Technical introduction







Table of contents



General information

ATEX guidelines



Rotational direction

 

The rotational direction is defined by the inlet-air side of the fan.
 
Right (standard) Left
The wheel turns to the right The wheel turns to the left
Drehrichtung Rechts Drehruchtung Links

 

Base, terminal box, and housing positions

Important note!

There are two types of base for fans.

  • Fan base: For small motor unit sizes.
    In the case of a motor unit size of 90 or less or motor units with a power of less than 1.5 kW,
    the fans generally have a fitted fan base.
  • Motor base: As a rule, larger motors - from motor unit size 90 or with a power of 1.5 kW
    or more - have motor bases.

The fan data sheet indicates whether the fan in question has a fan base or motor base.

 

Standard base and terminal box positions for fans with a
fan base
Right-hand design R90 base R0 terminal box
Left-hand design L90 base L0 terminal box
 
Standard base and terminal box positions for fans with a
motor base
Right-hand design R90 base R0 terminal box
Left-hand design L90 base L180 terminal box
 


Standard base and terminal box positions for fans with a
motor base for encapsulated Atex Ex112Gc motors
Right-hand design R90 base R270 terminal box
Left-hand design L90 base L270 terminal box
 
Standard terminal box positions for fans
WITHOUT a base
Right-hand design No base R0 terminal box
Left-hand design No base L0 terminal box
 
 
Unless the customer submits alternative requirements, fans are delivered as described above.
 
Customers who require other base, terminal box, or condensate hole positions must state their requirements when placing their order.
 
We recommend that you use the position configurator.


DRIVE MOTORS



All drive motors that we use are designed for continuous operation and comply with valid VDE (Association for Electrical, Electronic & Information Technologies) regulations, Eurocodes, and accident prevention regulations.

 

 

The standard motors are as follows:

 

  • 230 V, 50 Hz shaded pole motors
  • 230 V, 50 Hz single phase alternating current motors with operating capacitor
  • 230/400 V, 50 Hz three-phase alternating current motors
  • 202-306/350-530 V, 50/60 Hz wide range voltage motors

 

ATEX motors with ignition protection class EEX e or EEX de; for supported zones, see our information on ATEX designs. The shaded pole motor designs are insulation class B and IP 20, all others are insulation class F and IP 54 (to 120 W) or IP 55.

 

Single-phase motors can be delivered with power ratings of up to 1.1 kW.

 

Wide range voltage motors can be delivered with a power rating of up to 1.0 kW at 60 Hz.

 

In the case of three-phase alternating current motors with a power rating of more than 5.5 kW, the winding is designed with 200/690 voltage for delta/wye operation.

 

Special motors are available on request, including motors with different voltages, higher protection classes, thermal protection devices, motors in ISO class H, 60 Hz motors, CSA/UL designs, different motor shaft dimensions, and so on.

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TEMPERATURES



For a standard fan in insulation class 5, the permitted temperature of the feed medium is -20° C to +80° C. An ambient temperature of +40° C must not be exceeded for the drive motor.

 

A temperature guard is used for feeding hot air/gases. This permits a conveyor temperature of between 200° C and 300° C (higher temperatures on request).

 

If integrated frequency converters are used, the ambient temperature may not exceed +40° C, since otherwise the thermal load on the electronics would be too great, leading to a drop in performance or breakdown of the fan. In the case of applications with temperatures over 80° C in Ex zones, we recommend that you read our information on ATEX designs.

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TEMPERATURE GUARD



Fans that convey hot gas or air are fitted with a temperature guard. A temperature guard is required for medium temperatures of over 80° C.

 

The installation of a temperature guard places a spacer and cooling blade between the fan housing and the drive motor. In addition, the drive motor is distanced from the spacer so that heat transfer cannot take place.

 

The temperature guard can also be used as a sling disc (for example, for drops of water). The ambient temperature may not exceed 40° C. The temperature resistance of the fan depends on the speed of the drive motor. This is particularly important for adjustable fans.


Legend:

thermische Sperre

Thermal guard

kalte Luft

Cold air

heisse Luft

Hot air

Edelstahl-Ventilator (1.4301) mit stabiler Temperatursperre

Stainless steel fan (1.4301) with robust temperature guard

The maximum temperature of the conveyor may not exceed the following temperatures at the given nominal speed:

 

 

  • 300° C at 2,800 rpm
  • 200° C. at 1,400 rpm


It is important to note that when conveying hot air, the pressure differential of the fan drops, since the air density changes with the temperature. This is important for the fan design.

 

A temperature guard cannot be used with an (EX)e or (EX)de fan because the motor is directly flanged on.

 

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FAN WHEELS



All used fan wheels are dynamically balanced on two levels. The balancing quality is G6.3 in accordance with DIN ISO 1940 Part 1.

 

In the case of low-pressure fans, fans with shaded pole motors, and external rotor fans, forward-curved drum rotors or (from DNG 9-30), backward-curved high-performance impellers are used. The material used is normally galvanized steel sheet.

 

For medium-pressure fans (DMV/EMV), forward-curved medium-pressure impellers made from aluminium or steel sheet are used.

 

Backward-curved medium-pressure high-performance impellers are used for DMVL/EMVL types.

 

For fans for conveying dusty media (DSV/ESV), the impeller geometries prevent the accumulation of dust on the impellers. The standard material is galvanized steel sheet.

 

As a general rule, all fans are available in stainless steel (1.4301).

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TERMS, SYMBOLS, AND UNITS



V°

=

Volume flow rate, [m3/h] or [m3/min]

ΔPfa

=

Static pressure differential, [Pa]

ΔPt

=

Total pressure differential, [Pa]

U

=

Voltage, [V]

I

=

Nominal current, [A] or [mA]

PM(to)

=

Fan power input, [W] or [kW]

PL(from)

=

Motor power output, [W] or [kW]

La

=

Noise level, [dB(A)]

n

=

Speed, [rpm]

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Pressure conversion table
Pa daPA mbar=hPa kPa mm Ws
1
0,1
0,01
0,001
0,1
10
1
0,1
0,01
1
100
10
1
0,1
10
1000
100
10
1
100

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Parameters for Pressure Drop Online-Calculator

Flow medium

Condition:

=

gaseous

Weight density:

=

1,2040


Dynamic Viskosity:

=

18,206


Addtional data for gases:

Pressure (inlet, abs.):

=

1,013


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NOISE BEHAVIOUR



Whirling and turbulence during flow processes on the impeller and in the housing and other sounds (rotation noise that varies depending on the number of blades and rotational frequency) contribute to the noise generated when the fan is operated. Secondary noises as a result of mechanical vibrations can be mostly avoided by means of appropriate design measures and good impeller balancing quality.

 


Important factors that influence noise emission values are the installation position, different ambient conditions during operation, and the operating point of the fan.

 

The noise level is measured in dB(A) for each installation type as follows:

 

(see Characteristic Measurement Procedures) At the air outlet, at a distance of 1 m, and at less than 45 degrees. The noise level specifications on the separate data sheet relate to the roughly optimum operating point of the fan (around 60% of volume flow rate).

 

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CHARACTERISTIC MEASUREMENT PROCEDURES



The fan characteristic curves presented in this catalogue were determined in accordance with DIN 24163, test bench directive 1, installation type A on the chamber test benches (unimpeded suction and blowing).

 

 

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FAN CHARACTERISTIC CURVE



The characteristic curve and formulae in fig. 1 depict the chamber test bench results and shows the relationship between the static and total pressure increase and the volume flow rate. Standard characteristic curves reflect characteristics for defined suction and pressure connection conditions that are seldom found in real-life applications. This means that real-life results should be expected to differ from the results shown in standard characteristic curves. The depicted test results have been converted for an air density of 1.205 kg/m3, a temperature of 20° C, and an air pressure of 1013 mbar.
The formulae can be used to scale the results for other densities and speeds:

 

 

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SYSTEM CHARACTERISTIC CURVE



The system characteristic curve shows the pressure drop in the system resulting from friction, turbulence, speed changes, and so on in relation to the flow rate. In the case of flow systems, the curve is usually a parabola with an exponent of 2, and normally crosses zero.

 

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OPERATING POINT



The operating point of a fan corresponds to the point of intersection of the fan characteristic curve with the system characteristic curve.
The aim is to obtain a stable intersection point (the characteristic curves only intersect once with a sufficiently large angle) at around 60% of the maximum obtainable volume flow rate (optimum operating point).

 

 

FAN SELECTION



In principle, Karl Klein radial fans are designed for use over the entire characteristic curve range, from the minimum volume flow rate (V° = 0 m3/h) to the maximum rate (V° max.). The most effective working range is between 15 and 85%.
A correct choice of fan should be based on the required delivery rate (flow rate) and pressure differential. Naturally, available space, the level of operating noise generated, and chemical and thermal requirements also have an important role.

 

 

 



IMPORTANT DATA FOR INQUIRIES



  • Operating point (point of intersection of volume flow rate and static pressure)
  • Voltage
  • Frequency
  • Current type
  • Feed medium temperature (if > 80° C)
  • Type of feed medium
  • Rotational direction and terminal box position
  • Accessories and special requirements

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ATEX guidelines

IGNITION PROTECTION CLASSES



‘d’  – pressure-resistant enclosure

 


Ignition protection class whereby parts that could ignite an explosive atmosphere are enclosed in a housing that - if an explosive mixture does explode inside it - can resist the pressure and prevent the explosion from reaching the explosive atmosphere surrounding the housing.

 

In the case of electrical devices, sparks, electric arcs, and hot surfaces can occur during normal operation, and not only if defects arise. This can trigger an explosion. In cases like this, where it is impossible to avoid explosive gas mixtures and possible sources of ignition, there is only one solution: The explosion must be contained. This is the job of the so-called ‘pressure-resistant enclosure’.

 


‘e’ – increased safety


Ignition protection class whereby extra safety measures are taken to prevent unacceptably high temperatures and the occurrence of sparks and electric arcs inside or on external parts of electrical devices that are not subject to such occurrences during normal operation (DIN EN 60079-7).

 

Electrical devices that are used in places where there is a risk of explosion must be technically modified from the standard design in a way that prevents these dangerous occurrences from taking place. Such machines must have increased safety features. Unacceptably high temperatures and sparks/electric arcs may not be allowed to occur.

 

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ZONES



Spaces where there is a risk of explosion are places where the local and operating conditions mean that dangerous quantities of explosive atmosphere may accumulate.

 

An explosive atmosphere is a mixture of air and combustible gases, steam, vapour, or dust under atmospheric conditions that can allow a combustion process to spread independently from the source of ignition (explosion).

 

Spaces where there is a risk of explosion can be divided into the following ‘zones’ depending on the probability of an explosive atmosphere arising in them:

 

 

Gas:

Zone 0 (not supported)

Dust:

Zone 20 (not supported)

Zone 1

Zone 21

Zone 2

Zone 22

 

 

ZONE 0 – CATEGORY 1

 


Zone 0 encompasses spaces with constant or long-term explosive atmospheres.

 

Zone 0 mainly applies to the inside of containers or spaces immediately above the surfaces of fluids that are open to the air. An normal Ex installation is not sufficient here. Hazard analysis: Even possible sources of ignition that only arise as a result of very rare operating faults must be avoided. Each piece of equipment must be separately approved for zone 0.

 

Explosion-protected electric motors may not be used in zone 0, regardless of their protection class. Fans may only be used in this zone if they are approved by the PTB (Federal Institute of Physics and Technology), for example.

 

(For more information, see DIN EN 6079-14)

 

 

ZONE 1 – CATEGORY 2


Zone 1 encompasses spaces where an explosive atmosphere can be expected to occur frequently.


Zone 1 requires a normal Ex installation. Hazard analysis: Sources of ignition arising from frequently occurring operating faults must be avoided.


Motors in the following ignition protection classes can be used, as per DIN EN 6079-14:

 

  • Pressure-resistant enclosure, Ex d II A, B, or C
  • Pressure-resistant enclosure/terminal boxes, increased safety, Ex de II A, B, or C
  • Increased safety, Ex e II

 

The subclasses IIA, IIB, and IIC are only valid for pressure-resistant enclosure devices and not for increased safety devices.

 

 

 

ZONE 2 – CATEGORY 3


Zone 2 encompasses spaces where an explosive atmosphere can be expected to occur only rarely and for short periods of time.

 

Zone 2 is the transition area between zone 1 and safer areas that are no longer classed as being at risk of explosion.

 

Hazard analysis: Ignition sources that can occur during normal, defect-free operation are to be avoided.

 

Any equipment that is suitable for zone 1 can be used (as per DIN EN 6079-14).

 

Zones 0 and 20: Karl Klein fans cannot be used in zone 0 (gas) and zone 20 (dust).

 

ZONES 20, 21, and 22


Zone 20: This zone encompasses spaces where an explosive atmosphere in the form of a cloud consisting of combustible dust suspended in the air is present constantly, over a long period time, or frequently. Karl Klein fans are not suitable for use in zone 20.


Zone 21: This zone encompasses spaces where an explosive atmosphere in the form of a cloud consisting of combustible dust suspended in the air is present every now and then.

Note: Since May 2007, vibration monitoring is required when operating fans in zone 21 as per DIN EN 14986.

 


Zone 22: 

This zone encompasses spaces where an explosive atmosphere in the form of a cloud consisting of combustible dust suspended in the air is normally not present or is only present for a short period of time during normal operation.


Zone 22 is subdivided into regulations for conductive dust (for example, metal dust, which requires category 2D drives) and non-conductive dust (for example, grain, which requires category 3D devices).


Another important factor is whether the dusty medium is located only in the fan or also in the vicinity thereof.

 

 

 

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Additional measures for fans for use in zone 21 (vibration monitoring)



 

Note: Since May 2007, vibration monitoring is required when operating fans in zone 21 as per DIN EN 14986.

 

Fans with the appropriate additional equipment can be ordered from Karl Klein.
Such fans have installed vibration sensors and separate analysis devices if required.
(Click here for additional documentation)

Analysis devices must be mounted outside the Ex area. For more information, consult the relevant operating instructions.

 

The following points must be considered when implementing an individual solution:

 

  • Only vibration sensors that are approved for zone 21 may be used.
  • If possible, the vibration sensor should be mounted onto the bearing bracket on the A-  side of the drive motor, horizontal to the mounting orientation.
  • The standardized signal from the sensor is to be transmitted to a control or analysis device outside the Ex area. This device must shut down the fan if critical vibrations are detected on it.


Unbenanntes Dokument

Vibration limit values
Limit values as per ISO 14694
14694
Rigid mount
mm/s
Flexible mount
mm/s
Initial value
4,5
6,3
Alarm value
7,1
11,8
Shut-down value
9
12,5
These values apply to fans used in industrial applications.

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EXPLOSION GROUPS



Group 1: Mining (not available)


Group II: Everything except mining

 

Classification into the subgroups IIA, IIB, and IIC depends on the ignitability and transmission of internal ignition capability of the explosive atmosphere.

 

The degree of danger increases from A to C.

 

Specific permitted gaps for the various explosion groups are defined in EN 50018.



TEMPERATURE CLASSES



The temperature classes consolidate the minimum ignition temperatures of ignitable mixtures used during operation with the maximum surface temperature of electrical equipment used. If the maximum surface temperature reaches the ignition temperature of the ambient ignitable atmosphere, ignition can occur.

 

The temperature class specifies the maximum surface temperature maintained by the equipment at the highest permissible ambient temperature of + 40° C. te = 9s (T3), which means that the operator must use motor protection measures that switch of the motor within 9 seconds. T3 is the standard class since the voltage tolerance of +/- 10 % means that a higher thermal load can be created than T4 would permit.


Unbenanntes Dokument
Temperature classes

T1

T2

T3

T4

T5

T6

Maximum surface temperature
of equipment

450°C

300°C

200°C

135°C

100°C

85°C

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Labelling



Karl Klein fans are labelled as follows:

 

  • Fan rating plate on the fan housing
  • Two motor rating plates on the drive motor

 

Example

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The ATEX standard



ATmosphére EXplosible (explosive atmosphere)



ATEX Directive 94/9/EC has been valid since 01/07/2003 for manufacturers and marketers.

 

ATEX Directive 1999/92/EC has been valid since 01/07/2003 for operators.

 

DIN EN 13 463 Parts 1 to 8

 

Series of standards that intend to provide manufacturers with support for the labelling of their devices.

 

As of 01/07/2003, component parts must also be subjected to a risk assessment.

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‘NON-ELECTRICAL’ AND ELECTRICAL EQUIPMENT



Electrical equipment


There are many technical regulations and certification rules for electrical devices such as electric motors.

 

There are certificates for all motor sizes for all manufacturers, such as:

 

  • PTB certificates in Germany
  • LCIE certificates in France
  • SNCH certificates in Luxembourg

 

Non-electrical equipment


‘c’ (roller bearing lifetime, including maintenance intervals)

 

A new feature of explosion protection for devices is the inclusion of so-called ‘non-electrical’ devices.

 

Purely design-based explosion protection cannot be provided on the basis of hazard and risk analyses, since there is a risk that an explosive atmosphere might occur after all due, for example, to the restriction of the fan.

 

 

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DOCUMENTATION



Manufacturer’s declaration, declaration of conformity, inspection certificates for drive motors, operating and maintenance guides

 

The integration of fans in an assembly or system may not change the properties of the fan, since this would render the declaration of conformity invalid. The declaration of conformity and the prescribed documents for category 2 are lodged with an independent inspection authority.

 



USE OF FREQUENCY CONVERTERS



When frequency converters are used, motors with ‘increased safety’ are not permitted, since the motor must be certified along with the frequency converter as a single entity.

In the case of motors with a ‘pressure-resistant enclosure’, a separately certified frequency converter can be arranged.

 

 

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(Ex)e DESIGN INFORMATION (explosion-protected)



Notes

 

  • Only the rating plate data on the drives used is binding.
  • Motor protection switches are absolutely obligatory.
  • The permitted temperature range for the feed medium is -15° C to + 70° C. The voltage tolerance for ATEX drives is +/-5 %.
  • All ATEX fans must be subjected to individual testing during our final checking process.
  • Fitters and operators may not make any changes to these fans or to their motors.
  • Explosion-protected fans may not be operated in conjunction with a temperature guard.


ATEX presentation