MAICO ERM Series Semi-Centrifugal Duct Fans Instruction Manual

MAICO ERM Series Semi-Centrifugal Duct Fans

Specifications

• Models: ERM 18 Ex e, ERM 22 Ex e, ERM 25 Ex e, ERM 18 Ex t, ERM
  22 Ex t, ERM 25 Ex t

• Compliance: ATEX Directive 2014/34/EU

• Protection Class: IP 64

• Temperature Class: T1, T2, T3, T4

Product Usage Instructions:

Installation

1. Transport the fan to the installation site following the safety instructions and data from previous chapters.
2. Follow the applicable installation regulations, especially EU Directive 1999/92/EG, EN 60079-14, and VDE 0100.

FAQ

• Q: What should I do if the fan is not operating?
  A: First, check the power supply and ensure all connections are secure. If the issue persists, consult a qualified technician.

• Q: Can abrasive media be used with this fan?
  A: No, operating with abrasive media poses an explosion risk and should be avoided.

• Q: How should I store the fan when not in use?
  A: Store the fan in a dry and secure location away from extreme temperatures and moisture.

Translation of the original operating instructions Semi-centrifugal duct fans for use in potentially explosive atmospheres

Preface
Congratulations on having purchased a new MAICO fan. The unit is manufactured in accord-ance with the ATEX Directive 2014/34/EU and is suitable for areas subject to explosion hazards.
Before installing and using the fan for the first time, read these instructions carefully and follow the information they contain. Information video

The warnings provided indicate hazardous situ-ations which will result/could result in death or serious injury (DANGER/WARNING) or minor in-jury (CAUTION) if not avoided. ATTENTION in-dicates potential damage to the product or its surroundings. Keep the instructions safe for use later on.
The title page contains a duplicate of the rat-ing plate for your unit.

1 Figures
Title page with QR code for accessing the website directly by smartphone app.

For airflow direction/direction of rotation → Ar-rows on plastic housing

Scope of delivery

Fan with connection cable and explosion protec-tion terminal box (connecting cable pre-wired), two 220/200 REM-Ex reducers (supplied with ERM 22 Ex e/t), these installation and operating instructions.
For fan serial no. → Rating plate on title page or fan. EU declaration of conformity at the end of these instructions.

Qualification of installation, cleaning and maintenance staff

Installation, commissioning, cleaning and maintenance may only be undertaken by qualified electricians trained and authorised in explosion protection in accordance with Directive 1999/92/EC, Appendix II 2.8. These are qualified persons in accordance with the above-mentioned directive, that are also trained as qualified electricians. Further provisions of other national laws must be taken into account.

Intended use

The fan is used for air extraction or ventilation of rooms used for commercial purposes (dye shops, battery rooms, commercial premises, production facilities, etc.) with dangerous, explosive atmospheres in accordance with 1999/92/EC, articles 2, (4), (5).
The fan fulfils the safety requirements of Directive 2014/34/EU for units and protective systems in areas subject to explosion hazards.
The unit is classified as group II, category 2G for gas atmospheres or 2D for dust atmospheres, satisfies type of ignition protection “e”/“c” or
“t”/“c” and is suitable for use in areas subject to explosion hazards of zones 1 and 2 or 21 and 22. Its suitability can be found on the rating plate. For outdoor use, the fan must be protected from exposure to the elements.

 Non-intended use

The fan must not be used in the following situations under any circumstances. There is a risk of death. Read all the safety instructions.

EXPLOSION HAZARD

• DANGER Explosion hazard due to ignition of explosive substances if operating without motor protection switch.
• If used in potentially explosive gas atmospheres, operate only with a motor protection switch marked at least II (2) G in accordance with Directive 2014/34/EU.
• If used in potentially explosive dust atmospheres, operate only with a motor protection switch marked at least II (2) D in accordance with Directive 2014/34/EU.
• DANGER Explosion hazard from operating several fans in parallel with one single motor protection switch.
• Reliable tripping is not always guaranteed in the event of a fault.
• Do not, under any circumstances, operate several fans in parallel with one single motor protec-tion switch.
• DANGER Explosion hazard due to spark formation by the impeller scraping on the housing if the air gap is too small.
• Ensure a large enough air gap all the way around between the impeller and housing.
• DANGER Risk of explosion when conveying explosive liquid particles (e.g. paint), which may adhere to the unit.
• Do not, under any circumstances, use unit to convey explosive liquid particles.
• DANGER Risk of explosion when operating with abrasive media.
• Abrasive media are to be avoided.
• DANGER Risk of explosion if operated outside of the ambient and operating conditions.
• In particular, there is a risk of overheating when operating outside of the permissible operating temperature range.
• Only operate unit within the permitted ambient and operating conditions and permitted usage temperature.
• DANGER Risk of explosion when operating without the protective device, should foreign bodies fall or be drawn into the air duct. Risk of death due to spark formation.
• Be sure to fit any free air inlet/outlet with a protective device that meets the requirements of EN 13857 and is suitable for Ex areas, e.g. with MAICO protective grille SG..Ex (IP 20 degree of protection according to EN 60529). When using non-Maico products, an ignition hazard assessment must be carried out.
• DANGER Explosion hazard if the explosive atmosphere cannot be removed when the supply air intake is insufficient.
• This can occur if, e.g., rooms are too air-tight or room filters are clogged.
• Ensure sufficient supply air intake.
• Operate unit in permissible air power range.
• DANGER Explosion hazard when operating with frequency converter for speed con-trol.
• Bearing currents may be a direct source of ignition.
• Operation with frequency converter not permitted.
• DANGER Explosion hazard due to unauthorised conversions on unit, incorrect installation or damaged components.
• Danger if installation or modification work is carried out by unqualified staff.
• Operation not permitted if unit is modified, installation is incorrect or components are damaged.
• Unit is not approved if installation work is carried out by possibly unqualified staff.
• DANGER Risk of explosion when operat-ing with layers of dust on the motor.
• To avoid the motor from overheating, regular inspections and cleaning is necessary.
• CAUTION Risk of injury if there is no protection against accidental contact (protective grille) on the free air inlet/outlet.
• In particular, there is danger if the unit is installed in a manner accessible to people.
• Fan may only be operated with an access guard.
• Areas with possible access to rotating parts (impeller) should be made safe with an access guard according to EN ISO 13857, e.g. with MAICO protective grille SG.. (meets IP 20 degree of protection according to EN 60529).

Motor protection switch needed

Motor protection switches that meet the following conditions are permitted, otherwise the conformity ceases to apply:

• Type-examination in accordance with Directive 2014/34/EU.
• Labelling according to the directive, at least II (2) G for use in gas atmospheres or II (2) D for use in dust atmospheres.
• The motor protection switch must be wired in accordance with wiring diagram Fig. D. The motor protection switch should be set to the nominal motor current (not Imax).
• The specification of the nominal current on the rating plate only refers to the fan’s free-blowing condition. The nominal current at the respective operating point of the fan may differ depending on the air resistance of the ventilation system. When installed, the actual operating current must be determined accordingly and set on the motor protection switch so that the motor protection switch trips reliably.

Prescribed setting/tripping values for motor protection switch, see rating plate.
The switch must trip in the event of a short circuit.
Once all causes of faults have been eliminated, the connected motor must not start up again automatically. It may only be switched on again manually (restart interlock).
For optimum protection, we recommend the MAICO MVEx motor protection switch, which has been type-examined in accordance with Directive 2014/34/EU – please observe the MVEx operating instructions.

Obligations of the installer and

operating company
The fan may only be operated at permissible ambient and airstream temperatures of -20 to+50 °C and only if fully mounted.
The fan must be regularly inspected and maintained by a qualified person, as described in these instructions.
Cleaning and maintenance intervals should be determined by the operating company in accordance with EN 60079-17 – frequency de-pends on ambient conditions and anticipated limitations. Shorten the maintenance intervals in the event of dust or a corrosive atmosphere.
Additional safety regulations should be observed during installation and operation, e.g. in accordance with the following directives and regulations:

• EG Directive 1999/92/EC, ATEX 137: imple-mented in Germany with the Ordinance on Industrial Safety and Health.
• EN 60079-14: Design, selection and erection of electrical installations.
• National accident prevention requirements.

Safety instructions for users

• DANGER Explosion hazard due to spark formation if foreign bodies are inserted into the unit.
• Do not insert any objects in the unit.
• WARNING Risk of injury due to suction from the unit and rotating impeller.
• Hair, clothing, jewellery etc. may be pulled into the unit if you get too close to it.
• Keep sufficient distance during operation.
• Do not insert any objects into the unit.
• DANGER Risks for children and people with reduced physical, sensory or mental capabilities or a lack of knowledge.
• Unit may only be installed, commissioned, cleaned and maintained by persons who can safely recognise and avoid the risks associated with this work.
• CAUTION Hot motor surfaces may result in skin burns if touched.
• Do not touch hot motor surfaces. Always wait until the motor has cooled down.

Switching unit on / off

• The unit is switched on or off with an optional switch. The unit is designed for continuous oper-ation (S1). Frequently switching on/off may result in improper heating and should be avoided.

Reversing mode

• Unit not suitable for reversing mode.

Action to take in the event of a fault

Check whether the motor protection switch has responded. Unplug the fan from the mains in the event of operational disturbances. Before switching on again, have qualified staff determine the cause of the fault and remedy it. This procedure is particularly recommended after the motor pro-tection switch has been tripped.

Unit installation

Safety instructions
Do not use the unit for “purposes other than those for which it was intended” under any cir-cumstances.
The installation may only be carried out by a qualified person, as described in these in- instructions.

• DANGER Danger of electric shock. Whenever working on the unit, release the sup-ply current circuits, secure to prevent them from switching on again and ensure the unit is de-energized.
• Attach a clearly visible warning sign.
• Ensure that there is no explosive atmosphere.
• DANGER Risk of explosion if the cables are incorrectly inserted into the terminal box. Degree of protection is not guaranteed.
• Ensure degree of protection by correctly inserting the cables into the terminal box.
• DANGER Explosion hazard when operat-ing with unit not fully mounted and if air inlet or outlet is not correctly protected.
• The fan may only be operated if the unit is fully mounted and with the protective devices fitted (in accordance with EN 13857) for the air channel.
• Ensure that foreign bodies cannot be sucked into the unit and ducts.
• DANGER Explosion hazard due to incorrect adjustment.
• The rotating parts of the unit were adjusted in the manufacturer’s factory.
• The unit must not therefore be taken apart. The temporary removal of the terminal box cover during unit installation is the only exception to this restriction.
• DANGER Risk of explosion/risk of injury due to incorrectly mounted or falling unit. Only mount on walls/ceilings with sufficient load-bearing capacity and sufficiently dimensioned mounting material.
• Mounting material is to be provided by the customer.
• During installation, do not allow people to stand under the installation location.
• NOTICE Damage to unit due to incorrect installation position.
• Loss of IP degree of protection if fan is mounted in damp rooms with air being transported upwards.
• Do not mount the fan in damp rooms with air being transported upwards.

Transport, storage

DANGER Danger from unit falling if transported with unauthorized transport equipment.
Use lifting and transport equipment suitable and approved for the fan and transport weight. Ensure that persons do not step under suspended loads.
Note weight and centre of gravity (centre). Observe the maximum permitted loading capacity for lifting gear and means of transport. For total weight → rating plate on title page. During transport do not place load on sensitive components, such as impeller or terminal box. Fit transport equipment correctly.
CAUTION Risk of cuts from metal hous-ing plates with sharp edges.
Wear personal protective equipment (cut-resistant gloves) for installation.

• Only ship unit in original packaging.
• Store unit in dry location (-25 to +55 °C).

Technical data

→ Rating plate on title page or on unit.
→ Unit overview

Quality grade: G 6.3

Weight| → Rating plate

Ambient/operating conditions

• Permitted ambient and airstream temperature → Rating plate.
• Division of maximum surface temperature into classes for gas atmospheres. Temperature class T… → Rating plate.

For use in dust atmospheres, the surface temperature specified in the labeling on the rating plate is to be observed.

Installation

During installation, note the applicable installa-tion requirements → especially EU Directive 1999/92/EC, EN 60079-14 and VDE 0100 (in Germany).

installation instructions
NOTICE Damage to the unit if the line feed-through to the terminal box is pre- installed. Line feedthroughs may be damaged if the connection line is pulled or the unit is lifted by the line.
Do not pull connection lines or lift the unit using the lines.

ERM … Ex e, ERM … Ex t fans

• For permanent installation in ducts with ventilation duct or flexible duct suited to the unit type (nominal size).
• For surface mounting on duct, wall, foot with sufficient load-bearing capacity.
• Any installation position, do not install in damp rooms with air being transported upwards.
• For ventilation or air extraction, depending on the installation position.
• Unit connection sockets on both sides for direct installation in ventilation ducts.
• For reducers for connecting to other duct diameters → Internet.
• To avoid the transmission of vibrations to the duct system, we recommend mounting type ELM-Ex and ELA Ex flexible cuffs, FUM mounting foot and GP vibration dampers from MAICO.

Checks before mounting

1. Perform the following checks: D = detailed check, N = close inspection, S = visual inspection

Unit installation

1. Check unit for transport damage.

2. Prepare installation location for duct, wall or foot mounting: Lay ventilation duct or flexible duct. If mounting on wall, make sure there is a level support surface.

3. Lay a permitted power cable to the installa-tion location. Use a connection cable suited to the unit type.
   CAUTION Risk of cuts from metal housing plates with sharp edges.
   Wear personal protective equipment (cut-resistant gloves) for installation.

4. ERM … Ex e, ERM … Ex t: Transport fan to installation location. Note safety instructions and data in the previous chapter.
   DANGER Risk of explosion/risk of injury due to incorrectly mounted or falling unit. Only mount on walls/ceilings with sufficient load-bearing capacity and sufficiently dimensioned mounting material.
   Mounting material is to be provided by the customer.
   During installation, do not allow people to stand under the installation location.

5. If mounting with FUM mounting foot: Mount a suitable mounting foot on fan housing with the self-cutting tapping screws provided (do not use screws near the impeller). Any install-ation position can be selected. Make sure that there is free access to the terminal box at the installation location.

6. Install fan and firmly screw fan down to wall at all flange holes [X] (4x). Mounting material of a sufficient size should be provided by the customer. Note rotation direction and airflow direction → air direction arrows on unit sticker.

7. ERM 22 Ex e, ERM 22 Ex t: If reduced to 200 mm, fit the reducer [3] between the fan and ventilation duct or flexible cuff.
   DANGER Risk of explosion when operat-ing without the protective device, should foreign bodies fall or be drawn into the air duct. Risk of death due to spark formation.
   Be sure to fit any free air inlet/outlet with a protective device that meets the requirements of EN 13857 and is suitable for Ex areas, e.g. with MAICO protective grille SG..Ex (IP 20 degree of protection according to EN 60529). When using non-Maico products, an ignition hazard assess-ment must be carried out.

8. If the air inlet or outlet is not covered, mount a permitted protective grille, e.g. MAICO SGM-Ex protective grille in front of the unit → Fig-ure C.

9. Ensure a sufficient fresh air supply intake.

10.  Fit suitable insulation, sound-absorbing and installation materials.

Electrical connection

• DANGER Danger of electric shock. Prior to accessing the connection terminals, disconnect all supply circuits.
• Secure against being switched back on, check that no voltage is present.
• Earth and connect the EARTH with active parts which are to be short-circuited.
• Cover or block off neighboring live components.
• Attach a clearly visible warning sign.
• Ensure that there is no explosive atmosphere and/or dust layers.
• NOTICE Damage to unit due to speed con-trol.
• No speed control allowed.

Operating conditions
Operation only permitted, if the following conditions are met:

• Permanently installed electrical installation.
• Connection cable permitted for explosion risk areas and load.
• Mains disconnect device with a contact opening of at least 3 mm per pole.
• Permitted voltage and frequency → rating plate.
• Explosion protection terminal box provided.
• Protective-conductor terminal, at mains end in the terminal box. There is a terminal on the outsideof the fan for earthing a duct system.
• Operating in intended air power range.
• Permitted operating point. The current andpower stated on the rating plate are measured with free suction and free blow-out. They may be higher or lower depending on the operating point.

A motor protection switch is essential for thermal fusing.

Connect the fan electrically

1. Switch off power supply circuits, and position a visible sign warning against being accidentally switched back on.
2. Open the terminal box, route cables into terminal box and screw down with cable feedthrough. Note tightening torques (in Nm at 20 °C). Check tightness and tighten if necessary.

Terminal box cover:

M4 stainless steel cylinder head bolts| 1.4 Nm
Mantle terminals| 2.5 Nm
M20 x 1.5 cable feedthrough:
3x connection thread| 2.3 Nm
Cap nut

Clamping area

| 1.5 Nm

7 … 13 mm

---|---

Earthing of fan and duct system

1. Connect PE conductor at mains end in terminal box with explosion protection.
2. Connect PE conductor duct system to the terminal on outside of fan.

Direction of rotation and airflow direction

1. Check direction of rotation and air flow direction → Arrows on fan housing.

Motor protection switch, on/off switch

1. Install motor protection switch and wire in accordance with wiring diagram (→ wiring diagram, Fig. D, terminals 4, 5 and 6). Recommendation: It is imperative that MAICO MVEx be installed outside the area with a potentially explosive atmosphere.
2. Set motor protection switch to nominal motor current (not Imax).
3. Fit an On/Off switch provided by the customer.

Checking electrical connection

1. Perform the following checks: D = detailedcheck, N = close inspection, S = visual in-spection

connections, are correct (e.g. connections are tight, conductor cross-sections are sufficient).| ●| ●| ●
VI II| Error loop impedance (TN system) or earth resistance (IT system) satisfactory.| ●| |
IX| Automatic electrical protective equipment set correctly (auto- matic resets not possible).| ●| |
X| Special operating conditions are satisfied (motor protection switch).| ●| |
XI| All cables and lines, which are not being used, are connected correctly.| ●| |
XI I| Installation with changeable voltage in agreement with the documentation.| ●| ●|
XI II| Electrical insulation clean/dry.| ●| |

Fit terminal box cover for explosion protection. Ensure that there are no dirt particles in the terminal box and that the seal of the terminal box cover has close contact all the way around the terminal box. Note tightening torques of 1.4 Nm. Check seal integrity of terminal box.

Commissioning

Checks before commissioning

1. Perform the following checks: D = detailedcheck, N = close inspection, S = visual in-spection

Checking correct functioning

1. Switch on unit and perform the following: D = detailed check, N = close inspection, S = visual inspection

be higher or lower depending on local conditions (duct distance, altitude, temperatures).

Imax may be exceeded at nominal voltage due to ageing or a reduction in terminal voltage (e.g. trans former).

| ●| |
III| Thermal safety is ensured by the motor protection switch system.| ●| |

Setting of motor protection switch

1. Set the motor protection switch to the nominal current according to the rating plate.
   The motor must be switched off at the specified pull-in current ratio IA/IN, within the specified time tE.
   If this is not the case, the effective nominal current occurring at the operating point must be determined, adjusted and the test repeated.

Cleaning, maintenance

According to Directive 1999/92/EC, the workplace and work equipment must be maintained with due regard to safety. The points listed in EN 60079-17 must be taken into account and carried out.

The intervals should be determined by the operating company in accordance with EN 60079-17 and may be extended if a sufficient maintenance concept is used – frequency depending on ambient conditions and anticipated restrictions. The maintenance intervals are to be shortened in case of dust or a corrosive atmosphere.

• DANGER Danger of electric shock. Prior to accessing the connection terminals, disconnect all supply circuits.
• Secure against being switched back on, check that no voltage is present.
• Earth and connect the EARTH with active parts which are to be short-circuited.
• Cover or block off neighboring live components.
• Attach a clearly visible warning sign.
• Ensure that there is no explosive atmosphere and/or dust layers.
• CAUTION Hot motor surfaces may result in skin burns if touched.
• Do not touch hot motor surfaces. Always wait until the motor has cooled down.
• CAUTION Risk of injury if there is no protection against accidental contact (protective grille) on the free air inlet/outlet.
• In particular, there is danger if the unit is installed in a manner accessible to people.
• Fan may only be operated with an access guard.
• Areas with possible access to rotating parts (impeller) should be made safe with an access guard according to EN ISO 13857, e.g. with MAICO protective grille SG.. (meets IP 20 degree of protection according to EN 60529).
• NOTICE Damage to the unit if the line feed-through to the terminal box is pre-installed. Line feedthroughs may be damaged if the connection line is pulled or the unit is lifted by the line.
• Do not pull connection lines or lift the unit using the lines.

Cleaning by a qualified person

• Regularly clean unit at appropriate intervals with a damp cloth, especially after long periods out of service.
• Clean unit at shorter intervals if you expect layers of dust to accumulate on the impeller and other parts of the unit.

Maintenance by a qualified person
The fan should be regularly checked and maintained. In particular, ensure:

• unimpaired flow in the air duct.
• the effectiveness of the protective grilles.
• compliance with the permitted temperatures.
• quiet bearings. Bearing life of 40 000 hours, depending on application.
• cables are secure in the terminal box.
• potential damage to terminal box, cable screw-connections, sealing plugs and cables.
• secure routing of cables.
• During regular safety checks (maintenance interval), undertake a complete check in accordance with the previous test schedules.
• This involves checking the function of safety components, air gap, power consumption, bearing noise, damage and disproportional vibration (e.g. impeller imbalance). Remove dirt and foreign particles.

Repairs
In the event of wear/tear on unit components, have the unit repaired or overhauled only by a certified repair shop.

Fault rectification

See Action to take in the event of a fault [} 10]

Disassembly and environmentally sound disposal

• DANGER Danger of electric shock. Prior to accessing the connection terminals, disconnect all supply circuits.
• Secure against being switched back on, check that no voltage is present.
• Earth and connect the EARTH with active parts which are to be short-circuited.
• Cover or block off neighbouring live components.
• Attach a clearly visible warning sign.
• Ensure that there is no explosive atmosphere and/or dust layers.
• Only a qualified electrician trained in and authorised for explosion protection work may undertake disassembly.

Old devices and electronic components may only be dismantled by specialists with
electrical training. Proper disposal avoids detrimental impact on people and the environment and allows valuable raw materials to be reused with the least amount of environmental impact.

Do not disposeof the following components in household waste!Old devices, wearing parts (e.g. air filters), defective components, electrical and electronic scrap, environmentally hazardous liquids/oils, etc. Dispose of them in an environmentally friendly manner and recycle them at the appropriate collection points (→ Waste Disposal Act).

1. Separate the components according to material groups.
2. Dispose of packaging materials (cardboard, filling materials, plastics) via appropriate recycling systems or recycling centres.
3.  Observe the respective country-specific and local regulations.

Acknowledgments
© Maico Elektroapparate-Fabrik GmbH. Translation of the original operating instructions. Misprints, errors and technical changes are reserved. The brands, brand names and protected trade marks that are referred to in this document refer to their owners or their products.

Declaration of conformity

Maico Elektroapparate-Fabrik GmbH Steinbeisstr. 20
78056 Villingen-Schwenningen Deutschland
Service +49 7720 6940
info@maico.de
7185.1181.0005_RLF.9_03.24_DSW-AV

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