ruck VENTILATOREN k10001 Axial Fan User Manual

: June 10, 2024
: ruck VENTILATOREN

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ruck VENTILATOREN k10001 Axial Fan User Manual
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ruck VENTILATOREN k10001 Axial Fan User Manual

Installation, operating and maintenance instructions

AL…D

Example configuration shown

ruck Ventilatoren GmbH
Max-Planck-Str. 5
D-97944 Boxberg-Windischbuch
Tel. +49 7930 9211-300
Fax +49 7930 9211-166
info@ruck.eu
www.ruck.eu

The original instructions were created in the German language.
Information updated
print 07.06.2022
Subject to change

FOREWORD

Dear customers,

Thank you for choosing our device.

Before operating the unit, please read carefully these installation, operating and maintenance instructions. If you have any questions, please contact: (Contact details see page 1)

The data provided in these installation, operating and maintenance instructions are for the product description only. A statement about a certain condition or a suitability for a certain application cannot be derived from our information. The information does not release the user from his own assessments and examinations.

Any disposal such as copying and distribution rights lies with us.

IMPORTANT INFORMATION

This manual contains important information on the safe and appropriate assembly, transport, commissioning, operation, maintenance, disassembly and simple troubleshooting of the product.

The product has been manufactured according to the accepted rules of current technology.

There is, however, still a danger of personal injury or damage to equipment if the following general safety instructions and the warnings before the steps contained in these instructions are not complied with.

Read these instructions completely and thoroughly before working with the product.
Keep these instructions in a location where they are accessible to all users at all times.
Always include the operating instructions when you pass the product on to third parties.

Provisions and regulations

When properly installed and operated, the device complies with the applicable standards and EU Directive at the time of its placing on the market.

In addition, observe generally valid, legal and other binding regulations of the European or national legislation as well as the regulations in your country for accident prevention and environmental protection.

Warranty and liability

Our devices are manufactured to the highest technical level in accordance with the generally accepted rules of technology. They are subject to constant quality controls. Because the products are being constantly developed, we reserve the right to make changes to the products at any time and without prior announcement. We assume no liability for the correctness or completeness of these installation, operating and maintenance instructions.

To ensure your warranty claims, it is imperative to provide a commissioning report and a maintenance record.

Warranty and liability claims for personal injury and property damage are excluded if they are due to one or more of the following causes:

Improper use
Improper mounting, commissioning, operation and maintenance
Operating the device with defective and / or non-functional safety and protective devices
Failure to observe the instructions regarding transportation, installation, operation and maintenance
Unauthorized structural changes to the device
Poor monitoring and replacement of maintenance parts
Improperly performed repairs
Disasters and force majeure

GENERAL SAFETY INSTRUCTIONS

Planners, plant engineers and operators are responsible for ensuring that the product is installed and operated correctly.

Use our devices only in perfect technical condition.
Check the device for obvious defects, such as cracks in the housing or missing rivets, screws, caps or other application-relevant defects.
Only use the device in the power range specified in the technical data and on the nameplate.
Protection against contact and being sucked in and safety distances should be provided in accordance with DIN EN 13857.
Generally prescribed electrical and mechanical protection devices are to be provided by the client.
Safety components must not be bypassed or put out of operation.
The product may be operated by personnel with limited physical, sensory or mental capacities only if they are supervised or have been instructed by responsible personnel.
Children must be kept away from the product.

Intended use

Our devices are incomplete machineries as defined in the EU Machinery Directive 2006/42/EC (partly completed machinery). The product is a not ready- for-use machine in terms of the machine directive. Fan for conveying clean and slightly dusty air. It is intended exclusively for installation in a machine or in ventilation equipment and installations or for combination with other components to form a machinery or installation. The product may be commissioned only if it is integrated in the machinery/system for which it is designed and the machinery/system fully complies with the EC machinery directive.

Observe the operating conditions and performance limits specified in the technical data.

Conveying and ambient temperatures must be observed according to the technical data and the nameplate.

Intended use also implies that you have fully read and understood this manual.

Improper use may result in danger to the life and limb of the user or third parties or damage to the system or other property.

Improper use

Any use of the product other than described in chapter “Intended use” is considered as improper.

The following points are improper and dangerous:

Delivery of explosive and flammable media or operation in potentially explosive atmospheres.
The conveyance of greasy and moist media (over 90% relative humidity).
Delivery of aggressive and abrasive media.
Operation without the duct system.
Operation with closed air connections.
The use on vehicles, aircrafts and ships.

Personnel qualifications

Assembly, commissioning, operation, disassembly and service (including maintenance and repair) require basic mechanical and electrical knowledge, as well as knowledge of the appropriate technical terms. In order to ensure operating safety, these activities may therefore only be carried out by qualified technical personnel or a person under the direction and supervision of qualified personnel. Qualified personnel are those who can recognize possible hazards and institute the appropriate safety measures due to their professional training, knowledge, and experience, as well as their understanding of the relevant conditions pertaining to the work to be done. Qualified personnel must observe the rules relevant to the subject area.

Safety instructions in this manual

In this manual, there are safety instructions before the steps whenever there is a danger of personal injury or damage to the equipment. The measures described to avoid these hazards must be observed.

Safety instructions symbols

Safety instructions are set out as follows:

Safety sign (warning triangle) – Draws attention to the risk.

• Type of risk! – Identifies the type or source of the hazard.

» Consequences – Describes what occurs when the safety instructions are not complied with.

→ Precautions – States how the hazard can be avoided.

Safety Signs

ADHERE TO THE FOLLOWING INSTRUCTIONS

General instructions

Persons who assemble, operate, disassemble or maintain our devices must not be under the influence of alcohol, drugs or pharmaceuticals that may affect perception and responsiveness.
Responsibilities for the operation, maintenance and regulation of the product should be clearly determined and observed so that there can be no unclear areas of responsibility with regard to safety.

Indications assembly

Disconnect all of the product’s poles from the mains before installing the product or connecting or removing plugs. Make sure that the product cannot be switched back on again.
Lay cables and lines so that they cannot be damaged and no one can trip over them.
Information signs must not be changed or removed.

Indications Commissioning

Make sure that all electrical connections are either used or covered. Commission the product only if it is installed completely.
The power switch must always be fully functional and easy accessible!

Indications during operation

Only authorized personnel is allowed to operate the setting mechanisms of the components or parts, under the provision that the system is used as intended.
In an emergency, or if there is a fault, or other irregularities, switch the equipment off and make sure it cannot be switched back on again.
The technical data given on the rating plate must not be exceeded.

PRODUCT INFORMATION

Description:

Fan for ventilation systems
Conveyance of clean and slightly dusty air up to 60°C
Aerodynamically optimized axial impeller
Motor inside the airflow
Thermal motor protection to be connected on site
Outdoor installation possible
Discharge pushing over the motor
Housing made of powder-coated steel
Impeller made of powder-coated steel
Three-phase motor in IE3 design
Three-phase motor controllable via frequency converter

Nameplate

ATTENTION! The information on the nameplate must always be observed!

Nameplate

DELIVERY CONTENTS

1 x Axial fan
1 x Installation, operating and maintenance instructions
EC Declarations of conformity
EC-Declaration of Incorporation (Directive 2006/42/EC)

TECHNICAL DATA

Technical Data

Due to the maximum permissible frequency, these devices must be operated with a frequency converter.

DIMENSIONS

AL…D

Dimensions Table

TRANSPORT AND STORAGE

Transport and storage should only be performed by specialist personnel in accordance with the assembly and operating manual and regulations in force.

The following points should be noted and followed:

Check the delivery according to the delivery note to ensure it is complete and correct and check for any damage. Any missing quantities or damage incurred during transport should be confirmed by the carrier. No liability is accepted if this is not observed.
For weight see technical data
It should be transported with suitable lifting equipment in the original packaging or on the transport equipment indicated.
If transported with a forklift, it should be ensured that the product is resting with the basic profile or base frame completely on the forks or on a pallet and the product’s centre of gravity is between the forks.
The driver must be authorized to drive a forklift.
Do not go beneath the suspended load.
Avoid damage or deformation of the housing.
The product must be stored in a dry area and protected from the weather in the original packaging. Open pallets should be covered with tarpaulins. Even weatherproof modules should be covered because their weather resistance is only guaranteed after complete installation. If moisture has penetrated into the original packaging, remove it immediately.
Storage temperature between +5 °C and +40 °C. Avoid severe temperature fluctuations.
If the product has been in storage for more than a year, check the smooth running of impellers and valves by hand.

Unpacking example:

Packaging may vary, depending on the size of the device.

Unpacking Example 1

Release screws (1)
Lift the device (2) out of the packaging
Final assembly of the device depending on the location (see installation!)
Care must be taken to load the flange evenly and in a vertical direction. If necessary, use crossbar and rotating hooks.

Transport of the device on a pallet:

Release screws (1)
Final assembly of the device depending on the location (see installation!)

ASSEMBLY

Assembly work may only be performed by specialist personnel in accordance with the installation and operating manual and the regulations and standards in force.

The following points should be noted and followed:

The foundation must be even and levelled. It must not exhibit unevenness or a slope in any direction.
Set up and align the machine with the aid of a water level. A perfect function of the device can be guaranteed only if levelled mounted.
Only suitable installation aids, in accordance with regulations, should be used.
The device must be installed in such a way that it is easily accessible for maintenance and cleaning purposes.
The unit should only be installed with authorized and suitable fastening materials at all fastening points.
Do not distort the unit when installing.
Just use the indicated mounting and fixing places. No holes should be made in the housing or any screws screwed into it.
The duct system must not be supported on the housing.
For structure-borne sound decoupling, a flexible connection is recommended when connected on a duct system.
At least 2.5 times the diameter of the tube straight duct length before and after the fan
For all units from size 1000, the use of a pressure-side connecting tube and a crossbeam is necessary when using mounting feet. The motor-side mounting foot must be attached to the outside of the connecting tube.

Assembly with accessories

ELECTRICAL CONNECTION

Electricity warning

The electrical installation may only be carried out by qualified electricians in compliance with the installation, operating and maintenance instructions and the applicable national regulations, standards and guidelines:

ISO, DIN, EN and VDE specifications, including all safety requirements.
Technical connection conditions.
Safety at work and accident prevention requirements.

This list does not claim to be complete.
Requirements should be applied under one’s own personal responsibility.

The electrical connections must be made as shown in the corresponding wiring diagrams and terminal diagrams.
The type of cable, size of cable and method of laying should be determined by an authorized electrician.
Low and extra-low voltage cables should be laid separately.
An all-pole mains disconnection device with at least 3 mm contact gap must be provided in the supply line.
Use a separate cable inlet for each cable.
Any cable inlets that are not used must be sealed so that it is airtight.
All cable inlets must have strain relief.
Create equipotential bonding between the unit and the duct system.
Check all protective measures after the electrical connection work (earthing resistance, etc.)
Motor current and motor power must not exceed the values stated on the motor nameplate. The specified max. fan speed must never be exceeded, otherwise the motor and fan will be destroyed by this overload and dissolved or flying parts can destroy other components.

Unit supply cable

Connect the mains supply cable as shown in the wiring diagram. For the dimensioning of the line, observe the unit’s rating plate and the relevant guidelines. Appropriate protection with correctly dimensioned automatic safety breakers (circuit protection breaker) must be provided.

The device must be connected according to the wiring diagram. For fans which are controlled by external control devices, the corresponding operating instructions of the manufacturer must be observed.

Star circuit / Delta circuit

Star or delta operation only possible by the following types: AL 315 D4 01, AL 315 D2 01, AL 355 D4 01, AL 355 D2 01, AL 400 D4 01, AL 400 D2 01, AL 450 D4 01, AL 500 D4 01, AL 560 D4 01, AL 630 D6 01, AL 710 D6 01, AL 800 D6 01

For the other types a star-delta start is possible.

Star circuit

Delta circuit

Delta circuit

If, in spite of the correct connection to the mains or to the frequency converter, the devices turn contrary to the given direction of rotation, this must be corrected. For this purpose two phases can be interchanged at the terminal block (e.g. L1 with L2 or L2 with L3). Afterwards the direction of rotation is to be checked again.

For the electrical connection, for the setting of the motor protection switch or for the parameterization of a frequency inverter, only the technical data on the nameplate of the fan are relevant. These may differ from the technical data of the motor.

Thermal motor protection

During operation, electric motors heat up. Under certain circumstances (excessively high ambient or fluid temperatures, heavy contamination, etc.), the motor temperature may exceed the safety limit of the electrically isolated parts. In order to avoid engine damage, various types of temperature monitoring are possible, of which at least one must be installed on site:

Monitoring of the thermal motor current via a FU
Motor protection switch

Frequency converter

The fans can have speed control. This is only possible by means of frequency converters. Using other speed controls, such as voltage control, will directly damage the motor.

We offer tested and approved frequency converters as accessories. These are pre-programmed and delivered exactly matched to the respective engine power and speed. When using a frequency converter, the cable (max. length 50 m) between motor and frequency converter must be shielded. If third-party products are used, the following parameters must be set correctly.

Frequency converter

Fault current protection switch

If a fault current protection switch is used, only AC/DC sensitive RCD protective devices (type B or B+) are permitted.

Even when the device is switched off, voltage is applied to terminals and connections. Do not touch the device for 5 minutes after all-pole disconnection from the mains.

COMMISSIONING

Commissioning by trained technical personnel may only be performed after any risk has been ruled out. The following checks should be performed in accordance with the installation and operating manual and the regulations in force:

Correctly sealed installation of the unit and duct system.
Check the duct system, unit and medium lines, if present, remove any foreign bodies if necessary.
The intake opening and inflow into the unit must be clear.
Check all mechanical and electrical protection measures (e.g. earthing).
Voltage, frequency and type of current must correspond with the rating plate.
The fan must be checked for vibrations. Contact manufacturer if necessary.

Note:

Standard frequency inverters have a modified sine-wave at the output. This may cause noises, depending on the combination motor – frequency converter. Depending on the fan design and the radiating surface, these are perceptible.

At very high noise requirements, this can be disturbing. For industrial applications, the noises are generally acceptable.

Remedial measures may be a change in the clock frequency or the use of a sine- wave filter or a frequency converter with integrated sine-wave filter.

In speed-controlled operation with frequency converter, critical frequencies (frequencies at which resonances occur due to natural frequencies) must be masked out at the frequency converter.

MAINTENANCE AND CLEANING

Servicing, troubleshooting and cleaning may only be performed by specialised personnel in accordance with this installation and operating manual and the regulations in force.

Make sure that no connections or components are loosened unless the device is disconnected from the mains. Make sure that the equipment cannot be switched back on again.
Individual components must not be interchanged. For example, the components intended for one product may not be used for other products.
The regular maintenance and care of our devices is designed to ensure proper function, value retention and avoidance of damage. Keep a maintenance log.
Perform the specified maintenance on the unit at the specified intervals. Our devices require little maintenance when operated properly. The following work should be performed at regular intervals, in accordance with health and safety regulations:
Check the operation of the control system and safety devices.
Check electrical connections and wiring for damage.
Remove any dirt from the fan impeller or impellers and from inside the fan housing in order to prevent any unbalance or reduction in output.
- Do not use aggressive or easily flammable products for cleaning (impellers/housing).
- Preferably only water (not flowing water) or mild soapsuds should be used.
- The impeller should be cleaned with a cloth or brush.
- Never use a high-pressure cleaner.
- Balancing clips must not be moved or removed.
- The impeller and fittings must not be damaged in any way.

Before putting the unit back into operation after maintenance and servicing work, carry out a visual inspection as described in section 11. and 12.

Checklist Maintenance and Service

Impeller installation with Taperlock clamping bush

The impeller is connected by means of the clamping bush to the shaft end of the drive motor.

Assembly

Clean all bare surfaces (mating surfaces of the clamping bushings and motor shaft).
Insert the clamping bush (1) into the hub (2) and bring the holes into alignment.
Loosely lubricate the threaded pins (3) and screw in – do not tighten yet.
Push the impeller onto the shaft with the clamping sleeve, align it in the axial position and tighten the threaded pins evenly on both sides. Observe the tightening torque according to table.

Disassembly

Loosen all the threaded studs (3) and screw them out completely. Lubricate a threaded pin and screw it into the disassembly hole (4).
Tighten the threaded pin until the clamping bush (1) is released from the hub (2).
The impeller can be removed.

Technical data

Technical data Illustration

Commissioning (after replacement)

Remove any remaining installation material and foreign objects from the impeller and suction area.
Check direction of rotation (direction of rotation arrow on the impeller base disc).
During initial commissioning, the entire unit must be checked for mechanical vibrations. If necessary, re-balancing must be carried out.
Pay attention to a quiet operation, without vibrations.

LIFETIME AND DISPOSAL

Product life

The motors are equipped with maintenance-free, permanently lubricated ball bearings. Under normal operating conditions, the expected lifetime is about 30,000 operating hours.

The information given here depends strongly on the respective field of application as well as the environmental conditions. We recommend replacing these fans after reaching about 30,000 operating hours or 5 years.

Decommissioning and disposal

When disassembling, parts under voltage are exposed, which can lead to electric shock when touched. Before dismantling, disconnect the fan from all poles of the mains and secure against being switched on again!

Parts and components of the device that have reached their lifetime, e.g. due to wear, corrosion, mechanical stress, fatigue and/ or all other, not directly recognizable effects, must be disposed of professionally and properly after disassembly in accordance with national and international laws and regulations. The same applies to excipients in use such as oils and fats or other substances. The conscious or unconscious reuse of used components such as e.g. impellers, rolling bearings, motors. etc. can lead to a risk to persons, the environment as well as machinery and equipment. The applicable local operating regulations must be observed and applied.