connection Diaphragm pump N630.12 EX Fig.11 Mounting dimensions N630.1.2.12 EX Cooling air supply 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. WARNING à Ensure sufficient ventilation or heat dissipation in the vicinity of the pump. Danger of burning on hot surfaces Hot surfaces could occur if the pump overheats. à When installing the pump, make sure that WARNING Immediate environment of the hot pump parts Installation location sufficient cooling air infeed and discharge is ensured. 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. 26 Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 Diaphragm pump N630.12 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. Personal injury and/or property damage from vibrations WARNING 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. Protection against foreign objects à Protect the pump against contact and the ingress of foreign bodies. 7.2 Electrical connection Danger to life from electric shock à Only have the pump connected by an authorized specialist. DANGER à Only have the pump connected if the power supply is disconnected. Risk of explosion from electrostatic charge à Connect the pump so that the risk of ignition from electrostatic charge is avoided. WARNING 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. Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 27 Installation and connection Diaphragm pump N630.12 EX Automatic restart after interruption of the power supply WARNING 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. à Install a device for separating the pump motor from the electrical mains in the electrical installation. à 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. Potentially explosive atmospheres à Only place the electrical equipment that is necessary for the operation of the pump . à Take lightning protection measures. Fastening the connection cables à 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) PTC thermistor sensor 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 Personal injury or property damage through ejected plugs CAUTION 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 à Only connect components to the pump that are designed for the pneumatic data and thermal requirements of the pump. (see Chapter 4 Technical data). Pressure relief device 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. 28 Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 Diaphragm pump N630.12 EX Installation and connection Risk of explosion during pressure limitation resulting from the medium mixing with the environment à Make certain that there is no risk of explosion WARNING Pump discharge posed by the medium mixing with the environment. 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. 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. Risk of injury from mixing up suction side and pressure side CAUTION 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 dimensions, 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. Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 29 Installation and connection Diaphragm pump N630.12 EX 7.4 Installing monitoring device and monitoring diaphragm innerspace Risk of dangerous gas mixtures during pump operation if the working diaphragm breaks WARNING Depending on the medium being transferred, breakage of the working diaphragm can result in a dangerous mixture if the medium mixes with the air in the innerspace between the working diaphragm and the safety diaphragm. à KNF recommends monitoring the innerspace between the working diaphragm and the safety diaphragm (see Fig. 4) through the hole(s) (see Fig. 12) in the intermediate ring for a change in pressure or the presence of gas. If the pressure changes in the innerspace, the pump is to be stopped immediately. Fig.12 Sectional drawing of hole for pressure monitoring à Immediately stop the pump if the working diaphragm breaks. Replace the working diaphragm and safety diaphragm prior to further operation (see Chapter 9 Servicing). 7.5 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] Water pressure [bar g] Water flow rate [l/min] Value + 5 to + 30 < 1.0 > 1.0 Tab.18 Recommended parameters for connecting the water cooling 1. Connect the water cooling system to the provided hose connections. à Safely drain the water discharge. The flow direction is allowed in both directions. Mounting dimensions For mounting dimensions, see the following dimensional drawings: 30 Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 Diaphragm pump N630.12 EX Installation and connection Fig.13 Mounting dimensions N630.12 EX Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 31 Installation and connection Diaphragm pump N630.12 EX Fig.14 Mounting dimensions N630.3.12 EX 32 Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 Diaphragm pump N630.12 EX Installation and connection Fig.15 Mounting dimensions N630.1.2.12 EX Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 33 Operation Diaphragm pump N630.12 EX 8 Operation 8.1 General Risk of burns from hot pump parts and/or hot medium WARNING 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. Damage to the pump due to oveheating WARNING 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. Risk of explosion due to excessively high surface temperature WARNING 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. 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. 34 Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 Diaphragm pump N630.12 EX Operation Injury to eyes WARNING 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. 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). à Eliminate the possibility of improper use of the pumps (see Chapter 2.2 Improper use). à Observe safety notices (Chapter 3 Safety). Risk of pump head bursting due to excessive pressure increase à Do not exceed the maximum permissible op- WARNING erating 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. Risk of explosion from elevated ambient temperature à Monitor the ambient temperature (compres- WARNING sion heat, motor heat). à Ensure sufficient cooling air supply. Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 35 Operation Diaphragm pump N630.12 EX Risk of dangerous gas mixtures during pump operation if the working diaphragm breaks WARNING If the working diaphragm should break, the medium will mix with the air in the innerspace between the working diaphragm and the safety diaphragm. à Immediately stop the pump if the working diaphragm breaks. Breakage of the working diaphragm can be detected by monitoring the innerspace for a pressure change in the innerspace between the working diaphragm and the safety diaphragm. A change in the pressure or flow rate of the pump without apparent reason may also indicate breakage of the working diaphragm. à Replace the working diaphragm and safety diaphragm prior to further operation (see Chapter 9 Servicing). Because the diaphragm is a wear part, diaphragm breakage may occur at any time. Pump standstill à When the pump is at a standstill, establish normal atmospheric pressure in the lines. Start-up against pressure/ vacuum Vapors as medium Please contact KNF Customer Service. 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. 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). Recommissioning à Before recommissioning, observe the applicable standards, guidelines, regulations and technical standards at the electrical connection. Inspecting the pump 36 à Inspect the pump periodically for external damage or leakage. Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 Diaphragm pump N630.12 EX Servicing 9 Servicing Servicing the pump NOTICE 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 Risk of explosion from wear à Have the connecting rod bearing replaced by KNF according to servicing schedule. WARNING à Have the motor bearing replaced by KNF according to servicing schedule. Risk of explosion if genuine spare parts are not used. WARNING 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. Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 37 Servicing Diaphragm pump N630.12 EX Component Pump Servicing interval à Perform periodic inspections for external damage or leakage. à Periodically check for noticeable changes to noises and vibrations. Pump bearing (on pump shaft and connecting rod) à Replace after 34,000 operating Motor bearing à See the operating and installa- hours or after no more than 48 months tion instructions for the motor; inquire with the manufacturer of the motor if necessary Gas connections à Inspect the pump periodically for external damage or leakage Coupling à Inspect coupling play periodically à See operating instructions for coupling Working diaphragm, safety diaphragm and valves à Replace immediately if the pressure in the (monitored) inner space between the working diaphragm and the safety diaphragm changes (working diaphragm is broken). à Replace immediately if the pressure or flow rate of the pump changes for no apparent reason. à At the latest, replace when the performance decreases. 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. 38 Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 Diaphragm pump N630.12 EX Servicing 9.2 Cleaning 9.2.1 Flushing the pump 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 WARNING 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 Risk of explosion from electrostatic charging of the components WARNING à Only clean the pump with a damp cloth. à 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. 9.3 Changing diaphragm and reed valves Requirements 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. à Remove the transport eyebolt from the pump if necessary. Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 39 Servicing Diaphragm pump N630.12 EX Risk of explosion from formation of potentially explosive atmosphere WARNING 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 Risk of dangerous gas mixtures and leakage of the medium being transferred from the pump during pump operation if the safety diaphragm is not changed at the same time as the working diaphragm. à If the working diaphragm is changed, always change the safety diaphragm at the same time. Health hazard due to dangerous substances in the pump WARNING 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. Risk of burns from hot pump parts The pump head or motor may still be hot after operation of the pump. CAUTION 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. à Always replace the working diaphragm and safety diaphragm together so as to maintain the performance and safety of the pump. With multi-headed pumps, the parts of the various pump heads could get mixed up. à Change the parts of the individual pump heads that are to be replaced one after the next. 40 Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 Diaphragm pump N630.12 EX Spare parts Servicing Spare part* Working diaphragm Safety diaphragm Washer (ST head only) O-ring O-ring O-ring O-ring O-ring O-ring Valve Valve limiter Retainer plate screw Slotted cheese head screw Item designation** (17) (8) (26) (2) (3) (5) (10) (6) (22) (20) (19) (13) (21) Quantity 1 (per pump head) 1 (per pump head) 1 (per pump head) 2 (per pump head) 1 (per pump head) 1 (per pump head) 2 (per pump head) 1 (per pump head) 1 (per pump head) 2 (per pump head) 2 (per pump head) 1 (per pump head) 2 (per pump head) Tab.20 *According to spare parts list, Chapter 11.1 Spare parts ** According to Fig. 16 Tool and material Quantity 1 1 1 1 1 1 1 Tool/material TORX ® T30 screwdriver with torque indicator Size 5 Allen key with torque indicator Screwdriver blade width 5.5 mm Felt-tip pen 19 mm open end wrench (for two-headed pumps only) PZ2 Phillips-head screwdriver (for fan cover) Open-end wrench 8 mm Tab.21 *According to accessories list, Chapter 11.2 Accessories Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 41 Servicing Diaphragm pump N630.12 EX 1 Head plate 2 O-ring 3 O-ring 4 Retainer plate 5 O-ring 6 O-ring 7 Conrod plate, top 8 Safety diaphragm 9 Conrod plate, bottom 10 O-ring 11 Connecting rod 12 Shim rings 13 Retainer plate screw 14 Housing 15 Intermediate ring 16 Hexagon socket head cap screw 17 Working diaphragm 18 Intermediate plate 19 Valve limiter 20 Valve 21 Slotted cap screw 22 O-ring 23 Screw plug 24 Hexagon socket head cap screw 25 Cylindrical pin 26 Washer (ST head only) Fig.16 Components of the pump head The following item numbers refer to Fig. 16 unless specified otherwise. 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. 17 and loosen them. Union nut Marking Fig.17 Marking of the union nuts 3. Mark the head plate (1), intermediate plate (18) and housing (14) with a continuous line made with a felt-tip pen. This helps to avoid incorrect assembly later. 4. Loosen the six cheese head screws (24) by turning them counterclockwise with an Allen key; remove the head plate (1) and intermediate plate (18). Risk of explosion from damage If the housing cover is bent or if the paint is damaged, there is no risk of explosion. WARNING 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. 42 Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 Diaphragm pump N630.12 EX Servicing Replacing the diaphragm 1. Loosen the retainer plate screw (13) by turning it counterclockwise with the Torx key. 2. Remove the O-rings (10), retainer plate (4), washer (26; ST head only) and working diaphragm (17). 3. Remove the O-rings (10) from the retainer plate screw (13). 4. Remove the O-ring (5) from the intermediate ring (15). 5. Loosen the six hexagon socket head cap screws (16). 6. Remove the intermediate ring (15). 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. Remove the O-ring (6) from the housing (14). 8. Remove the safety diaphragm (8). 9. Check all parts for contamination and damage. Clean them if necessary. 10. Insert the new O-ring (6) in the housing (14). 11. Turn the fan blade to move the lower connecting rod plate (9) to the middle position. 12. Place the safety diaphragm (8) together with the upper connecting rod plate (7) on the lower connecting rod plate (9). Make sure that the bulge on the inner diameter of the safety diaphragm (8) is in the groove of the lower connecting rod plate (9). 13. Place the intermediate ring (15) on the housing (14) according to the felt-tip pen marking and hand-tighten the hexagon socket head cap screws (16) crosswise. Make sure that the bulge on the outer diameter of the safety diaphragm (8) lies in the groove of the housing (14). 14. Tighten the hexagon socket head cap screws (16) (tightening torque: 11 Nm). 15. Turn the fan blade to move the upper connecting rod plate (7) to the middle position. 16. Place the new working diaphragm (17) on the upper connecting rod plate (7). Make sure that the bulge on the inner diameter of the working diaphragm (17) is in the groove of the upper connecting rod plate (7). 17. ST head only: Place the washer (26) on the working diaphragm (17). 18. Insert the new O-ring (10) in the upper connecting rod plate (7). 19. Insert the new O-ring (5) in the intermediate ring (15). 20. Put on the retainer plate (4). 21. Insert the new O-ring (10) in the retainer plate (4). 22. Screw the retainer plate screw (13) into the connecting rod (11). 23. ST head only: Tighten the retainer plate screw (13) (tightening torque: 11 Nm). 24. For two-headed pumps: Perform steps 1 to 23 for the second pump head. Changing valves 1. Remove the two O-rings (2) from the intermediate plate (18). Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 43 Servicing Diaphragm pump N630.12 EX 2. Remove the O-ring (3) from the intermediate plate (18). 3. Loosen the two screws (21) and remove the valves (20) and valve limiters (19) from the intermediate plate (18). 4. On the suction side and pressure side, fit the new valves (20) and valve limiters (19) with the slotted cap screw (21, tightening torque: 2 Nm). Make certain that the valves (20) and valve limiters (19) are placed symmetrically on the valve hole. 5. For two-headed pumps: Perform steps 1 to 4 for the second pump head. Fitting the pump head 1. Place the intermediate plate (18) on the housing (14) in accordance with the felt-tip pen marking (diaphragm should be held in the middle position by holding the fan blade). 2. Insert the two new O-rings (2) in the intermediate plate (18). 3. Insert the new O-ring (3) in the intermediate plate (18). 4. Place the head plate (1) on the intermediate plate (18) in accordance with the felt-tip pen marking and the orientation predefined by the cylindrical pins (25). 5. Screw in the hexagon socket head cap screws (24) by one to two turns. 6. Tighten the hexagon socket head cap screws (24) crosswise (tightening torque: 11 Nm). 7. Check the pump for smooth running by turning the fan. 8. For two-headed pumps: Perform steps 1 to 7 for the second pump head. 9. Install the motor fan cover (see Chapter5 Product description and function) according to the felt-tip pen marking. 10. For two-headed pumps: Reinstall the pneumatic connection between the pump heads. In doing so, retighten the union nuts slightly above the original position (as marked during disassembly, see Fig. 17). 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. 11. 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. 12. 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. 44 Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 Diaphragm pump N630.12 EX Servicing Risk of explosion from leaks à Before recommissioning the pump, check the WARNING pump heads and pneumatic connections for leaks. Leaks may lead to a risk of explosion. Risk of injury and poisoning from leaks à Before recommissioning the pump, check the WARNING 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. 9.4 Checking and replacing sprocket on coupling Requirements à Disconnect the motor from mains and ensure that it is voltage-free. à Allow the pump and the motor to cool. Risk of burns from hot pump parts The pump head or motor may still be hot after operation of the pump. CAUTION à Allow the pump to cool after operation. Personal injury and/or property damage due to incorrect or improper transport of the motor CAUTION 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 1 1 1 1 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 Tab.22 Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 45 Servicing Diaphragm pump N630.12 EX Spare parts Spare part Sprocket Item designation (4) Quantity 1 Tab.23 Fig.18 Lifting motor (depicted pump as an example) 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.19 Replacing sprocket (depicted pump as an example) 46 Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 Diaphragm pump N630.12 EX Servicing 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). 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. 20). Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 47 Servicing Diaphragm pump N630.12 EX Fig.20 Alignment of the ribbed disk (2) 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. 48 Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 Diaphragm pump N630.12 EX Troubleshooting 10 Troubleshooting Danger: electric shock can be life-threatening. à All work on the pump may only be performed by an authorized specialist. DANGER 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). à 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 Troubleshooting Pump is not connected to the elec- à Connect the pump to the electrical mains. trical mains. No voltage in the electrical mains. à Check the circuit breaker for the room and switch it on if necessary. Pneumatic connections or lines are à Check the pneumatic connections and lines. blocked. à Remove the blockage. External valve is closed or filter clogged. Condensation has collected in the pump head. à Check external valves and filters. 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. Working diaphragm, safety diaphragm or valves are worn. à Change the working diaphragm, safety di- Working diaphragm, safety diaphragm or valves are worn. à Change the working diaphragm, safety di- Working diaphragm, safety diaphragm or valves are worn. à Change the working diaphragm, safety di- Triggering device for PTC thermistor sensor tripped. à Determine the cause. à See operating instructions for motor. aphragm and the valves (see Chapter 9 Servicing). aphragm and the valves (see Chapter 9 Servicing). aphragm and the valves (see Chapter 9 Servicing). Tab.24 Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 49 Troubleshooting Diaphragm pump N630.12 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 à Isolate the source of condensation from the pump head. 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. 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 Change the pneumatic conditions. 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. Leaks occur at pneumatic connec- à Eliminate the leaks. tions, lines or pump head. Pneumatic connections or lines are à Check the pneumatic connections and lines. partially or completely blocked. à Remove any parts and particles that are causing the blockage. Head parts are soiled. à Clean the head components. Operating diaphragm broken à Stop the pump immediately. à Check whether the pressure has changed in the monitored innerspace between working diaphragm and safety diaphragm. Replace working diaphragm and safety diaphragm prior to further operation of the pump (see 9 Servicing). Working diaphragm, safety diaphragm or valves are worn. à Change the working diaphragm, safety di- Pump exhibiting changed running noises and vibrations. à Stop the pump immediately. à Contact KNF Customer Service. aphragm and the valves (see Chapter 9 Servicing). Tab.25 Pump exhibiting changed running noises and vibrations. Cause Troubleshooting Pump bearing worn or defective. à Determine the cause. Drive worn or defective. Coupling worn or defective. à Contact KNF Customer Service. à See operating instructions for the drive. à See operating instructions for coupling. Tab.26 50 Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 Diaphragm pump N630.12 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 325089 11/22 51 Spare parts and accessories Diaphragm pump N630.12 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 Working diaphragm Safety diaphragm Washer O-ring (D10 x 2.0) O-ring (D38 x 3) O-ring (D105 x 3) O-ring (D5 x 1.5) Valves Valve stopper Slotted cap screw Item number* (17) (8) (26) (10) (2) (3), (5), (6) (22) (20) (19) (21) Quantity N630.12 1 1 1 2 2 3 Quantity N630.1.2.12 2 2 2 4 4 6 Quantity N630.3.12 2 2 2 4 4 6 1 2 2 2 2 4 4 4 2 4 4 4 Tab.27 *See Chapter 9.3 Changing diaphragm and reed valves Spare parts set N630.12EX N630.1.2.12 EX N630.3.12 EX Order number 325528 325527 325527 Tab.28 Spare part Sprocket for coupling Retainer plate screw Item number* (13) Order number 322095 314280 Tab.29 *See Chapter 9.4 Checking and replacing sprocket on coupling 11.2 Accessories Accessories Transport eyebolt Suction filter G1/4 Wrench for retainer plate Test adapter for coupling Water cooling connection: N630.12 N630.3.12 N630.1.2.12 Order number 311535 316661 321664 322184 310064 310444 310444 Tab.30 52 Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 Diaphragm pump N630.12 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 325089 11/22 53 Appendix Diaphragm pump N630.12 EX 13 Appendix à 13.1 Declaration of Conformity à 13.2 Motor à 13.3 Coupling 13.1 Declaration of Conformity For further information, see also § Konformitätserklärung N630.12EX.pdf 54 Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 Diaphragm pump N630.12 EX Appendix 13.2 Motor For further information, see also § Betriebsanleitung Motor.pdf § Konformitätserklärung Motor.pdf Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 59 Table of contents 2021-05-31 Operating manual Electric motors ATEX / IECEx Doc-ID: 6316 Size 63 - 225 Read the operating manual before starting all work. © Herforder Elektromotoren-Werke 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. 2 2021-05-31 Electric motors Size 63 - 225 ATEX / IECEx Table of contents 1 2 3 4 5 2021-05-31 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 Copyright........................................................................ 8 1.5 Spare parts .................................................................... 8 1.6 Warranty conditions ....................................................... 8 1.7 Customer service ........................................................... 8 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 Technical data ...................................................................... 20 3.1 Operating conditions .................................................... 20 3.2 Type plate .................................................................... 20 3.3 Explosion protection marking ....................................... 21 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 Transportation, packaging and storage ............................ 27 5.1 Delivery inspection ....................................................... 28 5.2 Transportation .............................................................. 29 5.3 Packaging .................................................................... 30 5.4 Storage ........................................................................ 31 3 Electric motors Size 63 - 225 ATEX / IECEx Table of contents 6 Installation and commissioning .........................................32 6.1 Safety ...........................................................................32 6.2 Installation ....................................................................34 6.3 6.4 7 8 9 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 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 Commissioning.............................................................40 Operations ............................................................................42 7.1 General information......................................................42 7.2 Shutting down in an emergency ...................................42 Faults .....................................................................................43 8.1 Safety ...........................................................................43 8.2 Fault table ....................................................................45 8.3 Commissioning after remedied fault ............................47 Maintenance ..........................................................................48 9.1 Safety ...........................................................................48 9.2 Cleaning .......................................................................50 9.3 Maintenance schedule .................................................50 9.4 Tightening torque values for screws ............................52 9.5 10 6.2.1 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 Measures on completion of maintenance ....................54 Removal.................................................................................55 10.1 Safety ...........................................................................55 10.2 Removal .......................................................................56 10.3 Disposal .......................................................................57 4 2021-05-31 Electric motors Size 63 - 225 ATEX / IECEx General information Pos : 1.1 /KN2006- SM/Allgemei nes /100 1 Allgemeines _Titel @ 8\mod_1142088318714_1.doc @ 75727 1 General information Pos : 1.2 /KN2006- SM/Allgemei nes /110 1.1 Informati onen z ur Anl eitung (Maschi ne) @ 40\mod_1182336499793_1.doc @ 495957 a 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. Pos : 1.3 /KN2006- SM/Allgemei nes /111 1.1.0 Neben di eser Anleitung gelten di e i m Anhang befindlichen Anl eitungen @ 8\mod_1142089202762_1.doc @ 75765 . Pos : 1.4 /KN2006- SM/nL.......... Seitenumbr uc h .......... @ 8\mod_1141998334703_0.doc @ 75489 2021-05-31 5 Electric motors Size 63 - 225 ATEX / IECEx General information Pos : 1.5 /KN2006- SM/Allgemei nes /120 1.1 Symboler kl ärung @ 8\mod_1142089345047_1.doc @ 75774 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. Pos : 1.6 /KN2006- SM/nL.......... Seitenumbr uc h .......... @ 8\mod_1141998334703_0.doc @ 75489 6 2021-05-31 Electric motors Size 63 - 225 ATEX / IECEx General information Pos : 1.7 /KN2006- SM/Allgemei nes /121 1.1.1 Bes ondere Sic her heitshi nweis e_Titel @ 8\mod_1142090242324_1.doc @ 75783 Special safety instructions The following symbols are used in safety instructions in order to point out particular hazards. Pos : 1.8 /KN2006- SM/Allgemei nes /122 1.1.1.0 Symbol Gefähr dung durc h elektrischen Strom @ 41\mod_1182344857792_1.doc @ 496362 ... indicates risks from electrical current. Failure to observe the safety instructions will result in the risk of serious or fatal injury. Pos : 1.9 /KN2006- SM/nL---------- Abschnittsende ---------- @ 8\mod_1141997892953_0.doc @ 75471 Pos : 1.10 /KN 2006-Pr ojekte/Herforder Elektromotoren-Wer ke/Allgemeines /AT EX/003 1.1.1.0 EX-Sc hutz _Bes ondere Sicher heits hi nweis e @ 59\mod_1203491034413_1.doc @ 1039243 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. Pos : 1.11 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75471 Pos : 1.12 /KN 2006-SM /Allgemeines/130 1.1 H aftungsbesc hränkung @ 8\mod_1142091543501_1.doc @ 75810 1.3 Limitation of liability 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. Pos : 1.13 /KN 2006-SM /Allgemeines/131 1.1.0 T ec hni sche Änderungen vorbehalten --> Wenn Kunde verlangt! @ 8\mod_1142965766069_1.doc @ 80002 We reserve the right to make technical changes within the scope of further development and improvement of the performance characteristics. Pos : 1.14 /KN 2006-SM /nL.......... Sei tenumbr uch .......... @ 8\mod_1141998334703_0.doc @ 75489 2021-05-31 7 Electric motors Size 63 - 225 ATEX / IECEx General information Pos : 1.15 /KN 2006-SM /Allgemeines/140 1.1 Ur heberschutz @ 8\mod_1142092015791_1.doc @ 75819 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. Pos : 1.16 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75471 Pos : 1.17 /KN 2006-Pr ojekte/Herforder Elektromotoren-Wer ke/Allgemeines /AT EX/007 1.1 EX-Sc hutz _Ers atz teil e @ 59\mod_1203491040178_1.doc @ 1039264 1.5 Spare parts Explosion protection 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. Pos : 1.18 /KN 2006-SM /Allgemeines/151 1.1.0 Di e Ersatzteilliste befi ndet sich im Anhang @ 8 \mod_1142092788222_1.doc @ 75837 The spare parts list can be found on pages 23-24. Pos : 1.19 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75471 Pos : 1.20 /KN 2006-SM /Allgemeines/160 1.1 Garantiebesti mmungen_Titel @ 9\mod_1144054714613_1.doc @ 84756 1.6 Warranty conditions Pos : 1.21 /KN 2006-SM /Allgemeines/161 1.1.0 Gar antiebesti mmungen i n den AGB des H erstellers @ 9\mod_1144054766031_1.doc @ 84763 The warranty conditions are included in the manufacturer's General Terms and Conditions. Pos : 1.22 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75471 Pos : 1.23 /KN 2006-SM /Allgemeines/170 1.1 Kundendienst_Titel+Text @ 8\mod_1142095433275_1.doc @ 75900 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. Pos : 1.24 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75471 8 2021-05-31 Electric motors Size 63 - 225 ATEX / IECEx Safety 2.1 /KN2006/F I/.......... SM/Sic Seitenumbr uch .......... @ 1522 Pos : 2.2 herheit/001 1 Sic@ her0\mod272_1.doc hei t_Titel @ 8\mod_1142425976781_1.doc @ 77461 2 Safety Pos : 2.3 /KN2006- SM/Sic herheit/001 1.0 Einführung @ 8\mod_1142427208593_1.doc @ 77470 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. Failure to observe the instructions and safety instructions for actions in this operating manual can cause considerable risks. Pos : 2.4 /KN2006- SM/nL---------- Abschnittsende ---------- @ 8\mod_1141997892953_0.doc @ 75471 Pos : 2.5 /KN2006- SM/Sic herheit/003 1.1 Verantwortung des Betr eibers_Ti tel @ 8\mod_1142428931187_1.doc @ 77567 2.1 Responsibility of the user Pos : 2.6 /KN2006- Proj ekte/H erfor der El ektromotoren- Wer ke/Sicherheit/AT EX/003 1.1.0 Verantwortung des Betr eibers allgemei ner Teil (M asc hine) ATEX @ 59\mod_1203493296525_1.doc @ 1039307 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 2021-05-31 9 Electric motors Size 63 - 225 ATEX / IECEx 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. Pos : 2.7 /KN2006- SM/nL---------- Abschnittsende ---------- @ 8\mod_1141997892953_0.doc @ 75471 Pos : 2.8 /KN2006- Proj ekte/H erfor der El ektromotoren- Wer ke/Sicherheit/AT EX/003 1.1.0 Verantw. d. Betr. - Verl ust des Explosi ons schutzes - Ges amtanl age @ 59\mod_1203493477106_1.doc @ 1039352 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. Pos : 2.9 /KN2006- SM/nL---------- Abschnittsende ---------- @ 8\mod_1141997892953_0.doc @ 75471 Pos : 2.10 /KN 2006-SM /Sic her hei t/004 Pers onal/004 1.1 Personalanforderungen_Titel @ 8\mod_1142431816578_1.doc @ 77625 2.2 Staff requirements Pos : 2.11 /KN 2006-SM /Sic her hei t/004 Pers onal/004 1.1.1 Personal Qualifi kati onen @ 13\mod_1152880813359_1.doc @ 148322 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. Pos : 2.12 /KN 2006-SM /Sic her hei t/004 Pers onal/004 1.1.0 U nter wies ene Person/Fac hpers onal @ 13 \mod_1152880944937_1.doc @ 148341 10 2021-05-31 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. Pos : 2.13 /KN 2006-SM /Sic her hei t/004 Pers onal/004 1.1.0 Elektrofac hkr aft @ 13\mod_1152885134593_1.doc @ 148350 ◼ 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. Pos : 2.14 /KN 2006-Pr ojekte/Herforder Elektromotoren-Wer ke/Sic herheit/ATEX/004 1.1.0 EX-F ac hkraft @ 59\mod_1203494636587_1.doc @ 1039373 ◼ 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. Pos : 2.15 /KN 2006-SM /Sic her hei t/004 Pers onal/004 1.1.0 ...zuverläs siges Pers onal... @ 13\mod_1152892110812_1.doc @ 148627 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. Pos : 2.16 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75471 2021-05-31 11 Electric motors Size 63 - 225 ATEX / IECEx Safety Pos : 2.17 /KN 2006-SM /Sic her hei t/004 Pers onal/004 1.1.1 U nbefugte @ 13\mod_1152892272765_1.doc @ 148636 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. Pos : 2.18 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75471 Pos : 2.19 /KN 2006-SM /Sic her hei t/004 Pers onal/004 1.1.1 U nter weis ung @ 8\mod_1142946308736_1.doc @ 79799 2.2.3 Training Staff must be provided with regular training by the user. Training must be logged to keep better track. Date Name Type of training Training provided by Signature Fig. 1 2.20 /KN /FI/.......... Seitenumbruc h .......... @ 0 \mod272_1.doc @herheit/ATEX/005 1522 Pos : 2.21 2006-Pr ojekte/Herforder Elektromotoren-Wer ke/Sic 1.1 Besti mmungsgemäße Ver wendung (Mas chi ne) AT EX @ 59\mod_1203494796323_1.doc @ 1039394 2.3 Proper use 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. Pos : 2.22 /FI/.......... Seitenumbruc h .......... @ 0\mod272_1.doc @ 1522 Pos : 2.23 /KN 2006-SM /Sic her hei t/006 Pers önliche Schutz ausstattung/006 1.1 Pers önlic he Schutz ausrüs tung @ 8 \mod_1143360751363_1.doc @ 80980 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. Pos : 2.24 /KN 2006-SM /Sic her hei t/006 Pers önliche Schutz ausstattung/006 1.1.0_1 Grundsätzlich zu trag en_Titel @ 8 \mod_1143360998458_1.doc @ 80989 To be worn for all work The following must be worn for all work: Pos : 2.25 /KN 2006-SM /Sic her hei t/006 Pers önliche Schutz ausstattung/Ar bei tssc hutz kl eidung @ 8\mod_1143362598709_1.doc @ 81061 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. Pos : 2.26 /KN 2006-SM /Sic her hei t/006 Pers önliche Schutz ausstattung/Sic herheitssc huhe @ 8\mod_1143362886212_1.doc @ 81070 Safety shoes to protect from heavy falling parts and from slipping on slippery surfaces. Pos : 2.27 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75471 2021-05-31 13 Electric motors Size 63 - 225 ATEX / IECEx Safety Pos : 2.28 /KN 2006-SM /Sic her hei t/006 Pers önliche Schutz ausstattung/006 1.1.0_2 Bei bes onderen Ar beiten z u tragen_Titel @ 8\mod_1143361122656_1.doc @ 80999 To be worn for special tasks 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: Pos : 2.29 /KN 2006-SM /Sic her hei t/006 Pers önliche Schutz ausstattung/Atemschutz , l eicht @ 8\mod_1143361876540_1.doc @ 81034 Light breathing mask to protect from harmful dust. Pos : 2.30 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75471 Pos : 2.31 /KN 2006-SM /Sic her hei t/007 Besondere Gefahr en/007 1.1 Bes ondere Gefahr en_Titel und Einl eitung @ 8\mod_1143366409048_1.doc @ 81170 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. Pos : 2.32 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75471 Pos : 2.33 /KN 2006-Pr ojekte/Herforder Elektromotoren-Wer ke/Sic herheit/ATEX/007 1.1.0 Besonder e Gefahren EX-SCHUTZ @ 59\mod_1203496019641_1.doc @ 1039437 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. Pos : 2.34 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75471 14 2021-05-31 Electric motors Size 63 - 225 ATEX / IECEx Safety Pos : 2.35 /KN 2006-SM /Sic her hei t/007 Besondere Gefahr en/El ektrisc her Strom_Gefahr! @ 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 : 2.36 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75471 Pos : 2.37 /KN 2006-SM /Sic her hei t/007 Besondere Gefahr en/Bewegliche Bauteile_Warnung! @ 8\mod_1143369746320_1.doc @ 81253 Moving parts 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. Pos : 2.38 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75471 2021-05-31 15 Electric motors Size 63 - 225 ATEX / IECEx Safety Pos : 2.39 /KN 2006-SM /Sic her hei t/007 Besondere Gefahr en/Heiß e Oberfl 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 Gefahr 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 Gefahr en/Scharfe Kanten, 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/Herforder Elektromotoren-Wer ke/Sic herheit/008 1.1 Sic her heitsei nrichtungen_Titel @ 59\mod_1203337625484_1.doc @ 1037161 2.6 Safety devices Pos : 2.46 /KN 2006-SM /Sic her hei t/008 Sicherheits einric htungen/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 /Ausgemustert/Sicher heit/009 1.1 Sic hern g egen Wieder einschalten_Titel+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. 2021-05-31 17 Electric motors Size 63 - 225 ATEX / IECEx Safety Switch secured with a padlock on: …….. at ...... h. Securing the machine to prevent it from being switched back on: DO NOT SWITCH ON 1. Switch off the energy supply. The padlock must only be removed 2. If possible, secure the switch with a padlock and attach a clearly visible sign according to Fig. 2 to the switch. 3. Have the key kept safely by the member of staff named on the sign. 4. If it is impossible to secure a switch with a padlock, erect a sign according to Fig. 3. 5. Once all work has been carried out, make sure that nobody is in the danger area. by: ………………… 6. once you have made sure that there is nobody in the danger area. Make sure that all safety devices and mechanisms are installed and fully functional. 7. Do not remove the sign until you have done so. by: ………………… once you have made sure that there is nobody in the danger area. Fig. 2 Switched off on: …….. at ...... h. DO NOT SWITCH ON Only to be switched on 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 Titel und Einführung @ 9\mod_1143987199086_1.doc @ 84175 2.9 Environmental protection 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: Pos : 2.53 /KN 2006-SM /Sic her hei t/011 U mweltsc hutz/Sc hmierstoffe @ 9\mod_1143987769095_1.doc @ 84196 Lubricants 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/Herforder Elektromotoren-Wer ke/Sic herheit/H INWEIS - R ohstoffric 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.......... Seitenumbr uc h .......... @ 8\mod_1141998334703_0.doc @ 75489 2021-05-31 19 Electric motors Size 63 - 225 ATEX / IECEx Technical data Pos : 3.2 /KN2006- SM/T echnisc he D aten/001 1 Tec hnisc he Daten_Ti tel @ 8\mod_1143124628960_1.doc @ 80561 3 Technical data Pos : 3.3 /KN2006- Proj ekte/H erfor der El ektromotoren- Wer ke/T ec hnis che D aten/HIN WEIS - Die notwendigen tec hnischen D aten @ 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---------- Abschnittsende ---------- @ 8\mod_1141997892953_0.doc @ 75471 Pos : 3.5 /KN2006- SM/T echnisc he D aten/003 1.1 Betriebs beding ung en_Titel @ 9\mod_1143989042992_1.doc @ 84238 3.1 Operating conditions Pos : 3.6 /KN2006- Proj ekte/H erfor der El ektromotoren- Wer ke/T ec hnis che D aten/003 1.1.0 Betri ebs bedi ngungen @ 54\mod_1196341403646_1.doc @ 832739 Environment Specification Value Unit Temperature range (standard) -20…+40 °C Temperature range (optional) -50…+85 °C Maximum installation height above sea level 1000 m Pos : 3.7 /KN2006- SM/nL---------- Abschnittsende ---------- @ 8\mod_1141997892953_0.doc @ 75471 The ambient temperature range is only indicated on the type plate if it deviates from the standard. Pos : 3.8 /KN2006- SM/T echnisc he D aten/008 1.1 T ypensc hild_Titel @ 9\mod_1144045129972_1.doc @ 84411 3.2 Type plate Pos : 3.9 /KN2006- Proj ekte/H erfor der El ektromotoren- Wer ke/T ec hnis che D aten/AT EX/008 1.1.0 Ex-T ypenschil d @ 62\mod_1205227533086_1.doc @ 1061982 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 Fig.4: Example of a type plate ◼ 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 Pos : 3.10 2006-SM /nL---------endeen---------@ 8\mod_1141997892953_0.doc 75471 eic hnung @ 60\mod_1203497200012_1.doc @ 1039729 s: 3.11 /KN/KN 2006-Pr ojekte/H erforderAbschnitts Elektr omotor Wer ke/Technisc he Daten/ATEX/009 1.1 @ Ex-Kennz 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 Electric motors Size 63 - 225 ATEX / IECEx Technical data Section Designation Significance Explosion protection symbol Marking for protection from explosions II Device group Device group II. The motor can be used in potentially explosive areas except in mining. 2 Category For application in Zone 1 and Zone 21 G Explosive atmosphere … cause by gas. … cause by dust. D Ex Standard Standard on explosion protection d / db Ignition protection type Pressurised enclosure. e / eb Increased safety. tb Protection by housing IIC Explosion group IIB IIIC Maximum experimental safe gap (MESG) Type and shape Dust group IIIB T1 – T6 Temperature class maximum surface temperature present T1 (450 °C) – T6 (85 °C) Gb EPL equipment protection level Db 3.12 2006-SM ende 3.13 /KN2006Proj/nL---------ekte/H erforAbschnitts der El ektromotorenWer@ ke/T ec hnisc he D aten/HIN WEIS - @ Weitere Sc hilder @ 59\mod_1203071538887_1.doc @ 1034103 Pos : /KN 4.1 /KN2006SM/nL.......... Seitenumbr uc---------h .......... @8\mod_1141997892953_0.doc 8\mod_1141998334703_0.doc @75471 75489 NOTE! There may be further signs on the machine with various pieces of information. 22 2021-05-31 Electric motors Size 63 - 225 ATEX / IECEx Construction and function Pos : 4.2 /KN2006- SM/Aufbau und F unktion/001 1 Aufbau und F unkti on_Titel @ 8\mod_1143713625726_1.doc @ 83161 4 Construction and function Pos : 4.3 /KN2006- Proj ekte/H erfor der El ektromotoren- 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 10 9 11 8 12 10 7 6 1 2 3 4 5 13 14 15 16 17 18 Fig. 5: Overview of sizes 63 to 132 1 2 3 4 5 6 7 8 9 Flange rings Sealing rings DS*1 Rolling bearings DS*1 Stator housing, complete Motor foot Terminal box seal Lower terminal box section Cable bushing Terminal board 10 11 12 13 14 15 16 17 18 Terminal box cover Terminal box cover seal Screwed cable gland Rotor shaft, complete Bearing cover NS*2 Rolling bearings NS*2 Sealing ring NS*2 Fan blade Ventilation hood (with optional safety cover) *1 DS = Drive side *2 NS = Nondrive side ! For sizes 63 and 71 the terminal box is casted 2021-05-31 23 Electric motors Size 63 - 225 ATEX / IECEx Construction and function 4.2 Overview of sizes 160 to 225 12 13 10 11 14 11 8 9 1 2 3 4 5 6 7 15 16 17 18 19 20 21 Fig. 6: Overview of sizes 160 to 225 1 2 3 4 5 6 7 8 9 10 11 Flange rings Sealing rings DS*1 Cover plate DS*1 Rolling bearings DS*1 Base flange Stator housing, complete Motor foot Terminal box adapter Cable bushing Lower terminal box section Terminal board 12 13 14 15 16 17 18 19 20 21 Terminal box cover seal Terminal box cover Screwed cable glands Rotor shaft, complete Bearing cover NS*2 Rolling bearings NS*2 Cover plate NS*2 Sealing ring NS*2 Fan blade Ventilation hood (with optional safety cover) *1 DS = Drive side *2 NS = Nondrive side Pos : 4.4 /KN2006- SM/nL---------- Abschnittsende ---------- @ 8\mod_1141997892953_0.doc @ 75471 24 2021-05-31 Electric motors Size 63 - 225 ATEX / IECEx Construction and function Pos : 4.5 /KN2006- SM/Aufbau 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 ekte/H erfor der El ektromotoren- 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---------- Abschnittsende ---------- @ 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/Aufbau 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/mm2. 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 Frequency curve 1 2 3 4 5 - 50 Hz 5 - 50 Hz 50 - 87Hz 50 - 87Hz Motor version Motor voltage / circuit Inverter Ventilation Torque curve in frequency range acc. to Catalogue Part 20 230/400 V 400 V Y U/f=constant internal fan reduced 400/690V 400 V U/f=constant 230/400 V 400 V Y U/f=constant external ventilation constant 400/690V 400V U/f=constant 230/400 V 400 V Y U=constant 400/690V 400V U=constant 230/400 V 230V U/f=constant internal fan drops with 1/f Field weakening operation internal fan constant 87 Hz curve 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) 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.......... Seitenumbr uc h .......... @ 8\mod_1141998334703_0.doc @ 75489 26 2021-05-31 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! Lebensgefahr 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---------- Abschnittsende ---------- @ 8\mod_1141997892953_0.doc @ 75471 2021-05-31 27 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---------- Abschnittsende ---------- @ 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_Titel @ 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 - Inhalt, 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/Herforder Elektromotoren-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 28 2021-05-31 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_Titel @ 9\mod_1145448098995_1.doc @ 90988 5.2 Transportation Pos : 5.15 /KN 2006-Pr ojekte/Herforder Elektromotoren-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 kstüc ken mit dem Kr an @ 9\mod_1144393009755_1.doc @ 86326 Transporting packages 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: Fig. 7 1. Fasten ropes, belts or multiple-point suspension gear according to Fig. 7. 2. Make sure that the package hangs straight, paying attention to the off-centre centre of gravity as necessary. 3. Begin transportation. 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 etten mit dem Kran @ 9 \mod_1144391982978_1.doc @ 86312 Transporting pallets by crane 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: 1. Fasten ropes, belts or multiple-point suspension gear to the pallet according to Fig. 8. 2. Check that the packages are not damaged by the fastening equipment. If necessary use other fastening equipment. 3. Begin transportation. Fig. 8 Pos : 5.20 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75471 2021-05-31 29 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 etten mit dem Gabels tapl er @ 9\mod_1144392667613_1.doc @ 86319 Transporting pallets by forklift 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: 1. Drive the forklift with the forks between or underneath the beams of the pallet. 2. Insert the forks so that they protrude on the opposite side. 3. Make sure that the pallet cannot tilt in case it has an off-centre centre of gravity. 4. Raise the package and begin transportation. Fig. 9 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 _Titel @ 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 smaterialien @ 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 Electric motors Size 63 - 225 ATEX / IECEx Transportation, packaging and storage 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/Herforder Elektromotoren-Wer ke/Trans port/007 1.1.0 Lager ung der Pac ks tüc ke @ 59\mod_1203074612840_1.doc @ 1034278 Storing packages 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 (veff ≤ 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.......... Seitenumbr 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/Installation & Inbetri ebnahme/001 1 Ins tall ati on und Ers tinbetriebnahme_Titel @ 9\mod_1144393592402_1.doc @ 86332 6 Installation and commissioning Pos : 6.3 /KN2006- Proj ekte/H erfor der El ektromotoren- Wer ke/Ins 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/Installation & Inbetri ebnahme/002 1.1 Sic her heit_Titel @ 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---------- Abschnittsende ---------- @ 8\mod_1141997892953_0.doc @ 75471 Pos : 6.8 /KN2006- Proj ekte/H erfor der El ektromotoren- Wer ke/Ins tall ation & Inbetriebnahme/003 1.1.0 Persönliche Sc hutzausr üstung @ 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/Herforder Elektromotoren-Wer ke/Installation & Inbetri 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 Electric motors Size 63 - 225 ATEX / IECEx Installation and commissioning Pos : 6.12 /KN 2006-SM /Installati on & Inbetriebnahme/003 1.1.0 El ektrisc he Anl age_Gefahr! @ 9\mod_1144397463440_1.doc @ 86395 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 : 6.13 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75471 Pos : 6.14 /KN 2006-SM /Installati on & Inbetriebnahme/003 1.1.0 Sic hern g egen Wiedereinschalten @ 9 \mod_1144397709746_1.doc @ 86412 Securing the machine 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. Pos : 6.15 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75471 Pos : 6.16 /KN 2006-SM /Installati on & Inbetriebnahme/003 1.1.0 Gr undl egendes _Warnung! @ 9\mod_1144396463455_1.doc @ 86388 Improper installation and commissioning 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 /Installati on & Inbetriebnahme/005 1.1 Installation_Titel @ 9\mod_1144401700720_1.doc @ 86426 6.2 Installation Pos : 6.19 /KN 2006-Pr ojekte/Herforder Elektromotoren-Wer ke/Installation & Inbetri ebnahme/1.1.1 Bel üftung 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/Herforder Elektromotoren-Wer ke/Installation & Inbetri ebnahme/ATEX/1.1.1 Baufor 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 IM V5 IM 1011 ◼ 2 bearing covers ◼ with feet ◼ 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 Electric motors Size 63 - 225 ATEX / IECEx Installation and commissioning Type of construction IM B7 IM 1061 Symbol Explanation ◼ 2 bearing covers ◼ with feet ◼ Construction type IM B3 ◼ Fastening on the wall ◼ Feet right, viewed from drive side IM B8 IM 1071 ◼ 2 bearing covers ◼ with feet ◼ Construction type IM B3 ◼ Fastening on the ceiling IM B35 IM 2001 ◼ 2 bearing covers ◼ with feet ◼ Securing flange type A IM B34 IM 2101 ◼ 2 bearing covers ◼ with feet ◼ Securing flange type C IM B5 IM 3001 ◼ 2 bearing covers ◼ without feet ◼ Securing flange type A IM V1 IM 3011 ◼ 2 bearing covers ◼ without feet ◼ Shaft end bottom ◼ Securing flange type A IM V3 IM 3031 ◼ 2 bearing covers ◼ without feet ◼ Shaft end top ◼ Securing flange type A IM B14 IM 3601 ◼ 2 bearing covers ◼ without feet ◼ Securing flange type C 2021-05-31 35 Electric motors Size 63 - 225 ATEX / IECEx Installation and commissioning Type of construction IM V18 IM 3611 Symbol Explanation ◼ 2 bearing covers ◼ without feet ◼ Shaft end bottom ◼ Securing flange type C IM V19 IM 3631 ◼ 2 bearing covers ◼ without feet ◼ Shaft end top ◼ Securing flange type C IM V6/IM V19 ◼ 2 bearing covers ◼ with feet ◼ Shaft end top ◼ Securing flange type C IM V36 IM 2031 ◼ 2 bearing covers ◼ with feet ◼ Shaft end top ◼ Securing flange type A IM V5/IM V18 ◼ 2 bearing covers ◼ with feet ◼ Shaft end bottom ◼ Securing flange type C IM V15 IM 2011 ◼ 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 Electric motors Size 63 - 225 ATEX / IECEx Installation and commissioning Pos : 6.23 /KN 2006-Pr ojekte/Herforder Elektromotoren-Wer ke/Installation & Inbetri ebnahme/1.1.1 M aschi nenaufstellung @ 59\mod_1203075619986_1.doc @ 1034390 6.2.3 Erecting the machine 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/Herforder Elektromotoren-Wer ke/Installation & Inbetri 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 6.26 /KN 2006-Pr 2006-SMojekte/Herforder /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75471 Pos : 6.27 Elektromotoren-Wer ke/Installation & Inbetri ebnahme/006 1.1 Elektrischer Ans chl uss _Titel @ 59\mod_1203082082094_1.doc @ 1034835 6.3 Connecting to the energy supply Pos : 6.28 /KN 2006-SM /Sic her hei t/007 Besondere Gefahr en/El ektrisc her Strom_Gefahr! @ 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/Herforder Elektromotoren-Wer ke/Installation & Inbetri 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 Electric motors Size 63 - 225 ATEX / IECEx Installation and commissioning Ex d motors Ex de motors 1. Connection to the terminal box with these motors is implemented with a standard connection. 2. 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. 3. The type and dimensions of the cable connections must match the cable type and cable cross section. 1. 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. 3. Properly insert the seals on the terminal box into the grooves provided. 4. Creepage paths and air gaps must comply with EN 60079-7. Pos : 6.31 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75471 Pos : 6.32 /KN 2006-Pr ojekte/Herforder Elektromotoren-Wer ke/Installation & Inbetri ebnahme/1.1.1 Spannung und Sc hal tung @ 59\mod_1203082128766_1.doc @ 1035016 6.3.2 Voltage and circuit ◼ 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/Herforder Elektromotoren-Wer ke/Installation & Inbetri ebnahme/1.1.1 Is ol ations wi ders tand pr üfen @ 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 /Installati on & Inbetriebnahme/007 1.1 Ers tinbetriebnahme_Titel @ 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 Electric motors Size 63 - 225 ATEX / IECEx Installation and commissioning Pos : 6.39 /KN 2006-Pr ojekte/Herforder Elektromotoren-Wer ke/Installation & Inbetri ebnahme/VOR SICHT - Her ausg esc hleuderte Pas sfeder @ 59\mod_1203079038551_1.doc @ 1034432 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. Pos : 6.40 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75471 Pos : 6.41 /KN 2006-Pr ojekte/Herforder Elektromotoren-Wer ke/Installation & Inbetri ebnahme/Vor Inbetriebnahme pr üfen @ 59\mod_1203079708164_1.doc @ 1034523 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.......... Seitenumbr 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 _Titel @ 9\mod_1144402040153_1.doc @ 86490 7 Operations Pos : 7.3 /KN2006- Proj ekte/H erfor der El ektromotoren- 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---------- Abschnittsende ---------- @ 8\mod_1141997892953_0.doc @ 75471 Pos : 7.5 /KN2006- SM/Bedienung/007 1.1 Stillsetz en im Notfall_Titel @ 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 Notfall --> 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: 1. Trigger an emergency stop immediately. 2. Remove any people from the danger zone and administer first aid. 3. Alert a doctor and the fire services. 4. Inform the responsible party at the location. 5. Switch off the master switch and secure it to prevent it from being switched back on. 6. Keep access routes for emergency vehicles clear. 7. If the seriousness of the emergency requires it, inform the respective authorities. 8. 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. 9. 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_Titel+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---------- Abschnittsende ---------- @ 8\mod_1141997892953_0.doc @ 75471 Pos : 8.6 /KN2006- Proj ekte/H erfor der El ektromotoren- Wer ke/Störungen/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---------- Abschnittsende ---------- @ 8\mod_1141997892953_0.doc @ 75471 Pos : 8.8 /KN2006- Proj ekte/H erfor der El ektromotoren- Wer ke/Störungen/ATEX/003 1.1.0 Arbeiten zur Störungsbes 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 2021-05-31 43 Electric motors Size 63 - 225 ATEX / IECEx Faults Pos : 8.10 /KN 2006-SM /Störungen/003 1.1.0 Elektrisc he Anlage_Gefahr! @ 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 /Störungen/003 1.1.0 Sic her n geg en Wi ederei nsc halten_Gefahr! @ 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 /Störungen/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 Electric motors Size 63 - 225 ATEX / IECEx Faults Pos : 8.16 /KN 2006-SM /Störungen/003 1.1.0 Verhalten bei Stör ung en (Ger ät) @ 9\mod_1144441786782_1.doc @ 87239 How to act in case of faults The following basic instructions apply: 1. In case of faults which pose an immediate risk to people or objects of material value, activate the emergency stop function immediately. 2. Determine the cause of the fault. 3. 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. 4. Inform the responsible party at the location of the fault immediately. 5. 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 /Störungen/005 1.1 Störungstabelle_Titel @ 9\mod_1144442349705_1.doc @ 87246 8.2 Fault table Pos : 8.19 /KN 2006-Pr ojekte/Herforder Elektromotoren-Wer ke/Stör ung en/005 1.1.0 Stör ungstabell e @ 54\mod_1196342592303_1.doc @ 833044 Fault Possible cause Remedy ◼ Bearing is too warm Too much grease in the bearing Remove excessive grease Qualified specialist Bearing is soiled Replace the bearing Manufacturer Belt tension too high Reduce belt tension Qualified specialist Bearing grease dark in colour Check for bearing currents Qualified specialist ◼ Bearing is too warm To be remedied by Coupling forces are pulling Align the motor exactly, or pushing adjust the coupling Qualified specialist Lubricate as stipulated ◼ Bearing noises Not enough grease in the bearing Qualified specialist ◼ Bearing is too warm Motor erected incorrectly Check the motor construction type Qualified specialist ◼ Motor is not running smoothly ◼ Bearing is too warm ◼ Bearing noises ◼ Motor is not running smoothly 2021-05-31 45 Electric motors Size 63 - 225 ATEX / IECEx Faults Fault Possible cause Remedy To be remedied by ◼ Bearing noises Scoring on inner bearing ring, e.g. from motor starting up with bearing locked Replace bearing, avoid vibrations when at a standstill Manufacturer ◼ Motor is not running smoothly Imbalance due to belt pulley or coupling Balance exactly Manufacturer Machine fastening insufficient Check machine fastening Qualified specialist Load moment too high Check motor torque and load moment Qualified electrician Supply voltage too low Check power supply conditions Qualified electrician Phase interrupted Check the mains connection Qualified electrician Incorrect circuit Adhere to wiring diagram and type plate Qualified electrician Overload Adhere to stipulations on type plate Qualified electrician ◼ Safety device is triggered Too many switching actuations Observe rated operating mode Qualified electrician ◼ Motor is too warm Ventilation insufficient Check cooling air routes, check direction of rotation Qualified electrician Ventilation ducts soiled Clean the ventilation ducts Qualified specialist Coil or terminal short circuit Measure the insulation resistance ◼ Motor does not start up ◼ Considerable drop in speed ◼ Motor does not start up ◼ Considerable drop in speed ◼ Safety device is triggered ◼ Motor does not start up ◼ Motor is too warm ◼ Considerable drop in speed ◼ Safety device is triggered ◼ Motor is too warm ◼ Considerable drop in speed ◼ Safety device is triggered ◼ Motor is too warm ◼ Safety device is triggered The start-up time has been Check the start-up exceeded conditions Qualified electrician 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 /Störungen/007 1.1.0 Inbetriebnahme nac h behobener Störung --> Standard --> 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. 2. Acknowledge the fault on the control unit. 3. Make sure that there is nobody in the danger area. 4. 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/Herforder Elektromotoren-Wer ke/Stör ung en/AT EX/007 1.1.0 Potential 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 Wartung_Titel @ 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 ekte/H erfor der El ektromotoren- 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 ekte/H erfor der El ektromotoren- 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 /Wartung/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 /Wartung/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 /Wartung/003 1.1.0 Grundlegendes @ 9\mod_1144434834059_1.doc @ 86831 Improperly performed maintenance work 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. Pos : 9.15 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75471 Pos : 9.16 /KN 2006-SM /Wartung/004 1.1.0 U mwelts chutz _Titel @ 9\mod_1144436206520_1.doc @ 86865 Environmental protection Adhere to the following instructions on environmental protection when performing maintenance work: Pos : 9.17 /KN 2006-SM /Wartung/004 1.1.0.0 Ents orgung F ett @ 9\mod_1144436328140_1.doc @ 86872 2021-05-31 49 Electric motors Size 63 - 225 ATEX / IECEx Maintenance ◼ 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. Pos : 9.18 /KN 2006-SM /Wartung/004 1.1.0.0 Ents orgung Öl @ 9\mod_1144439240623_1.doc @ 86943 ◼ 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 /Wartung/005 1.1 Rei nigung _Titel @ 9\mod_1144436963247_1.doc @ 86879 9.2 Cleaning Pos : 9.21 /KN 2006-Pr ojekte/Herforder Elektromotoren-Wer ke/Wartung/AT EX/005 1.1 Rei nigung EX-SCHUTZ @ 60\mod_1203501156710_1.doc @ 1040105 ◼ Additionally required safety equipment and clothing: ⚫ Light breathing mask Explosion protection 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/Herforder Elektromotoren-Wer ke/Wartung/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 /Wartung/006 1.1 Wartungs plan_Titel (Anleitung) @ 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. 9.26 /KN 2006-Pr 2006-SMojekte/Herforder /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75471 Pos : 9.27 Elektromotoren-Wer ke/Wartung/006 1.1.0 Wartungsplan @ 54\mod_1196342707944_1.doc @ 833101 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 30 6000 8000 13500 16000 20000 23000 200 40 4000 6000 11000 13000 17000 21000 225 50 3000 5000 10000 12500 16500 20000 2021-05-31 51 Electric motors Size 63 - 225 ATEX / IECEx Maintenance Pos : 9.29 /KN 2006-Pr ojekte/Herforder Elektromotoren-Wer ke/Wartung/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 52 Thread Tightening torque Thread value [Nm] Tightening torque value [Nm] M4 1.2 M 12 15.5 M5 2 M 16 30 M6 3 M 20 52 M8 6 M 24 80 M 10 10 M 30 150 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 Tightening torque Thread value [Nm] Tightening torque value [Nm] M4 2.3 M 14 105 M5 4.6 M 16 160 M6 7.9 M 20 330 M8 19 M 24 560 M 10 38 M 30 1100 M 12 66 M 36 1900 9.4.3 Screw connections of property class 5.6 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 Tightening torque Thread value [Nm] Tightening torque value [Nm] M4 1.1 M 14 49 M5 2.1 M 16 75 M6 3.7 M 20 150 M8 8.9 M 24 260 M 10 18 M 30 520 M 12 30 M 36 920 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 /Wartung/009 1.1 M aß nahmen nac h erfolgter Wartung_Titel @ 9\mod_1144438930025_1.doc @ 86928 9.5 Measures on completion of maintenance Pos : 9.32 /KN 2006-Pr ojekte/Herforder Elektromotoren-Wer ke/Wartung/AT EX/007 1.1.0 Potential 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 /Wartung/009 1.1.0 M aß nahmen nac h erfolgter Wartung --> Standard @ 9\mod_1144438981309_1.doc @ 86935 On completion of maintenance work, carry out the following steps before switching on: 1. Check that all screw connections which have been unfastened are fastened securely again. 2. Check whether all the safety devices and covers which have been removed have been properly re-installed. 3. Make sure that all tools, materials and other equipment which have been used, have been removed from the working area. 4. Clean the working area and remove any substances, e.g. liquids, processing material etc. 5. 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 emontage_Titel @ 9\mod_1144501489239_1.doc @ 87445 10 Removal Pos : 10.3 /KN 2006-SM /Demontag e/001 1.0 N ac hdem das Gebrauchsende 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_Titel @ 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/Herforder Elektromotoren-Wer ke/Demontage/ATEX/003 1.1.0 D emontagear beiten 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 emontage/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 emontage/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 emontage/008 1.1 Demontage --> 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 hnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75471 56 2021-05-31 Electric motors Size 63 - 225 ATEX / IECEx Removal Pos : 10.16 /KN 2006-SM/D emontage/009 1.1 Ents orgung --> Standar d --> ggf. anpas sen! @ 8\mod_1142093514566_1.doc @ 75855 10.3 Disposal 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. <nts styl e="Str ukturinfor mation" font=" Arial" siz e="1" fontcol our=" 0xffffff" c ontent=" ===== Ende der Stüc kliste ====="/> 2021-05-31 57 EC / EU – declaration of conformity HERFORDER ELEKTROMOTOREN-WERKE GmbH & Co. KG D – 32051 Herford D – 32008 Herford Goebenstraße 106 post office box 1852 Tel.: 05221 59040 [email protected] 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 DDEx 71 - 225 DCEx 250 and DCEx 280 DBEx 250 and DBEx 280 DDEx 250 and DDEx 280 DEx 315 marking gas II 2G Ex db e IIC T4-T6 Gb oder II 2G Ex db IIC T4-T6 Gb 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 2G Ex db eb 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 2G Ex db eb IIC T4-T6 Gb oder II 2G Ex db IIC T4-T6 Gb II 2G Ex de IIC T4-T6 oder II 2G Ex d IIC T4-T6 marking dust II 2D Ex tb IIIC T135°C - 85°C Db II 2D Ex tb IIIC T135°C - 85°C Db II 2D Ex tb IIIC T135°C - 85°C Db are conform to the regulations of the following European directives: - EMV- directive ATEX- directive RoHS- directive Electric motor Regulation Machinery directive 2014/30/EU 2014/34/EU 2011/65/EU 2019/1781/EU 2006/42/EC and (Amendment Annex II (EU) 2015/863) 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: D_Ex 71 – 225: D_Ex 250: D_Ex 280: DEx 315: SIQ 16 ATEX 142 X BVS 14 ATEX E 114 X BVS 19 ATEX E 005 X BVS 19 ATEX E 006 X PTB 10 ATEX 1047 X 0158 DEKRA DTC Gmbh 0158 DEKRA DTC Gmbh 0158 DEKRA DTC Gmbh 0158 DEKRA DTC Gmbh 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 Diaphragm pump N630.12 EX 13.3 Coupling For further information, see also § Rotex-BA.pdf 118 Translation of Original Operation and Installation Instruction, english, KNF 325089 11/22 ROTEX® Operating/Assembly instructions KTR-N Sheet: Edition: 40210 EN 1 of 27 23 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 Type No. 001 - shaft coupling Type No. 018 - DKM double-cardanic coupling Type with taper clamping sleeve 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 2 of 27 23 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 3 2 Advice 7 2.1 2.2 2.3 2.4 2.5 2.6 7 8 8 8 9 9 3 4 General advice Safety and advice symbols General hazard warnings Intended use Coupling selection Reference to EC Machinery Directive 2006/42/EC Storage, transport and packaging 9 3.1 3.2 9 9 Storage Transport and packaging Assembly 10 4.1 4.2 4.3 4.4 4.5 10 11 12 13 14 Components of the coupling Advice for finish bore Assembly of the hubs Assembly of taper clamping sleeve Displacements - alignment of the couplings 5 Start-up 16 6 Breakdowns, causes and elimination 17 7 Disposal 19 8 Maintenance and service 19 9 Spares inventory, customer service addresses 19 10 Enclosure A Advice and instructions regarding the use in 10.1 Intended use in potentially explosive atmospheres potentially explosive atmospheres 10.2 Inspection intervals for couplings in 10.3 Standard values of wear Please observe protection note ISO 16016. Drawn: Verified: 21 potentially explosive atmospheres 10.4 marking of coupling for potentially explosive atmospheres 10.5 EU Certificate of conformity 2019-07-02 Pz/Wb 2019-07-23 Pz Replacing: Replaced by: 20 22 24 25 27 KTR-N dated 2017-09-06 KTR-N Sheet: Edition: ROTEX® Operating/Assembly instructions 1 40210 EN 3 of 27 23 Technical data Illustration 1: ROTEX® (material: powder metal, Al-D and Al-H) Table 1: Material powder metal steel (Sint) Size 14 19 24 Component 1a 1a 1a Spider 1) (component 2) Rated torque [Nm] 92 ShA 98 ShA 64 ShD 7.5 12.5 10 17 34 60 - 2) Finish bore d (min-max) 6 - 16 6 - 24 9 - 28 L 35 66 78 l1, l2 11 25 30 E 13 16 18 Dimensions [mm] 3) General b s DH DZ 10 1.5 30 12 2.0 40 14 2.0 56 - DZ1 4) - dH 10 18 27 D1 - N - Table 2: Material aluminium diecast (Al-D) - no approval for ATEX Size 19 24 28 Component 1 1a 1 1a 1 1a Spider 1) (component 2) Rated torque [Nm] 92 ShA 98 ShA 64 ShD 10 17 - 35 60 - 95 160 - Finish bore 2) d (min-max) 6 - 19 19 - 24 9 - 24 22 - 28 10 - 28 28 - 38 Dimensions [mm] 3) General L l1, l2 E b s DH DZ DZ1 4) dH 66 25 16 12 2.0 41 - - 18 78 30 18 14 2.0 56 - - 27 90 35 20 15 2.5 67 - - 30 DZ1 4) - dH 7.2 8.5 10.5 18 27 30 38 46 51 D, D1 32 41 40 56 48 67 N 20 24 28 Table 3: Material aluminium (Al-H) Size Component 5 7 9 12 14 19 24 28 38 42 48 1a 1a 1a 1a 1a 1a 1a 1a 1a 1a 1a 1) 2) 3) 4) Spider 1) (component 2) Rated torque [Nm] 92 ShA 98 ShA 64 ShD 0.5 0.9 1.2 2.0 2.4 3.0 5.0 6.0 5.0 9.0 12 7.5 12.5 16 10 17 26 35 60 75 95 160 200 190 325 405 265 450 560 310 525 655 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 15 22 30 34 35 66 78 90 114 126 140 l1, l2 5 7 10 11 11 25 30 35 45 50 56 E 5 8 10 12 13 16 18 20 24 26 28 Dimensions [mm] 3) General b s DH DZ 4 0.5 10 6 1.0 14 8 1.0 20 10 1.0 25 10 1.5 30 12 2.0 40 14 2.0 55 15 2.5 65 18 3.0 80 20 3.0 95 21 3.0 105 - D1 - N - Maximum torque of the coupling TKmax. = rated torque of the coupling TK rated x 2 Bores H7 with keyway to DIN 6885 sheet 1 [JS9] and setscrew For dimensions G and t see table 8; there is a setscrew on the keyway (only with Al-D opposite the keyway) DZ1 = internal diameter of housing 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 KTR-N Sheet: Edition: ROTEX® Operating/Assembly instructions 1 40210 EN 4 of 27 23 Technical data Illustration 2: ROTEX® (material: GJL/GJS) Table 4: Material cast iron (GJL)/nodular iron (GJS) Size Component 65 75 90 1 1a 1b 1 1a 1b 1 1a 1b 1 1a 1 1 1 100 110 125 140 160 180 1 1 1 1 1 1 38 42 48 55 1) 2) 3) 4) Spider 1) (component 2) Rated torque [Nm] 92 ShA 98 ShA 190 325 265 450 64 ShD 405 560 310 525 655 410 685 825 625 1280 2400 940 1920 3600 1175 2400 4500 3300 4800 6650 8550 12800 18650 4950 7200 10000 12800 19200 28000 6185 9000 12500 16000 24000 35000 Finish bore 2) d (min-max) Dimensions [mm] 3) General L l1, l2 E Cast iron (GJL) 12 - 40 114 45 38 - 48 24 12 - 48 164 70 14 - 45 126 50 42 - 55 26 14 - 55 176 75 15 - 52 140 56 48 - 62 28 15 - 62 188 80 20 - 60 160 65 30 55 - 74 22 - 70 185 75 35 30 - 80 210 85 40 40 - 97 245 100 45 Nodular iron (GJS) 50 - 115 270 110 50 60 - 125 295 120 55 60 - 145 340 140 60 60 - 160 375 155 65 80 - 185 425 175 75 85 - 200 475 185 85 b s DH DZ DZ1 4) dH 18 3.0 80 - - 38 D, D1 66 78 75 20 3.0 95 - - 46 94 85 21 3.5 105 - - 51 22 4.0 120 - - 60 26 30 34 4.5 5.0 5.5 135 160 200 218 230 68 80 100 98 118 115 135 160 38 42 46 50 57 64 6.0 6.5 7.0 7.5 9.0 10.5 225 255 290 320 370 420 246 276 315 345 400 450 260 290 330 360 415 465 113 127 147 165 190 220 180 200 230 255 290 325 104 N 37 62 40 65 45 69 52 61 69 81 89 96 112 124 140 156 Maximum torque of the coupling TKmax. = rated torque of the coupling TK rated x 2 Bores H7 with keyway to DIN 6885 sheet 1 [JS9] and setscrew For dimensions G and t see table 8; there is a setscrew on the keyway DZ1 = internal diameter of housing 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 KTR-N Sheet: Edition: ROTEX® Operating/Assembly instructions 1 40210 EN 5 of 27 23 Technical data Illustration 3: ROTEX® (material: steel) Table 5: Material steel Size 14 19 24 28 38 42 48 55 65 75 90 100 110 125 140 160 180 1) 2) 3) 4) Component 1a 1b 1a 1b 1a 1b 1a 1b 1 1b 1 1b 1 1b 1 1b 1 1b 1 1b 1 1b 1 1 1 1 1 1 Spider 1) (component 2) Rated torque [Nm] 92 ShA 98 ShA 64 ShD 2) Finish bore d (min-max) 7.5 12.5 16 0 - 16 10 17 21 0 - 25 35 60 75 0 - 35 95 160 200 0 - 40 190 325 405 0 - 48 265 450 560 0 - 55 310 525 655 0 - 62 410 685 825 0 - 75 625 940 1175 0 - 80 1280 1920 2400 0 - 95 2400 3600 4500 0 - 110 3300 4800 6650 8550 12800 18650 4950 7200 10000 12800 19200 28000 6185 9000 12500 16000 24000 35000 0 - 115 0 - 125 60 - 145 60 - 160 80 - 185 85 - 200 L 35 50 66 90 78 118 90 140 114 164 126 176 140 188 160 210 185 235 210 260 245 295 270 295 340 375 425 475 l1, l2 11 18.5 25 37 30 50 35 60 45 70 50 75 56 80 65 90 75 100 85 110 100 125 110 120 140 155 175 195 E Dimensions [mm] 3) General b s DH DZ DZ1 4) dH D N 13 10 1.5 30 - - 10 30 - 16 12 2.0 40 - - 18 40 - 18 14 2.0 55 - - 27 55 - 20 15 2.5 65 - - 30 65 - 24 18 3.0 80 - - 38 26 20 3.0 95 - - 46 28 21 3.5 105 - - 51 30 22 4.0 120 - - 60 35 26 4.5 135 - - 68 40 30 5.0 160 - - 80 45 34 5.5 200 218 230 100 50 55 60 65 75 85 38 42 46 50 57 64 6.0 6.5 7.0 7.5 9.0 10.5 225 255 290 320 370 420 246 276 315 345 400 450 260 290 330 360 415 465 113 127 147 165 190 220 70 80 85 95 95 105 110 120 115 135 135 160 160 200 180 200 230 255 290 325 27 28 32 37 47 53 62 89 96 112 124 140 156 Maximum torque of the coupling TKmax. = rated torque of the coupling TK rated x 2 Bores H7 with keyway to DIN 6885 sheet 1 [JS9] and setscrew For dimensions G and t see table 8; there is a setscrew on the keyway DZ1 = internal diameter of housing 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 1 KTR-N Sheet: Edition: 40210 EN 6 of 27 23 Technical data Illustration 4: ROTEX® type DKM Table 6: Type DKM 5) 19 24 28 38 42 48 55 65 75 90 Dimensions d, D, D1 see table 1 to 5 Size Spider 1) (component 2) Rated torque [Nm] 92 ShA 98 ShA 10 17 35 60 95 160 190 325 265 450 310 525 410 685 625 940 1280 1920 2400 3600 LDKM 92 112 128 158 174 192 218 252 286 330 l1, l2 25 30 35 45 50 56 65 75 85 100 E 16 18 20 24 26 28 30 35 40 45 Dimensions [mm] 3) General b s 12 2.0 14 2.0 15 2.5 18 3.0 20 3.0 21 3.5 22 4.0 26 4.5 30 5.0 34 5.5 DH 40 55 65 80 95 105 120 135 160 200 dH 18 27 30 38 46 51 60 68 80 100 l11 10 16 18 20 22 24 28 32 36 40 l12 42 52 58 68 74 80 88 102 116 130 1) Maximum torque of the coupling TKmax. = rated torque of the coupling TK 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) 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 KTR-N Sheet: Edition: ROTEX® Operating/Assembly instructions 1 40210 EN 7 of 27 23 Technical data Coupling design: TB1 TB2 Screwing on cam side Screwing on collar side Different combinations of types TB1 and TB2 are possible. Illustration 5: ROTEX® type with taper clamping sleeve Table 7: Type with taper clamping sleeve Spider 1) (component 2) Rated torque [Nm] 92 ShA 98 ShA 35 60 95 160 190 325 265 450 310 525 410 685 625 940 Size Component 24 28 38 42 48 55 65 1a 1a 1a 1a 1a 1a 1 75 1 1280 1920 90 100 125 1 1 1 2400 3300 6650 3600 4950 10000 Finish bore d (min-max) 10 - 25 10 - 25 10 - 25 14 - 25 14 - 40 14 - 50 14 - 50 16 - 60 25 - 75 25 - 75 35 - 90 55 - 110 L l1, l2 64 23 66 23 70 23 78 26 106 39 96 33 101 33 E 18 20 24 26 28 30 35 Dimensions [mm] General b s DH DZ 14 2.0 55 15 2.5 65 18 3.0 80 20 3.0 95 21 3.5 105 22 4.0 120 26 4.5 135 - 144 52 40 30 5.0 160 149 52 230 90 288 114 45 50 60 34 38 46 5.5 6.0 7.0 DZ1 2) - dH 27 30 38 46 51 60 68 D1 78 94 104 118 115 N 15 16 28 20 5 - - 80 158 36 200 218 225 246 290 315 230 260 330 100 113 147 160 180 230 14 69 86 Taper clamping sleeve 1008 1108 1108 1610 1615 2012 2012 2517 3020 3) 3020 3535 4545 1) Maximum torque of the coupling TKmax. = rated torque of the coupling TK rated x 2 2) DZ1 = 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. Drawn: Verified: 2019-07-02 Pz/Wb 2019-07-23 Pz Replacing: Replaced by: KTR-N dated 2017-09-06 ROTEX® Operating/Assembly instructions 2 KTR-N Sheet: Edition: 40210 EN 8 of 27 23 Advice 2.2 Safety and advice symbols STOP ! 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. 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 This symbol indicates notes which may contribute to preventing material or machine damage. General advice 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. Drawn: Verified: 2019-07-02 Pz/Wb 2019-07-23 Pz Replacing: Replaced by: KTR-N dated 2017-09-06 ROTEX® Operating/Assembly instructions 2 KTR-N Sheet: Edition: 40210 EN 9 of 27 23 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. Drawn: Verified: 2019-07-02 Pz/Wb 2019-07-23 Pz Replacing: Replaced by: KTR-N dated 2017-09-06 ROTEX® Operating/Assembly instructions 4 KTR-N Sheet: Edition: 40210 EN 10 of 27 23 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 1 2 3 Number 2 1 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 1 2 3 Number 2 2 1 4 2 Description Hub Spider DKM spacer Setscrews DIN EN ISO 4029 1) Type DKM not available with DZ elements. Illustration 7: ROTEX® type DKM Components of ROTEX® type with taper clamping sleeve Component Number TB1/TB2 2 1 2 2 3 1 5 2) 4 4 Description 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. Illustration 8: ROTEX® type with taper clamping sleeve 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 KTR-N Sheet: Edition: ROTEX® Operating/Assembly instructions 4 40210 EN 11 of 27 23 Assembly 4.1 Components of the coupling Features of standard spiders 92 Shore A T-PUR® PUR (orange) (yellow) Spider hardness (Shore) 98 Shore A T-PUR® PUR (purple) (red) 64 Shore D T-PUR® PUR (light green) (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 dmax. • 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 TA [Nm] 14 M4 5 19 M5 10 24 M5 10 28 M8 15 38 M8 15 42 M8 20 48 M8 20 55 M10 20 65 M10 20 75 M10 25 90 M12 30 100 M12 30 110 M16 35 125 M16 40 140 M20 45 160 M20 50 180 M20 50 1.5 2 2 10 10 10 10 17 17 17 40 40 80 80 140 140 140 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 4 KTR-N Sheet: Edition: 40210 EN 12 of 27 23 Assembly 4.2 Advice for finish bore Table 9: Recommended fit pairs acc. to DIN 748-1 Bore [mm] above up to 50 Shaft tolerance Bore tolerance k6 m6 H7 (KTR standard) 50 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! STOP ! Touching the heated hubs causes burns. 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 H (see table 1 to 7) of the spider, one or two shaft ends may protude into the spider. 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 KTR-N Sheet: Edition: ROTEX® Operating/Assembly instructions 4 40210 EN 13 of 27 23 Assembly 4.3 Assembly of the hubs Illustration 10: Assembly of the hubs Illustration 11: Assembly of coupling 4.4 Assembly of taper clamping sleeve Assembly of taper clamping sleeve: 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. Drawn: Verified: 2019-07-02 Pz/Wb 2019-07-23 Pz Replacing: Replaced by: KTR-N dated 2017-09-06 ROTEX® Operating/Assembly instructions 4 KTR-N Sheet: Edition: 40210 EN 14 of 27 23 Assembly 4.4 Assembly of taper clamping sleeve Disassembly of taper clamping sleeve: 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 G [inch] 1/4 1/4 3/8 3/8 7/16 1/2 5/8 1/2 3/4 Screw dimensions L SW [inch] [mm] 1/2 3 1/2 3 5/8 5 5/8 5 7/8 6 7/8 6 1 1/4 8 1 1/2 10 1 3/4 12 TA [Nm] 5.7 5.7 20 20 31 49 92 115 170 Number 2 2 2 2 2 2 2 3 3 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 displacement figures (see table 11 to 13) are permissible. ! Please note: • 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 Radial displacements Axial displacements Kw = L1max. - L1min. [mm] Lmax = L + Ka [mm] Illustration 14: Displacements 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 KTR-N Sheet: Edition: ROTEX® Operating/Assembly instructions 4 40210 EN 15 of 27 23 Assembly 4.5 Displacements - alignment of the couplings Examples of the displacement combinations specified in illustration 15: Illustration 15: Combinations of displacement Example 1: Kr = 30 % Kw = 70 % Example 2: Kr = 60 % Kw = 40 % Ktotal = Kr + Kw 100 % Table 11: Displacement figures for 92 and 98 Shore A Size Max. axial displacement Ka [mm] Max. radial 1500 rpm displacement 3000 rpm Kr [mm] with Kw [degree] max. angular displacement with n=1500 rpm Kw [mm] Kw [degree] max. angular displacement with n=3000 rpm Kw [mm] 14 19 24 28 38 42 48 55 65 75 90 100 110 125 140 160 180 -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 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 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 1.3 1.2 1.2 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 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 Max. axial displacement Ka [mm] Max. radial 1500 rpm displacement 3000 rpm Kr [mm] with Kw [degree] max. angular displacement with n=1500 rpm Kw [mm] Kw [degree] max. angular displacement with n=3000 rpm Kw [mm] 14 19 24 28 38 42 48 55 65 75 90 100 110 125 140 160 180 -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 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 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 1.2 1.1 1.1 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 0.57 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 Ka [mm] Max. radial displacement Kr [mm] with n = Kw [degree] max. angular displacement with n = Please observe protection note ISO 16016. 1500 rpm 3000 rpm 1500 rpm 3000 rpm Drawn: Verified: 19 +1.2 -1.0 0.45 0.40 1.0 0.9 24 +1.4 -1.0 0.59 0.53 1.0 0.9 28 +1.5 -1.4 0.66 0.60 1.0 0.9 2019-07-02 Pz/Wb 2019-07-23 Pz 38 +1.8 -1.4 0.77 0.70 1.0 0.9 42 +2.0 -2.0 0.84 0.75 1.0 0.9 48 +2.1 -2.0 0.91 0.82 1.0 0.9 Replacing: Replaced by: 55 +2.2 -2.0 1.01 0.81 1.0 0.9 65 +2.6 -2.0 1.17 1.05 1.0 0.9 75 +3.0 -3.0 1.33 1.19 1.0 0.9 90 +3.4 -3.0 1.48 1.33 1.0 0.9 KTR-N dated 2017-09-06 ROTEX® Operating/Assembly instructions 5 KTR-N Sheet: Edition: 40210 EN 16 of 27 23 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. 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). 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: 2019-07-02 Pz/Wb 2019-07-23 Pz Replacing: Replaced by: KTR-N dated 2017-09-06 ROTEX® Operating/Assembly instructions 6 KTR-N Sheet: Edition: 40210 EN 17 of 27 23 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 Misalignment Different operating noise and/or vibrations occuring Wear of spider, shortterm torque transmission due to metal contact Screws for axial fastening of hubs working loose Wear of spider, torque transmission due to metal contact Breaking of cams Breaking of the cams due to high impact energy/overload Please observe protection note ISO 16016. Drawn: Verified: Hazard notes for potentially explosive atmospheres Elimination 1) Set the unit out of operation 2) Eliminate the reason for the misalignment Increased temperature on (e. g. loose foundation bolts, breaking of the the spider surface; ignition engine mount, heat expansion of unit risk by hot surfaces 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 Ignition risk due to coupling components that have been sparking 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 Ignition risk due to hot 3) Tighten the screws to fasten the hubs and surfaces and sparking secure against working loose 4) For inspection of wear see chapter 10.2 1) Set the unit out of operation 2) Replace complete coupling 3) Inspect alignment Ignition risk due to 1) Set the unit out of operation sparking 2) Replace complete coupling 3) Inspect alignment 4) Find out the reason for overload 2019-07-02 Pz/Wb 2019-07-23 Pz Replacing: Replaced by: KTR-N dated 2017-09-06 ROTEX® Operating/Assembly instructions 6 KTR-N Sheet: Edition: 40210 EN 18 of 27 23 Breakdowns, causes and elimination Breakdowns Breaking of cams Early wear of spider Early wear of spider (liquefaction of material inside the spider cam) ! Causes Hazard notes for potentially explosive atmospheres Elimination 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 Ignition risk due to 4) Inspect alignment sparking 1) Set the unit out of operation Operating error of the 2) Replace complete coupling unit 3) Inspect alignment 4) Instruct and train the service staff 1) Set the unit out of operation 2) Eliminate the reason for the misalignment Increased temperature on (e. g. loose foundation bolts, breaking of the Misalignment the spider surface; ignition engine mount, heat expansion of unit risk by hot surfaces 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 e. g. contact with residues of the spider aggressive liquids/oils, 3) Inspect coupling components and replace ozone influence, too coupling components that have been high/low ambient damaged temperatures etc. 4) Insert spider, assemble coupling causing physical components modification of the 5) Inspect alignment, adjust if necessary spider 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 Ambient/contact 3) Inspect coupling components and replace temperatures which coupling components that have been are too high for the damaged Ignition risk due to spider, max. 4) Insert spider, assemble coupling sparking with metallic permissible components contact of the cams -30 °C/+90 °C 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 Vibrations of drive 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) Operating parameters do not meet with the performance of the coupling 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 7 KTR-N Sheet: Edition: 40210 EN 19 of 27 23 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 10 KTR-N Sheet: Edition: 40210 EN 20 of 27 23 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 Rp0.2 ≥ 250 N/mm2. 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 KTR-N Sheet: Edition: 40210 EN 21 of 27 23 Enclosure A Advice and instructions regarding the use in 10.1 Intended use in potentially explosive atmospheres 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 T4 T5 T6 PUR / T-PUR® Ambient or operating temperature Ta 1) Max. surface temperature 2) -30 °C to +90 °C +110 °C -30 °C to +75 °C +95 °C -30 °C to +60 °C +80 °C Explanation: The maximum surface temperatures each result from the maximum permissible ambient or operating temperature Ta 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 Ta 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 KTR-N Sheet: Edition: 40210 EN 22 of 27 23 Enclosure A Advice and instructions regarding the use in 10.2 Inspection intervals for couplings in Equipment category potentially explosive atmospheres Inspection intervals 3G 3D M2 2G 2D No gases and vapours of explosion group IIC M2 2G 2D Gases and vapours of explosion group IIC potentially explosive atmospheres 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. 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. 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 KTR-N Sheet: Edition: 40210 EN 23 of 27 23 Enclosure A Advice and instructions regarding the use in 10.2 Inspection intervals for couplings in potentially explosive atmospheres 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 Replacing: Replaced by: KTR-N dated 2017-09-06 ROTEX® Operating/Assembly instructions 10 KTR-N Sheet: Edition: 40210 EN 24 of 27 23 Enclosure A Advice and instructions regarding the use in potentially explosive atmospheres 10.3 Standard values of wear 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. ! Illustration 18: Inspection of the limit of wear Illustration 19: Wear of spider Table 14: Size 9 14 19 24 28 38 42 48 55 Please observe protection note ISO 16016. Limits of wear (friction) Xmax. [mm] 2 2 3 3 3 3 4 4 5 Drawn: Verified: 2019-07-02 Pz/Wb 2019-07-23 Pz Limits of wear (friction) Xmax. [mm] 5 6 8 9 9 10 12 14 14 Size 65 75 90 100 110 125 140 160 180 Replacing: Replaced by: KTR-N dated 2017-09-06 ROTEX® Operating/Assembly instructions 10 KTR-N Sheet: Edition: 40210 EN 25 of 27 23 Enclosure A Advice and instructions regarding the use in 10.4 potentially explosive atmospheres 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 -30 °C ≤ Ta ≤ +60 °C … +90 °C KTR Systems GmbH, Carl-Zeiss-Straße 25, D-48432 Rheine Mb Gb Db • Hubs resp. spacer without aluminium Category 3 (hubs resp. clamping hubs without feather keyway) ROTEX® <Year> I M2 Ex h I II 3G Ex h IIC T6 … T4 II 3D Ex h IIIC T80 °C … T110 °C -30 °C ≤ Ta ≤ +60 °C … +90 °C KTR Systems GmbH, Carl-Zeiss-Straße 25, D-48432 Rheine Mb Gc Dc • 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 II 2D Ex h IIIC T80 °C … T110 °C -30 °C ≤ Ta ≤ +60 °C … +90 °C KTR Systems GmbH, Carl-Zeiss-Straße 25, D-48432 Rheine Gb Db • 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 II 3D Ex h IIIC T80 °C … T110 °C -30 °C ≤ Ta ≤ +60 °C … +90 °C KTR Systems GmbH, Carl-Zeiss-Straße 25, D-48432 Rheine Gc Dc 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 40210 EN 26 of 27 23 Enclosure A Advice and instructions regarding the use in 10.4 KTR-N Sheet: Edition: potentially explosive atmospheres 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 Ta +65 °C, +80 °C, +115 °C resp. +120 °C II 2D c T 140 °C/I M2 c -50 °C Ta +120 °C Complete marking: (valid for PUR only) II 2G c IIC T6, T5 resp. T4 -30 °C Ta +65 °C, +80 °C resp. +90 °C II 2D c T 110 °C/I M2 c -30 °C Ta +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 10 KTR-N Sheet: Edition: 40210 EN 27 of 27 23 Enclosure A Advice and instructions regarding the use in potentially explosive atmospheres 10.5 EU Certificate of conformity 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 Please observe protection note ISO 16016. Drawn: Verified: i. V. Reinhard Wibbeling Engineering/R&D 2019-07-02 Pz/Wb 2019-07-23 Pz i. V. Michael Brüning Product Manager Replacing: Replaced by: KTR-N dated 2017-09-06 KNF worldwide You can find our local KNF partners at: www.knf.com ">

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