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Operating instructions CMV 450-800 ATEX Centrifugal fan with direct drive Your point of contact: Colasit Representative Street Location Version 1.0-en | 03/2025...
Name 1-en EU/ATEX First version published. 3/01/2025 A. Roth Document identification Translation of the original German operating instructions. Colasit TD-000 891 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 Round PVC sleeves with flange on both sides .......... 5.3.3 Round flange connection ................5.3.4 Square PVC sleeve with flange on both sides (outlet side) ....... 5.3.5 Condensate drain..................5.3.6 Motor cover ....................5.3.7 Lip seals..................... 5.3.8 Back suction for lip seal ................
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Table of contents Instructions for frequency converter (FC) use ............8.3.1 Frequency converter (FC) installation options ........... 8.3.2 Frequency converter (FC) parameterization ..........8.3.3 Connecting the electric motor to a frequency converter (FC) ....Making an ATEX-compliant ground connection ............. Connecting the electric motor.................
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Table of contents 13.1 Safety instructions ....................13.2 Environmental protection..................13.3 Removal from service..................... 13.4 Disposal instructions ....................EU - Declaration of conformity................ATEX - Declaration of Conformity ..............15.1 ATEX test report..................... Index ........................6 / 88 Operating instructions CMV ATEX | Version 1.0-en...
Design notes For the sake of simplification, in these operating instructions, • the company Colasit AG is referred to as the “manufacturer,” • all sizes (CMV 450-800 ATEX) are generally referred to as the “fan,” • “frequency converter” is abbreviated as “FC,”...
Additional safety instructions | 2 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.
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Additional safety instructions | 2 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).
2 | Additional safety instructions 2.2.2 Reasonably foreseeable misuse Any use of the fan other than that for which it is intended or any other use is considered misuse and can lead to dangerous situations. The manufacturer as- sumes no responsibility for resulting injuries or material damage. The following list of misuse is exemplary and not exhaustive.
Additional safety instructions | 2 Interfaces for CMV 450-800 ATEX The fan has the following interfaces: 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: Procured by customer.
2 | Additional safety instructions When operating the fan in an overpressure condition, the conveyed medium can escape at the impeller hub and lead to an explosion hazard and/or adverse health effects. • Operate the fan at negative pressure for use with explosive and/or haz- ardous conveyed media.
Additional safety instructions | 2 • Ensure that the fan is always in a technically sound condition under obser- vance of the maintenance intervals per these operating instructions. • Initiate and verify that the function and integrity of all fan safeguards are checked regularly.
2 | Additional safety instructions • All work on the fan’s electrical components may only be carried out by elec- tricians. • The fan may only be connected to the frequency converter by an electrician • after its operating instructions have been read and understood, •...
Essential safety instructions | 3 Essential safety instructions The associated documents can contain additional operating instructions with important safety instructions Chap. 1.1 [} 8]. Notation of safety instructions The safety instructions and warnings in these operating instructions are identified by the following warning symbols, signal words, and colors (electronic version of the operating instructions only), which convey the severity of the dangers.
3 | Essential safety instructions 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.
Essential safety instructions | 3 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: •...
3 | Essential safety instructions Electrical hazards DANGER Danger to life due to electric shock from contact with current- 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.
Essential safety instructions | 3 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.
3 | Essential safety instructions 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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Essential safety instructions | 3 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.
4 | Explosion protection 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 [} 9]. •...
Explosion protection | 4 Explosion protection marking The explosion protection marking is located on the nameplate of the fan Chap. 5.2 [} 27] and classifies the fan for use in a potentially explosive at- mosphere Chap. 15 [} 81]. Explosion protection marking example II 2/3G Ex h IIB+H2 T3 Gb/Gc Droplets...
5 | Structure and function Structure and function Overview Fig. 2: Fan overview 1 Inspection port 8 Motor bracket with plate 2 Casing with casing reinforcement 9 Electric motor 3 Splinter protection 10 Front plate 4 Cover disc with screw 11 Support plates 5 Impeller with hole and keyway 12 Base frame 6 Rear plate...
Structure and function | 5 Signs and warning symbols on the fan 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 CMV 710 Serial No.
• A transition fitting from square to round is required at the outlet connection (pres- sure side). • Executions: See accessories for CMV 450-800 ATEX on the manufac- turer’s website (www.colasit.com). Fig. 5: Sleeves with round flange 5.3.3 Round flange connection • Optional.
• For flexible connection of the outlet con- nection to ductwork with flange connec- tion. • Executions: See accessories for CMV 450-800 ATEX on the manufac- turer’s website (www.colasit.com). Fig. 7: Sleeve with square flanges 5.3.5 Condensate drain • Optional. • For draining of condensate.
Structure and function | 5 Fig. 11: Double-layer seal with lubrication nipple 5.3.8 Back suction for lip seal • Optional. • Supplement to double-layer lip seal. • Leakage near the hub passage is directed to the suction connection via a tube and guided back into the main flow.
5 | Structure and function See instructions for use in the information sheet on fan seals. Contact your Colasit distributor to request this document. 5.3.9 Sealing gas for lip seal • Optional. • Supplement to double-layer lip seal. • Sealing gas is forced into the cav- ity between the impeller hub and the casing wall.
Structure and function | 5 5.3.11 Labyrinth seal • Optional. • Use with hazardous, aggressive conveyed media when the fan is operated in an overpressure condi- tion. • Weld the non-contact labyrinth seal to the rear plate and impeller before mounting. Fig. 15: Labyrinth hub seal 5.3.12 Impeller back-plates...
• Weld the flow rate measuring point to the inlet connection. • Executions: See accessories for CMV 450-800 ATEX on the manu- facturer’s website (www.colasit.com). 1) Connection to differential pressure gauge. Fig. 17: Flow rate measuring point 5.3.14 Isolation switch •...
6 | Transport Transport Safety instructions These safety instructions warn against potential hazards that apply when trans- porting the fan. WARNING Danger to life when remaining under suspended loads Injuries due to falling or swinging loads. Cordon off the 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 in accor- dance with the general terms and conditions (T&C). Save packing for a possible return shipment. Mount the fan and place it in service only after repairs and resolution of complaints.
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 • Provide suitable clearance around the fan for • maintenance and repair work, • motor cooling. Fig. 24: Space requirement for work area and motor cooling Dimensioning notes The minimum distance at the installation site for the fan cowl of the electric mo- tor must be larger than one fourth the diameter (Y) of the fan cowl.
• Executions: See accessories for CMV 450-800 ATEX on the manufac- turer’s website (www.colasit.com). Fig. 26: Proper mounting of the inspection port The removable cover enables inspection of the inside of the casing. The location of the inspection port differs by fan size and the positioning of the casing/outlet connection.
7 | Mechanical installation 7.5.1 Floor mounting Conditions: • Installation location require- ments Chap. 7.2 [} 39]. • Suitable vibration absorbers and fastening elements are present. Fig. 27: Fastening recommendation for floor mounting 1. Transfer fan support hole pattern to the foundation (baseplate). Hole pattern dimensioning according to technical data sheet.
3. Screw the flange of the Wellflex sleeve to the ductwork. For fans in ATEX zone 2, a standard PVC sleeve can be used. Executions: See accessories for CMV 450-800 ATEX on the manufacturer’s website (www.colasit.com). Connecting condensate drain to siphon NOTICE...
Chap. 5.3.5 [} 29]. • Connect drain pipe to siphon. • Executions: See accessories for CMV 450-800 ATEX on the manufacturer’s website (www.colasit.com). Casing drain type F • Connect drain pipe with suitable flange to casing drain type F and to siphon.
Mechanical installation | 7 When planning for and mounting the siphon, observe a minimum installation height of 2 x H. Instructions for execution of the siphon • For negative pressure operation of the fan: If the siphon is insufficiently dimensioned or not filled with water, there is a risk that false air will be sucked in.
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 The isolation switch • is a required protective device, • 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, •...
8 | Electrical installation Connecting PTC thermistor tripping unit to FC When connected to a FC, shutdown should be performed by the "safe stop" safety function. This ensures that no residual voltage is applied to the motor windings and that the electric motor can cool down as quickly as possible. 8.2.4 Starting current limiter NOTICE...
Electrical installation | 8 DANGER Danger to life due to ignition of explosive gas mixtures by electric sparks Death or serious injuries. ▪ Spark formation in electric motor. Check whether the explosion protection marking of the electric motor is also valid for operation with a frequency converter.
8 | Electrical installation Fig. 31: Frequency converter installation 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. The FC is either • directly attached to the electric motor (2, order option), •...
Electrical installation | 8 To prevent mechanically overloading the fan, observe these minimum permissi- ble acceleration and braking times: Electric motor nominal power [kW] Acceleration/braking time [s] < 1.5 min. 15 > 1.5 min. 30 To avoid an FC error message, a longer acceleration/braking time could be necessary.
8 | Electrical installation Fig. 33: EMC cable gland Secure the motor connection cable to the motor terminal box with an EMC cable gland. • Strip the cable end appropriately so that contact can be made with the cable shield. Connect the motor connection cable to the electric motor Chap.
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Electrical installation | 8 Sizing and installing the motor connection cable Adequately size the cross section of the motor connection cable, taking into account: • Applicable standards and regulations • Cable lengths • Rated current • Environmental conditions • Type of installation To size the connection cable, consult the cable manufacturer's tables for current- carrying capacity or request sizing information directly from the cable manufacturer.
8 | Electrical installation • Connect the phase conductors (L1, L2, L3) of the motor connection cable to the terminal board in the correct order. • Use insulated ring terminals for phase conductors. • Attach the protective earthing (PE) to the protective earthing connection in the terminal box using a ring terminal and serrated lock washer.
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.
9 | Placement in service Check during the functional test: • Check acceleration and braking time Chap. 8.3 [} 48]. • 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.
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Placement in service | 9 The measured data provides comparison values during maintenance. Heating, ventilation, air conditioning (HVAC), and agriculture: BV-2 < 3.7 kW Industrial processes, etc.: BV-3 > 3.7 kW At the end of the test run: • Compare current values and parameters with initial values and parameters from the beginning of the test run: •...
10 | Operation Operation 10.1 Safety instruction This safety instruction warns against dangers that can arise during fan operation. 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.
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.
Maintenance | 11 • Back suction functional (tube free of contamination)? • Sealing gas available? • For functionality and contamination: • Ring tube of optional flow rate measuring point. • For loose screw connections. • Smooth operation of fan: • For irregular running, check for vibration or noise Chap.
11 | Maintenance • Remove cover of inspection port Chap. 7.4 [} 41]. • Loosen the sleeve at the inlet connection and remove the ductwork end if applicable Chap. 7.6 [} 42]. • Clean the impeller and the inside of the casing thoroughly. NOTICE Do not damage the impeller blades when doing so.
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Maintenance | 11 • Measure the temperature of the electric motor and compare the result with the information in the technical data sheet. CAUTION Risk of burns Inside inspection and cleaning • Check the impeller and casing for deformation and for damage such as cracking and corrosion Chap.
12 | Repair 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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Repair | 12 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 [} 73]. be reached. Improper phase volt- Measure phase volt- Check/replace fuses,...
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12 | Repair Fault Possible cause Fault discovery Remedy Overheating due to ex- Operating point ad- Set operating point ac- cessive current con- justed. Defect in motor cording to specifica- sumption. or cable. tion. Impeller stiff or Visual inspection. Remove deposits or stopped.
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Repair | 12 Fault Possible cause Fault discovery Remedy Impeller dips into con- Type K: Visual inspec- Drain condensate densate at bottom of tion. Chap. 5.3.5 [} 29]. casing. Type V, type F: Visual Clean and replace inspection. condensate drain/ siphon Chap.
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12 | Repair Fault Possible cause Fault discovery Remedy FC parameter "max. Check FC parameters Adjust parameters ac- frequency" set improp- cording to characteris- Chap. 8.3.2 [} 50]. erly (speed too high, tic map in technical overheating of electric data sheet. motor).
Repair | 12 Fault Possible cause Fault discovery Remedy Casing leaks. Sleeve not leak tight. Check leak tightness Replace seal/sleeve. during operation. Inspection port not Replace seal. leak tight. Improper flow Indication is incorrect. Verify reading with Correct the settings of rate (measur- handheld device.
Special centering pieces are needed for proper installation and alignment of the electric motor/motor shaft and impeller to the casing and rear plate. Contact your Colasit distributor for details and a comprehensive installation manual. Prepare the fan for repairs (impeller, electric motor, hub seal, etc.) as follows: Observe safety instructions Chap.
Repair | 12 NOTICE Risk of damage due to grinding impeller Damage to impeller. If necessary, tighten the fastening screws on the casing and impeller. Determine grinding point. Inspect the casing and impeller for grinding marks and replace damaged parts after consulting the manufacturer. Remove de- posits or foreign objects in the casing Chap.
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12 | Repair Fig. 37: Impeller exchange Procedure: • Remove the cover disc (1). • Remove the screw (2) and washer (3). • Pull the impeller off the shaft. With CMV fans with direct drive, the shaft seat on the impeller is adapted to the shaft diameter of the electric motor.
Special centering pieces are needed for proper installation and alignment of the electric motor/motor shaft and impeller to the casing and rear plate. Contact your Colasit distributor for details and a comprehensive installation manual. Operating instructions CMV ATEX | Version 1.0-en...
12 | Repair • Use installation tools and centering pieces. • Fasten mounting nuts according to the following table. • The thread is based on the motor size: Thread Max. tightening torque [Nm] • Connect electric motor Chap. 8.5 [} 52], Chap.
9. Install the casing. Installation tools Special centering pieces are necessary for proper installation of the double-layer lip seal. Contact your Colasit distributor for details and a comprehensive installa- tion manual. Important The impeller should turn freely by hand after mounting. Observe the direction of rotation Chap.
12 | Repair 3. Mount felt ring. NOTICE The felt ring may not protrude into the casing. 4. Mount the impeller on the motor shaft Chap. 12.7 [} 71]. Important The impeller should turn freely by hand after mounting. Observe the direction of rotation Chap.
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 13.3 Removal from service WARNING Risk of injury due to improper removal Injuries by pinching and crushing of body parts. Wear protective equipment. Safeguard work area and prevent unauthorized access using enclosures, safety nets, etc.
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Removal from service, disposal, and recycling | 13 Disassembly instructions • Separate the fan components into material groups and dispose of them separately: • Metals • Plastics • Electrical components Dispose of plastic parts contaminated by conveyed media that are harmful to health and the environment as special waste.
EN 60079-7: 2015 EN 60079-15: 2019 Name and address of the document Andreas Roth 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 appendix to this Declaration of Conformity and in the technical report. (8) Colasit AG certifies compliance with the essential health and safety requirements for the design and construction of equipment and protective systems intended for use in potentially explosive atmospheres according to Annex II of Directive 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, 3/1/2025 B. Stucki Andreas Roth (Division manager)
ATEX - Declaration of Conformity | 15 (17) Special conditions • 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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