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Summary of Contents for Colasit CRDV-D ATEX Series
- Page 1 Operating instructions CRDV-D 200-315 ATEX Roof fan with direct drive Your point of contact: Colasit Representative Street Location Version 1.0-en | 07/2024...
- Page 2 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-000879 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...
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Page 3: Table Of Contents
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.................. - Page 4 Table of contents 5.3.2 Frequency converter (FC)................5.3.3 Speed adjustment potentiometer ............... 5.3.4 Inlet/outlet grilles ..................5.3.5 Check valve with boot ................5.3.6 Roof mounting base................... Transport....................... Safety instructions ....................Incoming goods inspection..................Packing........................Intermediate storage ....................Transport to installation location................6.5.1 Transport by pallet stacker or forklift............
- Page 5 Table of contents Operation ......................10.1 Safety instruction....................10.2 Operating instructions .................... 10.3 Outside cleaning..................... Maintenance......................11.1 Safety instructions ....................11.2 Maintenance table ....................11.3 Maintenance work ....................11.3.1 Check operating condition ................. 11.3.2 Inside inspection ..................11.3.3 Inside cleaning ................... 11.3.4 Annual inspection..................
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Page 6: Operating Instruction Information
Design notes For the sake of simplification, in these operating instructions, • the company Colasit AG is referred to as the “manufacturer,” • all sizes (CRDV-D 200-315 ATEX) are generally referred to as the “fan,” • “frequency converter” is abbreviated as “FC,”... -
Page 7: Copyright
Copyright These operating instructions are protected by copyright. © COLASIT AG. All rights reserved. The use and distribution of the operating instructions is permitted in the context of using the fan. Any other use is only permitted with the written consent of the manufacturer. -
Page 8: Additional Safety Instructions
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. - Page 9 • 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.
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Page 10: Reasonably Foreseeable Misuse
2 | Additional safety instructions Note especially: • Equipment category as well as ATEX certification of electric motor and ac- cessories (FC, isolation switch, etc.) must be zone-compliant. • The drive motor of the fan is designed for continuous operation (S1) or FC operation (S9). -
Page 11: Equipment Limits
Additional safety instructions | 2 • Conveyance of explosive dust. • 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. -
Page 12: Residual Risks
2 | Additional safety instructions Outlet connection (pressure side). Isolation switch: Terminals for electrical supply to accessories and options (e.g., FC for electric motor). Fan mounting plate (roof mounting flange). Inlet connection (suction side): Connection to supply air ductwork via roof mounting base is recom- mended Chap. -
Page 13: Target Groups And Personnel Requirements
Additional safety instructions | 2 Target groups and personnel requirements These operating instructions are intended for: • The operator of the system in which the fan is installed. • The qualified personnel who carry out work on the fan during its various life cycle phases, from installation to disposal. -
Page 14: Transport Personnel
2 | Additional safety instructions • Determine the priority of shutting down the fan upon system malfunction or in an emergency. • Clearly determine and regulate the responsibility for installation, servicing, maintenance, and repair of the fan. • Ensure that the responsible qualified personnel •... -
Page 15: Operating Personnel
Additional safety instructions | 2 • and specialized knowledge of EMC-compliant wiring (consult the manu- facturer’s EMC guideline). • The fan manufacturer’s declaration of conformity is invalidated upon erro- neous connection of the frequency converter and electric motor. 2.3.4 Operating personnel The fan is generally used in automatic operations with a controller. -
Page 16: Essential Safety Instructions
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. -
Page 17: Personal Protective Equipment
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. -
Page 18: Personal Protective Equipment For Potentially Explosive Environments
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: •... -
Page 19: Electrical Hazards
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. -
Page 20: Explosion Hazards
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. -
Page 21: Conveyed Medium Hazards
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. - Page 22 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.
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Page 23: Explosion Protection
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]. •... - Page 24 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.
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Page 25: Structure And Function
Structure and function | 5 Structure and function Overview Hood/upper part of housing with outlet and vent connections, com- plete. Profile seal: Seals the connection between the hood/upper part of housing and motor mounting plate. Electric motor with motor shaft (C). Motor mounting plate. -
Page 26: Signs And Warning Symbols On The Fan
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-D 250/250 Serial No. -
Page 27: Options And Accessories
Structure and function | 5 Options and accessories 5.3.1 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. -
Page 28: Inlet/Outlet Grilles
5 | Structure and function 5.3.4 Inlet/outlet grilles • Required accessory for free-sucking and/or free-blowing installation, as access and safety protection. • Made of material that conforms to zone. • The inlet grille (1) is permanently attached (welded) to the free-sucking inlet connection via a mounting ring. -
Page 29: Roof Mounting Base
Ceiling cut-out (rectangular connection) b) Ductwork connection A sleeve should be used for connection to ductwork. See the CRDV-R acces- sories on the manufacturer’s website (www.colasit.com). Dimensions in [mm] Type/NW Ø Operating instructions CRDV-D 200-315 ATEX | Version 1.0-en... -
Page 30: Transport
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. -
Page 31: Packing
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. -
Page 32: Transport By Crane
6 | Transport 6.5.2 Transport by crane Transporting package with lifting eye bolts • Position crane hook over the middle of the package. • Attach sling to all lifting eye bolts of the packing. WARNING Do not lift the fan by the lifting eye bolt of the electric motor. -
Page 33: Mechanical Installation
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. -
Page 34: Connecting Fan To Ductwork
(use in zone 2 environment if the pip- ing is still in the explosion protection zone). See accessories for the CRDV-R fan on the manufacturer’s website (www.colasit.com). 34 / 76 Operating instructions CRDV-D 200-315 ATEX | Version 1.0-en... -
Page 35: Condensate Drain
Mechanical installation | 7 Condensate drain • Incoming rainwater is drained via two openings (1) in the lower part of the housing. • NOTICE Remove both plugs from the openings during installation. Fig. 14: Condensate drain If the equipment is roof mounted, both openings (1) in the lower part of the fan housing must remain open. -
Page 36: Electrical Installation
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. ▪... -
Page 37: Motor Protection Switch Installation
Electrical installation | 8 • 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. -
Page 38: Starting Current Limiter
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. -
Page 39: Frequency Converter (Fc) Installation Options
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. - Page 40 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 •...
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Page 41: Frequency Converter (Fc) Parameterization
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. -
Page 42: Making An Atex-Compliant Ground Connection
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, observe the maximum permissible length of the motor connection cable between the FC and the electric motor as well as the corresponding grounding concept. -
Page 43: Connecting The Electric Motor
Electrical installation | 8 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 electrical power supply (connection option No. 1 in overview Chap. -
Page 44: Final Inspection
8 | Electrical installation • Open terminal box on electric motor. • If necessary, move the jumpers on the terminal board according to the ter- minal assignment. The terminal assignment is also located on the inside of the terminal box cover. •... -
Page 45: Placement In Service
Placement in service | 9 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. -
Page 46: Conduct Test Run
9 | Placement in service • with the local potentiometer Chap. 5.3.3 [} 27]. Check during the functional test: • Check acceleration and braking time Chap. 8.3 [} 38]. • Commands shall cause corresponding speed changes. • The electric motor may not generate any unusual vibration or noises when operating within the characteristic curve range according to the technical data sheet. - Page 47 Placement in service | 9 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. •...
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Page 48: Operation
10 | Operation 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. -
Page 49: Maintenance
Maintenance | 11 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. -
Page 50: Maintenance Table
11 | Maintenance 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. -
Page 51: Inside Inspection
Maintenance | 11 11.3.2 Inside inspection NOTICE Risk of damage due to vibration Material damage and production downtime, reduced service life. ▪ Improper use or deposits on the impeller lead to imbalance and vibration. Switch fan off immediately in case of unusual vibration. Check parts in contact with the medium. - Page 52 11 | Maintenance Check during outside inspection • Cracking: Fan housing • Noise: Motor bearings • Proper mounting and damage of: Protective devices (isolation switch) as well as inlet/outlet grilles, check valve, and roof mounting base, if in- stalled. • Unobstructed condensate drain: Clean blocked openings in the lower part of the housing Chap.
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Page 53: Repair
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. - Page 54 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 [} 62]. be reached. Improper phase volt- Measure phase volt- Check/replace fuses,...
- Page 55 Repair | 12 Fault Possible cause Fault discovery Remedy Impeller stiff or Visual inspection. Remove deposits or stopped. foreign objects Chap. 11.3.3 [} 51]. Winding damage on Winding measure- Repair or replace elec- the electric motor. ment. tric motor Chap. 12.8 [} 62]. Electric motor bearing Turn electric motor by Check EMC guide-...
- Page 56 12 | Repair Fault Possible cause Fault discovery Remedy Improper mounting. Installation location re- Fortify foundation quirements met (baseplate). Resize Chap. 7.2 [} 33]. fastening elements (anchors). Overheating of Bearing or winding Auditory inspection, Repair or replace elec- electric motor. damage. current draw measure- tric motor ment, winding mea-...
- Page 57 Repair | 12 Fault Possible cause Fault discovery Remedy Impeller misaligned. Impeller loosened on Tighten the impeller. the motor shaft? Impeller exchange Chap. 12.7 [} 60]. Deposits or foreign ob- Determine grinding Remove deposits or jects between impeller point. foreign objects and inlet cover.
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Page 58: Spare Parts And Wear Parts
Installation tools 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. 58 / 76 Operating instructions CRDV-D 200-315 ATEX | Version 1.0-en... -
Page 59: Check Impeller
Repair | 12 Prepare the fan for repair (impeller, electric motor, V-ring seal, etc.) as follows: Observe safety instructions Chap. 12.1 [} 53]. Switch off the fan and FC (option) and use the isolation switch to remove voltage on all phases. Secure the isolation switch with a personal padlock to prevent unauthorized energization until completion of the repair work. -
Page 60: Replacing The Hood/Upper Part Of Housing
12 | Repair 12.6 Replacing the hood/upper part of housing Conditions: • Fan has been prepared for repairs Chap. 12.4 [} 58]. 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). - Page 61 Repair | 12 Procedure: • Cut out and remove the hub cap (3) with appropriate tools. The hub cap cannot be removed non- destructively - order spare part 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...
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Page 62: Electric Motor Exchange
12 | Repair • Push the impeller onto the motor shaft as far as it will go. The impeller posi- tion cannot be adjusted. NOTICE Risk of bearing damage! Never strike the motor shaft when mounting the impeller. • Tighten the hub adapter with the fastening screws, with RIPP LOCK® wash- ers for fastener security, in accordance with the following table: Fan/size Fastener threads... - Page 63 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.
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Page 64: Replacing The V-Ring Seal
12 | Repair Thread Max. tightening torque [Nm] 4. Connect electric motor Chap. 8.5 [} 43]. 5. Check motor rotation direction Chap. 9.2.1 [} 45]. 6. Mount impeller Chap. 12.7 [} 60]. 7. Conduct test run Chap. 9.2.3 [} 46]. 12.9 Replacing the V-ring seal Conditions: •... -
Page 65: Removal From Service, Disposal, And Recycling
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. -
Page 66: Disposal Instructions
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 damper in the supply air ductwork. • Drain and dispose of condensate in the casing drain (option). •... -
Page 67: Eu - Declaration Of Conformity
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. -
Page 68: Atex - Declaration Of Conformity
(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. - Page 69 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)
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Page 70: Atex Test Report
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. •... -
Page 71: Index
Index Index Electromagnetic fields 19 Entry protection 28 Annual inspection 50, 51 Explosion protection 11, 53 Application limits 11 Explosion protection marking 9, 11, 23 ATEX 8, 11, 12, 23, 35, 37, 44, 47, 49, 53, 68, 70 Attachment points 30 Fan cowl 20, 51... - Page 72 Index Outside cleaning 15, 50 Overheating 50 Leakage current 19 Overload 37 Lifting eye bolt 30, 32 Overpressure 12 Load 30 Load capacity 33 Load handling attachments 31 Lower part of housing 25 Package 30, 31, 32 Packing 31, 32 Padlock 18, 19, 27, 45, 49, 59, 66 Pallet stacker...
- Page 73 Index Specification sheet 7, 8, 9 Speed adjustment 27 Speed control 27 Start-up 18, 20 Storage temperature 31 Supply air duct 45, 49, 59 Support 20, 40 Supports 33, 65 Swinging movements 30 Tension ring 25, 59 Terminals 12 Terms and conditions 31 Test report 47, 52...
- Page 74 Notes Notes 74 / 76 Operating instructions CRDV-D 200-315 ATEX | Version 1.0-en...
- Page 75 Notes Operating instructions CRDV-D 200-315 ATEX | Version 1.0-en 75 / 76...
- Page 76 - since 1945 - When it comes to thermoplastics, Colasit AG is one of the world's leading brands in fan and system engineering. Our qualified staff impress with technical expertise and great dedication, guaranteeing you the highest quality on all five continents.
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