Ebmpapst K3G500-AP25-90 Operating Instructions Manual

Operating instructions

K3G500-AP25-90

` II 2G Ex d e ib IIB T3 Gb

IBExU14ATEX1122 X /03

`

Translation of the original operating instructions54005-4-8670

ebm-papst Mulfingen GmbH & Co. KG

Bachmühle 2
D-74673 Mulfingen
Phone [phone]
Fax [phone]
[e-mail]
www.ebmpapst.com

CONTENTS

1. STANDARDS AND DIRECTIVES

11. STANDARDS AND DIRECTIVES

1.1 Applied standards and directives

11.1 Applied standards and directives

As per directive 2014/34/EU in accordance with the following standards:

EN 14986: 2007

Design of fans for use in potentially explosive atmospheres

EN 60079-0: 2012 +A11: 2013

Explosive atmospheres
Part 0: Equipment - General requirements

EN 60079-1: 2007

Explosive atmosphere Part 1: Equipment protection by pressure­resistant enclosure "d"

EN 60079-7: 2007

Explosive atmosphere Part 7: Equipment protection by increased safety
"e"

EN 60079-11: 2012

Explosive atmosphere Part 11: Equipment protection by intrinsic safety "i"

TR CU 012/2011

The fan satisfies the requirements of the Technical Regulations of the
Customs Union "On safety of equipment intended for use in explosive
atmospheres".

These operating instructions are available in other languages on
our website, www.ebmpapst.com.

22. SAFETY REGULATIONS AND NOTES

22.1 Levels of hazard warnings

22.2 Staff qualification

22.3 Basic safety rules

22.4 Electrical voltage

22.5 Safety and protective functions

32.6 Electromagnetic radiation

32.7 Mechanical movement

32.8 Emission

32.9 Hot surface

32.10 Transport

32.11 Storage (including stockkeeping of spare parts)

42.12 Disposal

43. PROPER USE

54. TECHNICAL DATA

54.1 Product drawing

64.2 Nominal data

64.3 Technical features

64.4 Mounting data

64.5 Transport and storage conditions

74.6 Electromagnetic compatibility

74.7 Ex areas

74.8 The type plate

85. CONNECTION AND START-UP

85.1 Connecting the mechanical system

85.2 Connecting the electrical system

105.3 Connection in terminal box

125.4 Factory settings

135.5 Connection screen

145.6 Checking the connections

145.7 Switch on device

145.8 Switching off the device

146. INTEGRATED PROTECTIVE FUNCTIONS

147. MAINTENANCE, MALFUNCTIONS, POSSIBLE

CAUSES AND REMEDIES

157.1 Cleaning

157.2 Safety test

157.3 Maintenance interval

167.4 Vibration check

Item no. 54005-5-9970 · ENG · Revision 90396 · Release 2016-09-21 · Page 1 / 16

ebm-papst Mulfingen GmbH & Co. KG · Bachmühle 2 · D-74673 Mulfingen · Phone [phone] · Fax [phone] · [e-mail] · www.ebmpapst.com

Operating instructions

K3G500-AP25-90

` II 2G Ex d e ib IIB T3 Gb

IBExU14ATEX1122 X /03

`

Translation of the original operating instructions54005-4-8670

2. SAFETY REGULATIONS AND NOTES

Read the operating instructions carefully before working on the device
and every time before using it. Observe the following safety instructions
to prevent malfunctions or danger to persons. These operating
instructions are to be regarded as part of the device. Keep the operating
instructions close to the product so that users can access them at any
time. The device may only be sold or passed on together with the
operating instructions. The operating instructions must be accessible for
the operating and maintenance personnel. These operating instructions
may be duplicated and forwarded for information about potential dangers
and their prevention.

2.1 Levels of hazard warnings

These operating instructions use the following hazard levels to indicate
potentially hazardous situations and important safety regulations:

DANGER

Indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury. Compliance with
the measures is mandatory.

WARNING

Indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury. Exercise extreme
caution while working.

CAUTION

Indicates a potentially hazardous situation which, if not avoided,
may result in minor or moderate injury or damage of property.

NOTE

A potentially harmful situation can occur and, if not avoided, can
lead to property damage.

2.2 Staff qualification

Only electricians specialising in electrical explosion protection may
install the device, perform the test run and work on the electrical system.
The device may only be unpacked, operated, switched on or off, set,
used, run, disassembled and transported by suitable, qualified, trained
and authorised personnel.

2.3 Basic safety rules

A risk assessment in accordance with the Industrial Safety Regulation
(BetrSichV) must be performed before any use of the device. The safety
hazards associated with the device must be assessed again following
installation in the final product.
Observe the following when working on the unit:

; The device is only to be used in proper technical working order for its

intended purpose, in a safe manner with attention to potential dangers
and in accordance with the operating instructions.

; Any faults and defects which impair safety must be rectified

immediately.

; Do not make any modifications, additions or conversions to the

device (such as modifying the guard grille or attaching other
equipment to the wall ring) without the approval of ebm-papst.

; Modifications to the device result in loss of Ex approval. ebm-papst

Mulfingen GmbH & Co. KG does not accept any liability for resultant
damage.

2.4 Electrical voltage

; Check the electrical equipment of the device at regular intervals; see

chapter 7.2 Safety test.

; Replace loose connections and defective cables immediately.

DANGER
Live terminals and connections even with device
switched off

Electric shock, unintentional triggering of an ignition spark and
capacitive residual voltage can cause an ignition spark in the
event of a short circuit.

→ Before disconnecting the wires in the terminal box,

short-circuit the wires (L1, L2, L3) and PE outside the
explosion-hazard area, see chapter 5.8.2 Switching off
the device for maintenance work. #Wait five minutes
following all-pole disconnection of the voltage before
opening the terminal box.

CAUTION
In the event of failure, there is electric voltage at the
rotor and impeller

The rotor and impeller are base insulated.

→ Do not touch the rotor and impeller once they are installed.

CAUTION
If control voltage is applied or a speed setpoint is stored,
the motor will restart automatically, e.g. after power
failure.

Risk of injury

→ Keep out of the device danger zone.# When working on the

device, switch off the mains power and ensure that it cannot
be switched back on.

→ After working on the device, remove any tools used or

other objects from the device.

2.5 Safety and protective functions

DANGER
Protective device missing and protective device not
functioning

Without a protective device there is a risk of serious injury, for
instance if the hands reach or are sucked into the device during
operation.

→ Operate the device only with a fixed protective device and

guard grille.# The fixed protective device must be able to
withstand the kinetic energy of a fan blade that becomes
detached at maximum speed. There must not be any gaps
which it is possible to reach into with the fingers, for example.

→ The device is a built-in component. As the operator, you

are responsible for ensuring that the device is secured
adequately.

→ Stop the device immediately if a protective device is

found to be missing or ineffective.

Item no. 54005-5-9970 · ENG · Revision 90396 · Release 2016-09-21 · Page 2 / 16

ebm-papst Mulfingen GmbH & Co. KG · Bachmühle 2 · D-74673 Mulfingen · Phone [phone] · Fax [phone] · [e-mail] · www.ebmpapst.com

Operating instructions

K3G500-AP25-90

` II 2G Ex d e ib IIB T3 Gb

IBExU14ATEX1122 X /03

`

Translation of the original operating instructions54005-4-8670

2.6 Electromagnetic radiation

Interference from electromagnetic radiation is possible, e.g. in conjunction
with open and closed-loop control devices.
If unacceptable emission intensities occur when the fan is installed,
appropriate shielding measures have to be taken by the user.

NOTE
Electrical or electromagnetic interferences after
integrating the device in installations on the customer's
side.

→ Verify that the entire setup is EMC compliant.

2.7 Mechanical movement

DANGER
Rotating device

Body parts that come into contact with the rotor and impeller
can be injured.

→ Secure the device against accidental contact.

→ Before working on the system/machine, wait until all

parts have come to a standstill.

WARNING
Rotating device

Long hair, dangling items of clothing, jewellery and similar items
can become entangled and be pulled into the device. Risk of
injury.

→ Do not wear any loose-fitting or dangling clothing or jewellery

while working on rotating parts.# Protect long hair with a cap.

WARNING
Flying parts

If safety devices are missing, this may cause parts to be
ejected at high speeds, causing bodily harm, or impair
explosion protection.

→ Take appropriate safety measures. The safety devices must

prevent contact with rotating and electrically live parts.

DANGER
The fan is not supplied with full protective equipment.

→ The system in which it is installed must generally be

protected against the penetration of objects (IP20 as per
EN60529/EN14986). #To ensure ignition protection, rotating
parts must be designed throughout the entire production
series such that the connection methods employed always
reliably stop parts or material working loose. In this context it
must also be ensured that loose metallic parts from the
surrounding area cannot get into the vicinity of the rotating
parts and thus impair ignition protection. #The suitability of the
protective device and its attachment must always be
assessed in the context of the overall safety concept for the
system as a whole.

2.8 Emission

WARNING
Depending on the installation and operating conditions,
a sound pressure level greater than 70 dB(A) may arise.

Danger of noise-induced hearing loss

→ Take appropriate technical safety measures.

→ Protect operating personnel with appropriate safety

equipment, e.g. hearing protection.

→ Also observe the requirements of local agencies.

2.9 Hot surface

CAUTION
High temperature at the electronics housing

Risk of burns

→ Ensure sufficient contact protection.

2.10 Transport

WARNING
Transportation of fan

Injuries from tipping or slipping.

→ Wear safety shoes and cut-resistant safety gloves. #Only

transport the fan in its original packaging. #Transport the fan
lying flat, in other words with the motor axis vertical.

→ Secure the fan(s) so that nothing can slip or tip, e.g. by

using a lashing strip.

NOTE
Packaging damaged

ebm-papst Mulfingen will not accept any liability for packaging
damages that are reported late.

→ Report damages immediately

→ Open the product as soon as it arrives.

→ Describe the damages in writing

→ Sign the description and have the shipper (driver) initial it.

NOTE
Packaging undamaged, content damaged.

In the case of covered transport damage, you have to show
that the damage occurred during transport and not afterwards.

→ Notify the supplier and ebm-papst of damages within 5

workdays in writing.

→ Keep the damaged goods with the packaging until the

situation has been clarified.

→ Operating damaged devices is prohibited.

2.11 Storage (including stockkeeping of spare parts)

; Store the device, partially or fully assembled, in a dry and

weatherproof manner in the original packing in a clean environment.

; Protect the device from environmental impacts and dirt until the final

installation.

; Protect the device from unwanted access, e.g. by unauthorised

personnel.

; We recommend storing the device for a maximum up to one year to

guarantee proper operation and longest possible service life.

; Even devices explicitly suited for outdoor use are to be stored as

described prior to being commissioned.

; Observe the correct storage temperature; see chapter 4.5 Transport

and storage conditions.

DANGER
Danger of explosion, ingress of dirt and humidity into
the motor

The IP type of protection is decreased.

→ Store the device in completely assembled condition only

(screwed cable gland and terminal box cover are sealed)

Item no. 54005-5-9970 · ENG · Revision 90396 · Release 2016-09-21 · Page 3 / 16

ebm-papst Mulfingen GmbH & Co. KG · Bachmühle 2 · D-74673 Mulfingen · Phone [phone] · Fax [phone] · [e-mail] · www.ebmpapst.com

Operating instructions

K3G500-AP25-90

` II 2G Ex d e ib IIB T3 Gb

IBExU14ATEX1122 X /03

`

Translation of the original operating instructions54005-4-8670

2.12 Disposal

When disposing of the device, please comply with all relevant
requirements and regulations applicable in your country.

3. PROPER USE

The device is exclusively designed as a built-in device for conveying
air according to its technical data.

Note

; The motor satisfies the requirements of category II 2G Ex d e ib IIB

T3 Gb. Devices of this category are intended for use in areas in
which the occasional occurrence of an explosive atmosphere of air,
gases and vapours or mists is to be expected (category 2G). The
device-related explosion protection measures of this category must
provide the required degree of safety even in the event of frequent
system malfunctions or fault statuses normally to be taken into
consideration (foreseeable faults). This involves assessment of the
individual risks of the system as a whole and implementation of the
necessary explosion protection measures.

Any other usage above and beyond this does not conform with the
intended purpose and constitutes misuse of the device.
Customer equipment must be capable of withstanding the mechanical
and thermal stresses that can arise from this product. This applies for the
entire service life of the equipment in which this product is installed.
When used in the intended manner, explosion-proof motors cannot ignite
explosive gases or vapours.
The manufacturer who installs ebm-papst devices is responsible for
ensuring operation in accordance with the intended use, operational
safety, proper installation, and EMC properties when installed.
The fan is designed for 40,000 hours of operation and must then be
replaced.
ebm-papst accepts no liability for subsequent modifications to the fan.

Proper use also includes:

● Use the device in power systems with earthed neutral (TN/TT power

systems) only.

● Conveying of air at an ambient air pressure of 750 mbar to 1050 mbar.

● Using the device within the permitted ambient temperature range; see

chapter 4.2 Nominal data and chapter 4.5 Transport and storage
conditions.

● Device protected against weather effects at the installation location.

● Operating the device with all protective devices.

● Using the device only in Zones 1 and 2 with explosion subcategories

IIA and IIB and temperature classes T1 to T3.

● Using the device only in stationary systems.

● Using the device only in resonance-free speed ranges to avoid spark

formation.

● Punctual, complete performance of all maintenance; see chapter 7.3

Maintenance interval.

● Observance of the operating instructions.

Improper use

Using the device in the following ways is particularly prohibited and
may cause hazards:

● Operating the device with an imbalance, e.g. caused by dirt deposits

or icing.

● Moving air that contains abrasive particles.

● Conveying of highly corrosive air, such as salt spray mist. This does

not apply to devices designed for use in a salt-laden atmosphere and
accordingly protected. The same applies to all other corrosive
substances.

● Moving solids content in flow medium.

● Conveying of air with a high dust pollution level, e.g. extraction of

sawdust, flour dust etc.

● Conveying of air containing iron and rust particles, e.g. use of the

device in a welding shop.

● Operation (also when stopped) with external vibrations.

● Operation in unstable flow conditions (vibration).

● Operation with severe contamination (see maintenance instructions).

● Installation and operation of the device with exposure to weather

effects.

● Using the device as a safety component or for taking on safety-

related functions.

● Operation in medical equipment with a life-sustaining or life-support

function.

● Operation with vibration transmitted to the fan from external machines

or attachments.

● Operation with externally induced mechanical loads that are in

excess of the permitted level.

● Opening of the terminal box during operation, see chapter 4.1 Product

drawing.

● Painting the fan.

● Standing or walking on the fan or ventilation unit.

● Operation with completely or partially disassembled, manipulated or

inadequate protective devices.

● Connections (e.g. screws) coming loose during operation.

● Upstream connection of frequency converters.

● Connection of attachments to the rotor housing.

● Flow medium and ambient conditions not conforming to those of Ex

marking.

● In addition, all application options that are not listed under proper use.

DANGER
Potential dangers in the event of non-compliance include
personal injury and property damage due to shaft
breakage, fatigue failure, reduced bearing service life or
explosions caused by elevated surface temperatures or
spark formation.

Item no. 54005-5-9970 · ENG · Revision 90396 · Release 2016-09-21 · Page 4 / 16

ebm-papst Mulfingen GmbH & Co. KG · Bachmühle 2 · D-74673 Mulfingen · Phone [phone] · Fax [phone] · [e-mail] · www.ebmpapst.com

Operating instructions

K3G500-AP25-90

` II 2G Ex d e ib IIB T3 Gb

IBExU14ATEX1122 X /03

`

Translation of the original operating instructions54005-4-8670

4. TECHNICAL DATA

4.1 Product drawing

All measures have the unit mm.

1 Inlet nozzle with pressure tap
2 Screw-on position for vibration-absorbing elements
3 Cable diameter min. 10 mm, max. 16 mm, tightening torque 6±0.6 Nm; standard value depending on cable
4 Screw plug M20x1.5
5 Cable diameter min. 10 mm, max. 14 mm, tightening torque 6±0.6 Nm; standard value depending on cable
6 Attachment screws for terminal box cover, tightening torque 3.5±0.5 Nm
7 Earth connection point M8 (functional earth to dissipate electrostatic charge, no protective earth), do not unfasten the existing nut, contact is

established with another nut.

8 Axial gap dimension
9 Radial gap dimension
10 Additional type plate and warning sticker in Russian

Item no. 54005-5-9970 · ENG · Revision 90396 · Release 2016-09-21 · Page 5 / 16

ebm-papst Mulfingen GmbH & Co. KG · Bachmühle 2 · D-74673 Mulfingen · Phone [phone] · Fax [phone] · [e-mail] · www.ebmpapst.com