Summary of Contents for Colasit CRDV-R ATEX Series
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Operating instructions CRDV-R 200-315 ATEX Duct fan with direct drive Your point of contact: Colasit Representative Street Location Version 1.0-en | 07/2024...
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Date Name 1-en EU/ATEX First version published. 7/1/2024 A. Roth Document identification Translation of the original German operating instructions. Colasit TD-000873 Contact information Manufacturer COLASIT AG Faulenbachweg 63 CH-3700 Spiez E-mail: fans@colasit.com Website: www.colasit.com Phone: +41 (0)33 655 61 61...
Table of contents Table of contents Operating instruction information ..............Further applicable documents ................Copyright ........................ Additional safety instructions................Use and storage of the operating instructions............Intended application of the fan ................2.2.1 Intended use ....................2.2.2 Reasonably foreseeable misuse..............2.2.3 Equipment limits..................
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Table of contents 5.3.2 Sleeves with flange ..................5.3.3 Flange connections..................5.3.4 Condensate drain..................5.3.5 Isolation switch................... 5.3.6 Frequency converter (FC)................5.3.7 Speed adjustment potentiometer ............... 5.3.8 Inlet grille....................5.3.9 Floor or ceiling mounting................5.3.10 Horizontal wall mounting................5.3.11 Vertical wall mounting ................Transport.......................
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Table of contents Safety instructions ....................Carrying out placement in service ................9.2.1 Check motor rotation direction ..............9.2.2 Functional test of the frequency converter (FC, optional accessory)..9.2.3 Conduct test run..................Operation ......................10.1 Safety instruction....................10.2 Operating instructions .................... 10.3 Outside cleaning.....................
Design notes For the sake of simplification, in these operating instructions, • the company Colasit AG is referred to as the “manufacturer,” • all sizes (CRDV-R 200-315 ATEX) are generally referred to as the “fan,” • “frequency converter” is abbreviated as “FC,”...
2 | Additional safety instructions Additional safety instructions This chapter contains information relevant to safety and additional as well as more in-depth safety instructions for operators and technical specialists. Additional safety instructions Depending on the execution of the fan, associated documents can contain addi- tional operating instructions with important safety instructions.
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• For independent assessment, the operator is to consult the pertinent available resistance lists for plastics. The SIMCHEM guide is found on the manufacturer's website (www.colasit.com). • The order confirmation or the additional specification sheet contains fur- ther information and notes regarding a potential reduction in service life of the fan.
2 | Additional safety instructions • The drive motor of the fan is designed for continuous operation (S1) or FC operation (S9). • Maximum speed, which is dependent on • the temperature of the conveyed medium, • chemicals present and their concentration in the air stream. •...
Additional safety instructions | 2 • Operation in explosion protection zone 0 or in a zone that is not specified in the explosion protection marking on the nameplate of the fan or in the tech- nical data sheet. • Operation of the fan outside the parameters and limit values specified in the technical data sheet.
2 | Additional safety instructions Inlet connection (suction side): Connection to supply air ductwork with sleeve. Outlet connection (pressure side): Connection to discharge air duct- work with sleeve. Terminal box on electric motor. Isolation switch: Terminals for electrical supply to accessories and options (e.g., FC for electric motor).
Additional safety instructions | 2 • Operate the fan at negative pressure for use with explosive and/or haz- ardous conveyed media. Target groups and personnel requirements These operating instructions are intended for: • The operator of the system in which the fan is installed. •...
2 | Additional safety instructions • Initiate and verify that the function and integrity of all fan safeguards are checked regularly. • Ensure that all manufacturer’s regulations are observed upon retrofitting of safeguards. • Determine the priority of shutting down the fan upon system malfunction or in an emergency.
Additional safety instructions | 2 • The fan may only be connected to the frequency converter by an electrician • after its operating instructions have been read and understood, • including detailed knowledge of the respective frequency converter, • and specialized knowledge of EMC-compliant wiring (consult the manu- facturer’s EMC guideline).
3 | Essential safety instructions Essential safety instructions The associated documents can contain additional operating instructions with im- portant safety instructions Associated documents. Notation of safety instructions The safety instructions and warnings in these operating instructions are identi- fied by the following warning symbols, signal words, and colors (electronic ver- sion of the operating instructions only), which convey the severity of the dan- gers.
Essential safety instructions | 3 Personal protective equipment The personal protective equipment to be worn: • is to be determined and made available by the operator based on the oper- ating conditions and conveyed medium. • is the personal responsibility of the qualified personnel to be worn as suit- able for the work to be conducted and to be supplemented as necessary.
3 | Essential safety instructions 3.2.1 Personal protective equipment for potentially explosive environments It must be ensured for maintenance work on the fan in a potentially explosive environment that maintenance personnel are never dangerously electrostatically charged. The following apply when in a potentially explosive environment: •...
Essential safety instructions | 3 Electrical hazards DANGER Danger to life due to electric shock from contact with cur- rent-carrying conductors or components under hazardous voltage. Immediate danger to life due to respiratory and cardiac arrest. ▪ Only a qualified and authorized electrician may work on the power mains and the electrical components of the fan.
3 | Essential safety instructions Explosion hazards DANGER Danger to life due to ignition of explosive gas mixtures Death or serious injuries if gas mixtures explode due to the following causes: ▪ Hot surfaces, such as frictional heat in hub seal or hot bearing surface of a defective motor bearing.
Essential safety instructions | 3 Conveyed medium hazards WARNING Risk of injury due to escape or inflow of a conveyed medium with the ability to cause adverse health effects Risk of eye irritation, cough, difficulty breathing, burn, and suffocation. Clarify what medium is being conveyed. Observe the Safety Data Sheet(s) of the conveyed medium.
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3 | Essential safety instructions WARNING Risk of injury due to damaged fan ▪ Fan can continue coasting for a long time after being switched off. ▪ Danger by contact with dangerous parts and conveyed medium if casing is damaged. Use caution when approaching the fan.
Explosion protection | 4 Explosion protection The zone of the conveyed medium and the installation site are to be specified by the system operator when ordering the fan. Explosion protection information • Intended use and operating conditions Chap. 2.2.1 [} 8]. •...
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4 | Explosion protection Symbol/ Description Code CE mark UKCA mark Explosion protection marking according to Directive 2014/34/EU (ATEX). Equipment group 2/3G Equipment category inside (2)/outside (3) the fan for gaseous conveyed media (G). Ex h Explosion protection (Ex) through protection type (h): Explosion protection through design safety.
Structure and function | 5 Structure and function Overview Flow direction Fig. 2: Fan overview 1 Sleeves: Connect the inlet connection (A) and outlet connection (B) to the connection tubes in a stress-free manner. 2 Hood/upper part of housing with vent connection, complete. 3 Profile seal: Seals the connection between the hood/upper part of hous- ing and motor mounting plate.
Max. Drehzahl darf nie überschritten werden! Maximum rotation speed may not be exceeded! Vitesse maximale d´utilisation à ne dépasser! COLASIT AG Faulenbachweg 63, CH-3700 Spiez Phone: +41 (0)33 655 61 61 • www.colasit.com • fans@colasit.com II 2/3G Ex h IIB+H T4 Gb/Gc Type CRDV-R 250/250 Serial No.
Structure and function | 5 • Executions: See accessories for the CRDV-R 200-315 on the manufac- turer’s website (www.colasit.com). • Permissible distance between fan connection and ductwork Chap. 7.3 [} 36]. 5.3.2 Sleeves with flange • Required accessory for fans with flange con- nections.
5 | Structure and function 5.3.5 Isolation switch • Required accessory. • In zone-compliant ATEX execution. • For removal of voltage on all phases before maintenance and repair work. • Can be locked in the OFF position with a cus- tomer-supplied padlock.
Structure and function | 5 5.3.8 Inlet grille • Required accessory for free-sucking installa- tion, as access and safety protection. • Made of material that conforms to zone. • Permanently installed (welded) on the free-suck- ing inlet connection. • Entry protection as well as protection against in- filtration of contamination and foreign objects ( IP20 degree of protection).
5 | Structure and function CRDV 200/180, 200/200 250/225, 250/250 315/280, 315/315 NW Ø [mm] A [mm] B [mm] C [mm] 5.3.10 Horizontal wall mounting • Optional. • Attachment to the wall with four screws. • The attachment to the wall must be secure. Fig. 14: Wall mounting, horizontal Fig. 15: Dimensions for installation CRDV...
Structure and function | 5 5.3.11 Vertical wall mounting • Optional. • Attachment to the wall with four screws. • The attachment to the wall must be secure. • NOTICE The outlet opening must be oriented upward. Fig. 16: Wall mounting, vertical Fig. 17: Dimensions for installation CRDV 200/180, 200/200...
6 | Transport Transport Safety instructions These safety instructions warn against dangers that can arise when transporting the fan. WARNING Danger to life when remaining under suspended loads Injuries due to falling or swinging loads. Avoid hazardous area under the suspended load. Never stand under or in swinging range of suspended loads.
Transport | 6 Claims for damages can only be made within the complaint period and accord- ing to the general terms and conditions (T&C). Save packing for a possible re- turn shipment. Mount fan and place in service only after repairs and resolution of com- plaints.
6 | Transport Transporting package on a pallet • Inspect pallet: A damaged or rotted pallet may not be transported by crane. • Preferably, transport pallet by crane fork or pallet jack. • Otherwise, attach sling to pallet such that it will not slip. •...
Mechanical installation | 7 Mechanical installation Safety instructions These safety instructions warn against dangers that can arise when mounting the fan. WARNING Risk of injury due to unsecured work area Injuries due to objects falling or being bumped. ▪ The installation location of the fan could be inaccessible or at a dangerous height.
7 | Mechanical installation Fig. 21: Aligning the vent connection for outdoor installation in a horizontal position Installing the fan outdoors in a horizontal position To prevent the intake of rainwater, the upper vent connections must be rotated by 90° so the inlet openings are oriented downward (see figure). Connecting fan to ductwork NOTICE Risk of damage due to deformation of fan housing...
Mechanical installation | 7 Fig. 22: Distance to ductwork connection Procedure: 1. Push the sleeve Chap. 5.3.1 [} 26] over the ductwork end together with the hose clamps. 2. Mount the ductwork and adjust it to the fan connection. 3. Observe the permissible distance X (see detail view). Standard: X = 30 –...
7 | Mechanical installation The casing drain shall always be located at the lowest point of the fan housing’s current mounting position. The applicable plug is removed for installation (welding) of the casing drain. • Weld drain pipe (outer diameter 20 mm) to casing drain (type V) Chap.
Mechanical installation | 7 Instructions for execution of the siphon • For negative pressure operation of the fan: If the siphon is insufficiently di- mensioned or not filled with water, there is a risk that false air will be sucked •...
8 | Electrical installation Electrical installation Safety instructions These safety instructions warn against dangers that can arise during electrical installation of the fan. DANGER Risk of injury due to electrical energy Immediate danger to life due to respiratory and cardiac arrest. ▪...
Electrical installation | 8 • shall be installed in an easily-accessible location near the fan, • provides qualified personnel a means of directly controlling and disconnect- ing the electrical power supply from the fan, • shall therefore be executed as a lockable all-pole disconnect switch. DANGER Use only an explosion-proof isolation switch if the isolation switch is installed in a potentially explosive area.
8 | Electrical installation 8.2.4 Starting current limiter NOTICE Strong mechanical load by the fan. Thermal and electrodynamic load on the motor windings. Reduced service life of the fan. Disturbance of nearby electrical equipment, such as controllers. ▪ When larger fans are switched on and ramped up under full mains voltage, a high inrush current is generated.
Electrical installation | 8 WARNING Risk of injury due to high contact voltage Injury by electric shock. ▪ If long cable shields are not connected/grounded, high contact voltages can occur during operation. Connect cable shields of motor connection cables and signal lines to a com- mon reference potential.
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8 | Electrical installation Connection options Depending on the execution, an electric motor can either be connected directly (1) to the electrical mains or can/shall be operated with a FC. L2 and L3 do not exist for a single-phase feed (230 V). The FC is either •...
Electrical installation | 8 8.3.2 Frequency converter (FC) parameterization NOTICE Risk of damage due to erroneous parameterization Unpredictable fan behavior resulting in damage. Carry out parameterization carefully according to the FC operating instruc- tions. The specialist shall be familiar with the FC. If necessary, consult the supplier.
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8 | Electrical installation EMC-compliant connection for FC operation Observe the EMC instructions of the fan manufacturer as well as the operating instructions of the FC manufacturer. In particular, the maximum permissible length of the motor connection cable be- tween the FC and the electric motor as well as the corresponding grounding concept.
Electrical installation | 8 Making an ATEX-compliant ground connection Fig. 27: Connecting the grounding cable to the fan Connect a grounding cable to the protective earthing connection in the terminal box to dissipate the static charge that builds up in the fan (see detail view). The cross section of the grounding cable must be at least 10 mm Connecting the electric motor This chapter describes the direct connection of a three-phase motor (IM) to the...
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8 | Electrical installation • For protection against vibration, run the connection cable between the fan and cable fasteners to the installation location such that it is flexible and movable. Making the cable connection • DANGER Establish an electrically safe work condition before beginning work.
Electrical installation | 8 Final inspection • Verify mains and motor connections with motor nameplate data. • Check the sizing and setting of the electrical protective devices (fuses, mo- tor protection switch). • Check installation of motor connection cable and isolation switch. •...
9 | Placement in service Placement in service Safety instructions These safety instructions warn against dangers that can arise when placing the fan in service. WARNING Risk of injury when placing the fan in service. Injuries due to electrical, mechanical, and chemical hazards. Installation work on the fan as well as final inspection have been completed in their entirety Chap.
Placement in service | 9 • with FC control elements or an external control unit, • with the local potentiometer Chap. 5.3.7 [} 28]. Check during the functional test: • Check acceleration and braking time Chap. 8.3 [} 42]. • Commands shall cause corresponding speed changes. •...
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9 | Placement in service At the end of the test run: • Compare current values and parameters with initial values and parameters from the beginning of the test run: • Irregular running, vibration, or noises. • Current draw of the electric motor. •...
Operation | 10 Operation 10.1 Safety instruction This safety instruction warns against dangers that can arise during fan opera- tion. WARNING Risk of injury due to fan operation Injuries due to electrical, mechanical, and chemical hazards or explosions. Only qualified and authorized operating personnel may operate the fan and clean the outside of it.
11 | Maintenance Maintenance 11.1 Safety instructions These safety instructions warn against dangers that can arise when performing maintenance on the fan. DANGER Risk of injury due to maintenance work on the fan in a poten- tially explosive atmosphere Death or serious injuries upon explosion. Injuries due to electrical, mechanical, and chemical hazards.
Maintenance | 11 11.2 Maintenance table The maintenance intervals (W/weekly, M/monthly, 6M/semi-annually and 12M/ annually) are to be adapted to the current operating conditions of the fan as de- termined by the customer. Maintenance activity Cross reference 12M* Check operating condition Chap.
11 | Maintenance For outdoor installation of the fan in a horizontal position, the upper vent con- nections must be oriented toward the ground Chap. 7.2 [} 35]. Rubber parts can be rotated in place. • Smooth operation of fan: For irregular running, check for vibration or noise Chap.
Maintenance | 11 • Loosen sleeve at inlet connection and remove ductwork end Chap. 7.3 [} 36]. • Remove the hood/upper part of the housing Chap. 12.6 [} 66]. • Clean the impeller and the inside of the housing thoroughly. NOTICE Do not damage the impeller blades when doing so. •...
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11 | Maintenance • If necessary, conduct outside and inside cleaning. Assembly and final inspection • Fixed position of all screw connections. • Check leak tightness of the casing between the upper part and lower part (sealing ring, tension ring). •...
Repair | 12 Repair 12.1 Safety instructions These safety instructions warn against dangers that can arise when repairing the fan. Modifications and adaptations to the fan are strictly prohibited and will result in the loss of ATEX certification. DANGER Risk of injury due to repair work on the fan in a potentially explosive atmosphere Death or serious injuries upon explosion.
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12 | Repair Fault Possible cause Fault discovery Remedy Observe minimum dis- tance between fan connection and damper valve or duct bends (L > 3 x duct Ø). Operating Faulty motor winding. Winding measure- Replace electric motor speed cannot ment. Chap. 12.8 [} 68]. be reached. Improper phase volt- Measure phase volt- Check/replace fuses,...
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Repair | 12 Fault Possible cause Fault discovery Remedy Impeller stiff or Visual inspection. Remove deposits or stopped. foreign objects Chap. 11.3.3 [} 56]. Winding damage on Winding measure- Repair or replace elec- the electric motor. ment. tric motor Chap. 12.8 [} 68]. Electric motor bearing Turn electric motor by Check EMC guide-...
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12 | Repair Fault Possible cause Fault discovery Remedy Type V: Visual inspec- Clean and replace tion. condensate drain/ siphon Chap. 5.3.4 [} 27]. Retrofit with casing drain. Loose or defective fas- Visual inspection. Tighten or replace fas- tening elements. tening elements. Improper mounting.
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Repair | 12 Fault Possible cause Fault discovery Remedy Grinding noise Casing too tight. Check distance and Adjust ductwork dis- coming from alignment of ductwork tance and connection the impeller. to fan connection. (sleeves) appropri- ately. Ductwork connected to Connect ductwork to fan without sleeves.
12 | Repair Fault Possible cause Fault discovery Remedy Sealing ring defective. Check sealing ring and Replace sealing ring, tension ring between and replace tension the upper and lower ring if necessary housing parts. Chap. 12.6 [} 66]. 12.3 Spare parts and wear parts DANGER Risk of injury due to impeller explosion Serious injuries due to debris being launched out.
Special centering pieces are needed for proper installation and alignment of the electric motor/motor shaft and impeller to the casing. Contact your Colasit distributor for details and a comprehensive installation manual. Prepare the fan for repair (impeller, electric motor, V-ring seal, etc.) as follows: Observe safety instructions Chap.
12 | Repair 12.6 Replacing the hood/upper part of housing Conditions: • Fan has been prepared for repairs Chap. 12.4 [} 65]. Procedure: • Loosen the tension ring (3). • Remove the hood/upper part of housing (1) and sealing ring (2) from the lower part of the housing (4).
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Repair | 12 Procedure: • Cut out and remove the hub cap (3) with appropriate tools. The hub cap cannot be removed non- destructively – order a spare in a timely manner. NOTICE Do not reuse a hub cap that has been removed! Only a leak-proof, undamaged hub cap prevents aggres- sive conveyed media from corroding the motor shaft and impeller hub,...
12 | Repair Mounting instructions • Clean and lightly grease motor shaft and impeller hub before mounting. • Insert hub adapter with inserted key into the impeller from the outside. • Push the impeller onto the motor shaft as far as it will go. The impeller posi- tion cannot be adjusted.
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Repair | 12 Procedure: 1. Remove all cables from the termi- nal box of the electric motor and protect from damage. 2. Remove the mounting nuts on the motor flange. 3. Move a heavy electric motor with suitable hoisting gear. a Use the lifting eye bolts on the electric motor for this purpose.
Removal from service, disposal, and recycling | 13 Removal from service, disposal, and recycling 13.1 Safety instructions These safety instructions warn against dangers that can arise during removal from service and disposal of the fan. WARNING Risk of injury during removal from service and disposal of the fan Death or serious injuries upon explosion.
13 | Removal from service, disposal, and recycling Procedure: • Switch off fan and FC (option) and prepare them for removal: • Allow to cool down. • Close the shut-off dampers in the supply air and discharge air lines. • Drain and dispose of condensate in the casing drain (option). •...
EN 60079-7: 2015 EN 60079-15: 2019 Name and address of the Andreas Roth document manager COLASIT AG , Faulenbachweg 63 3700 Spiez, Switzerland Deposit of the assessment and techni- Eurofins Electric + Electronic Testing cal documentation with AG, Fehraltdorf (1258) Deposit no.
(7) The design of this equipment and the various executions are specified in the ap- pendix to this Declaration of Conformity and in the technical report. (8) Colasit AG certifies compliance with the essential health and safety require- ments for the design and construction of equipment and protective systems in- tended for use in potentially explosive atmospheres according to Annex II of Di- rective 2014/34/EU.
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Ex h IIB+H2 T3 or T4* -/Gb Installation site Zone 1 *) T3 or T4 according to the attached motor. The fan as a non-electrical compo- nent corresponds to T4. COLASIT AG Spiez, 6/7/2024 B. Stucki Andreas Roth (Division manager)
15 | ATEX - Declaration of Conformity • If the fans are used in potentially explosive atmospheres of Zone 1 or 2, they may only be operated with electric motors for which a corresponding approval (EU type examination certificate) is available. •...
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