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Translation of the original instruction Operating and Maintenance Instruction Manual Q-FlapCompact II/Q-Flap Compact II Plus Inlet Isolation Device page 1 of 91 USB-QFLCII-14804/0...
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EC Declaration of Conformity We hereby declare that Q-FlapCompact II/Q-FlapCompact II Plus back pressure flap corresponds explosive decoupling of the following EU directive, harmonized standards and technical specification as far as services provided by the customer have been carried out...
..................25 3.10.3 Safety instructions during maintenance .......................... 26 3.11 Monitoring function Functional description: introduction ....................27 ................27 Functional description Q-FlapCompact II/Plus ........................... 29 4.1.1 Inspection lid ................... 29 4.1.2 Q-FlapCompact II/Plus locking mechanism page 4 of 91 USB-QFLCII-14804/0...
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Additional monitoring: Q-FlapCompact II Plus ..............34 4.2.1 Wear and tear sensor (Q-FlapCoompact II Plus only) ..... 35 Optional Level sensor (optional sensor for Q-FlapCompact II or Q-FlapCompact II Plus) ......................36 Monitoring panel requirements ....................37 4.4.1 Locking mechanism requirements ............
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Technical Data: Closed-Position Sensor ....................86 11.4 Technical Data KI505A (optional) ......................88 11.5 Operating Instructions KI505A Annex .............................. 91 12.1 Q-FlapCompact II/Plus Inlet isolation device sequence of operation with ....................91 ® REMBE , INC. Monitoring Panel page 6 of 91 USB-QFLCII-14804/0...
Technical data Hole pattern (row 2) on center Width Bolt size, bolt length (number per flange) Total length page 7 of 91 USB-QFLCII-14804/0...
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Technical data Q-FlapCompact II / Q-FlapCompact II plus series / Unit for size DN 140 (5.51’’) to DN 400 (15.75’’) Installed length inch 16.54 18.50 20.87 23.23 24.80 25.98 28.74 29.53 Width inch 14.96 15.75 17.32 19.29 20.47 22.44 24.80 26.77...
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Q-FlapCompact II / Q-FlapCompact II plus series / Technical data Unit for sizes DN 450 (17.72) to 1000 DN 1000 (39.37’’) 1090 1190 1320 1470 1625 Installed length inch 31.89 34.25 36.61 42.91 46.85 51.97 57.87 63.98 1100 1180 1260...
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Q-FlapCompact II / Q-FlapCompact II plus series / Mounting Unit distance for dust explosion class1 sizes bar x DN 140 (5.51’’) to Maximum K value DN 400 (15.75’’) Minimum mounting distance dust 8.53 6.56 6.56 6.56 6.56 6.56 8.53 8.53...
General information 2.1 Icons The following icons are used in this operating manual: Draws attention to dangerous situations with possible personal injury and used to alert to potential damage to machinery. Danger due to electrical current. Work must only be carried out by trained electricians.
Operating and Maintenance Instructions. The Q-FlapCompact II/ Q-FlapCompact II Plus serves as an inlet isolation Intended use device for dust category St1 (all sizes: DN 140 - DN 1000 (5.51-39.37 in)) and St 2 (sizes: DN 140 - DN 315 (5.51-12.40 in).
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Installation schema Q-FlapCompact II/ Plus Filter (Container) Q-FlapCompact II/ Plus inlet isolation device Flow direction Deviating installation situations are not allowed! The inlet isolation device cannot be used for materials impeding the closing of the flap blade in the event of an explosion. Additional important information: –...
Only skilled personnel are authorized to perform the commissioning and servicing of the system, preferably trained by the REMBE®, Inc. Service Consultant. Definition of skilled personnel: personnel who have extensive knowledge of below-mentioned regulations, directives and standards because of their specialized training and experience with •...
Warranty conditions to be observed by the system operator are as follows: Warranty conditions • ® Loading and shipping in accordance with REMBE instructions • Proper storage before installation and commissioning • Knowledge and implementation of the information, notes and references in the operating manual •...
Safety 3.1 Safety warning WARNING Working safely is only possible if all instructions for this system as well as other relevant system components have been read thoroughly and are adhered to carefully. Each person performing installation, commissioning, operation and servicing must read the Operating and Maintenance Instructions and must understand every detail.
3.2 Warning notices on the inlet isolation device Warning labels on the inlet isolation device give notice of immediate hazards. They have the following meaning: Meaning: Warning notice Do not open the inspection Do not open during operation/pay lid during operation or when there is an explosion risk.
Inadequately exhausted substances can endanger the health of personnel! Therefore, alterations should ® only be carried out after consulting REMBE --------------------------------------------------------------------------------------------------------- 3.5 Danger of crushing and overturning To avoid the risks mentioned below, this inlet isolation device should not be operated until assembly has been completed.
3.6 Crash hazard/danger of falling Transport by crane loops WARNING There is danger of physical harm to personnel near the inlet isolation device if the device is not properly secured to equipment having sufficient load capacity to transport the device. Death or serious injury can result if the inlet isolation device crashes! Please take into account adequate load carrying capacity! Fasten the lifting equipment to the following points:...
3.8 Fire and explosion hazard A residual risk of injury remains on systems used for the extraction of combustible or explosive substances despite fire and explosion protective measures. The manufacturer cannot provide a 100% safety guarantee and does not assume liability in case of damage.
Installation area Contact REMBE®, Inc. Division 1 Ex-Zone Comment Ductwork No zone and zone 22 All variants of Q-FlapCompact II and Q-FlapCompact II Plus All variants of Q-FlapCompact II and Installation area No zone Q-FlapCompact II Plus maintenance instructions apply (see Section 9,...
The classifications of hazardous areas is the responsibility of the owner or the designated design team of the company. Possible additional classifications shall be defined if explosive gases are involved. 3.8.3 Avoiding sources of ignition Access to areas presenting a fire and explosion hazard shall be marked with a prohibition sign, “fire, open flame and smoking prohibited”...
Only systems with approval for the corresponding zone may System categories be applied within the system. Assignment to the categories can be found in the following charts: For dust Category Safety measure Very high High Average To be utilized in zone 20 or 21 or 22 21 or 22 (ATEX)
The unit must be cleaned and repaired and the flap blade and pipe connection must be replaced (this work must be performed by trained ® personnel only, either by REMBE or the supplier). The suspension of the inlet isolation device should also be inspected.
3.10 Safety during maintenance and inspection Preventive and thorough maintenance and inspection is essential for the safety of personnel working within range of the inlet isolation device. In addition, preventive and thorough maintenance ensures the proper operation of the system. Please have only qualified staff perform the inspection, maintenance and service work! Information and specifications regarding maintenance work and its intervals Maintenance intervals...
Wear and tear may also cause impairment of function and may be a safety risk. In order to monitor the inlet isolation device for wear and tear, we suggest ordering the Q-FlapCompact II Plus, which includes the wear and tear sensor. (see Section 4.2 Additional monitoring: Q-FlapCompact ll Plus).
4.1 Functional description Q-FlapCompact II/Plus General functional The Q-FlapCompact II /Plus serves as an inlet isolation device for dust category St1 description (all sizes: DN 140 – DN 1000 (5.51-39.37 in)) and St 2 (sizes: DN 140 - DN 315 (5.51- 12.40 in).
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The inlet isolation device is attached on the suction side and remains opened due to the air current during system operation. A stopper, located on the inside of the inspection lid, limits the opening angle of the flap blade. The maximum opening angle depends on size, (see Section 1, Technical data).
The Q-FlapCompact II/Plus has a locking mechanism on every model. This locking mechanism consists of a locking unit with an electromagnetic locking pin and a locking lever. See also Section 12.1 Q-FlapCompact II/ ® Plus inlet isolation device sequence of operation with REMBE monitoring panel.
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The locking lever is tightly connected to the flap blade by means of a shaft. Locking lever During opening or closing, the locking lever rotates in clockwise direction. System shutdown/ During the closing process, the locking lever is “led” over the locking pin. If the locking the unit flap blade is closed completely, the locking pin snaps in by means of a spring force.
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Flap Locking lever Locking pin If the E1 and E2 wire terminals do not switch to “0-signal” (one of the entries does not switch off), a malfunction is signaled and the system shuts down. Since the electromagnetic release is still under tension, the locking mechanism would not work. Locking mechanism technical data: •...
Flap locked Flap Pressure wave in the event of an explosion 4.1.3 Q-FlapCompact II/Plus closed-position sensor (Formerly known as deposit sensor) Closed-position sensor The closed-position sensor is an inductive proximity switch that detects the flap in the closing position on every inlet isolation device. By monitoring the...
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Per NFPA 69, the closed-position sensor shall be used to initiate an immediate, See also Section 12.1 Q-FlapCompact II/ automatic shutdown of the protected process. ® Plus inlet isolation device sequence of operation with REMBE monitoring panel. Terminal box Closed position sensor WARNING...
Monitoring wear For enhanced monitoring, and to potentially increase maintenance intervals, the and tear with Q-FlapCompact II Plus is available. In addition to the closed-position sensor, the Q-flapCompact II Q-FlapCompact II Plus comes with a wear and tear sensor. Plus...
The information stated in the operating instructions is to be supplemented with your own practical experience. 4.3 Optional Level sensor (optional sensor for Q-FlapCompact II or Q-FlapCompact II Plus) Level sensor Since deposits in the inlet isolation device cannot be excluded completely, there al- ways exists a risk of fire and explosion in the flap.
------------------------------------------------------------------------------------------------------- 4.4 Monitoring panel requirements NOTE: THE Q-FLAPCOMPACT II/Q-FLAPCOMPACT II PLUS REQUIRES controls or a properly programmed PLC. ® REMBE , INC. CAN PROVIDE A MONITORING PANEL OR YOU MAY SOURCE YOUR OWN.
4.4.1 Locking mechanism requirements Unlocking the flap blade To allow for the opening of the flap blade, the locking mechanism's electromagnet must be operated with a control current. The locking unit’s locking pin is retracted and the locking lever is released. The air flow, created by the fan, will open the flap blade.
The monitoring panel must be designed to ensure that the closed-position sensor monitored during the entire system operation. See also Section 12.1 Q-FlapCompact II/Plus inlet isolation device sequence of operation with REMBE® monitoring panel. page 38 of 91...
WARNING If the flap blade is closed during operation due to an explosion, a signal is sent to the monitoring panel and an emergency shutdown is initiated! If a signal is received from the closed-position sensor at the monitoring panel during operation, an immediate emergency shutdown must take place through the monitoring panel! --------------------------------------------------------------------------------------------------------...
WARNING If the wear and tear sensor signals, the inlet isolation device must be inspected for wear and tear. The flap blade, wear and tear sensor and all other worn parts must be replaced or the entire inlet isolation device should be replaced, depending on condition.
Transport and storage prior to commissioning 5.1 Transport Transport with pallet The inlet isolation device is - depending on the size – shrink-wrapped and shipped on a pallet: • Immediately following delivery, please check the unit for possible shipping damage. •...
14°F (-10°C) and not exceed 140°F (60 °C). • Q-FlapCompact II/Plus is certified for pull/flow applications. The inlet isolation device should be installed in the following order (in flow direction): Inlet isolation device - filter (container) - fan.
6.2 Installation conditions The inlet isolation device should be transported to the place of installation. Loosen the tensioning belts and remove the shrink-wrapping/other packing materials. Unload the inlet isolation device with a crane and suitable lifting accessories from the pallet. WARNING There is danger of physical harm to personnel near the inlet isolation device if the device is not properly secured to equipment...
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The correct direction of flow is indicated in the safety instructions on the inlet isolation device! The pressure surge resistance of the ductwork between the Q-FlapCompact II/Plus and the protected container/filter unit must be at least the same as the pressure surge resistance of the Q-FlapCompact II/Plus (generally minimum 2 mm sheet thickness, welded piping system.
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Plant ceiling Min. distance = inspection lid range Air flow Required straight ductwork Total length (stretched length) of the ductwork All inlet isolation sensors and the locking mechanism are connected to a Electrical connection ter minal box attached to the inlet isolation device. Connect the sensors and locking mechanism to the control system.
6.3 Mounting distances and measures Mounting Q-FlapCompact II / Q-FlapCompact II plus series / Unit distance for dust explosion class 1 from DN 140 (5.51’’) to Minimum mounting DN 400 (15.75’’) distance for dust 8.53 6.56 6.56 6.56 6.56 6.56 8.53...
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Q-FlapCompact II / Q-FlapCompact II plus Mounting Unit series / distance for aluminum dust explosion class1 Minimum mounting (no heating value distance at St1 restriction)) aluminum dust (no heating value 11.48 11.48 11.48 11.48 11.48 11.48 restriction Maximum mounting distance dust...
6.5 Commissioning Inspection prior to first commissioning Prior to commissioning of the inlet isolation device, please perform a complete visual check, paying attention to the following points: • Foreign substances (i. e. tools) within the system? • Ductwork tightly connected? •...
Operation Examination prior to system start up Complete a visual inspection prior to each system start-up. Please note the following issues: • ductwork tightly connected? • Check if the inspection door is tightly closed • Check if a malfunction message is indicated on the monitoring panel Operation of the inlet isolation valve During normal system operation, no manual intervention or monitoring panel intervention at the inlet isolation device is required.
8. Inspection and maintenance plan Inlet isolation device should be re-commissioned after cleaning, adjustment or other maintenance! See Section 6 Assembly and commissioning Recommission after maintenance Operating hours Components Operations to be performed Manual Section After 40 hours Flap To be inspected concerning deposit build-up and wear and tear. (weekly on 1-shift Remove any existing deposit build-up.
. When replacing parts, please note part serial number and date of replacement. Service agreement With a service agreement, you will receive extensive, rapid and ® reliable system supervision by a REMBE Certified Service ® Contractor. Contact your local REMBE , Inc. representative or ®...
9.3 Safe system shutdown shut down the system, proceed as follows: • Turn off the main switch • Secure the main switch against unauthorized reactivation (lock it with a padlock) • Turn off the explosion suppression unit, if applicable, to avoid an unintended release or false trigger.
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Inspection lid opening Please proceed as follows: Ensure that the system is safely shut down . a) Turn locks (fasteners) counter-clockwise to unlock the inspection lid locks b) The inspection lid can now be opened. For inlet isolation device sizes up to and including DN 560, open the inspection lid until the maximum opening angle has been reached (opening angle >...
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WARNING Danger of physical harm due to incorrectly opened or unsafeguarded inspection lid. If the inspection lid is not opened wide enough or the latch pin does not snap in, there is danger of physical harm if the lid rapidly closes. Ensure that the inspection door is opened wide enough and safeguarded against closing! -------------------------------------------------------------------------------------------------------- WARNING...
Inspection lid a) Hold the inspection lid with one hand on the handle which is attached out- closure with inlet side. isolation devices b) Pull the latch pin's ring to unlock the holding device. DN 630 and larger Latch pin ring c) Swivel the inspection door from opened position into closed position.
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Inspection lid Locks Flap stopper Maintenance safety latch Latch pin Gas spring lift assist Inspect the surface of the flap blade and the housing of the inlet isolation device for material deposits accumulation, wear and tear. • Remove visible material deposits. •...
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Push the locking mechanism locking pin downwards and carefully lift the flap blade. CAUTION Crushing hazard between locking lever and locking pin Carefully lift the flap blade. Release the locking pin so that it is pressed down by the locking lever. -------------------------------------------------------------------------------------------------------- Flap Locking lever...
Carefully close the flap blade after inspection/maintenance/service is complete. Don't let the flap blade fall into the closed position—manually lower it slowly. WARNING Danger: there is a risk of harm to extremities from a falling/closing flap blade! Inspect the flap blade prior to closing and control the lowering of the flap blade to minimize the risk of harm.
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Locking mechanism cover Screws Push the locking mechanism locking pin downwards and carefully lift the flap blade. CAUTION Crushing hazard between locking lever and locking pin Carefully lift the flap blade. Release the locking pin so that it is pressed down by the locking lever.
9.9 Inspect the locking mechanism Ensure that the system is disconnected safely. Remove the locking mechanism cover which is attached to the inlet isolation device. All screws must be loosened and removed to remove the cover. Cover of the locking Fixing bolts Check to confirm the flap blade is locked in the proper “disconnected”...
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Functional test of the locking mechanism Do the following to ensure that the flap blade is safely locked in the event of an explosion: Open inspection lid (see Section 9.4 Inspection lid opening and closing) WARNING Danger of head injuries due to protruding flap stopper when inspection lid is opened! Please watch out for the protruding flap blade stopper while working inside the inlet isolation device.
WARNING Crushing hazard/risk of injury to extremities from a falling/closing flap blade! careful that all persons are some distance from the inlet isolation device pipe socket, flap blade, locking unit and locking lever before dropping the flap blade! Dangerous injuries could otherwise result. -------------------------------------------------------------------------------------------------------- e) Wait until the flap rests on the pipe socket.
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b) Loosen both locking unit mounting screws as shown below. To adjust the locking unit, the screws only have to be loosened but not removed. Mounting screws c) Loosen the counter nut of the latch pin. Counter nut d) Turn the setting screw at the stop and manually adjust the panel until the required position is reached.
e) Tightly re-screw the counter nut at the stop. Counter nut f) Tighten both locking unit mounting screws as shown below . Mounting screws Verify the gap between the locking unit and the locking lever again after having tightened the counter nut and mounting screws. Verify the flap blade closes properly (see Section 9.10 Inspection locking unit).
e) Lift the flap blade as high as the locking unit allows or until the locking lever is in contact with the locking unit's locking pin Check to see if the flap blade is still detected by the closed-position sensor. ...
WARNING Danger of head injuries due to protruding flap stopper when inspection lid is opened! Please watch out for the protruding flap blade stopper while working inside the inlet isolation device. If necessary, equip the stopper with a bumper during the maintenance process.
Level sensor View of the inlet isolation valve with open inspection door Check to see if the material is detected by the sensor. If the level sensor detects deposits, it will be indicated as a malfunction message sent to the monitoring panel .
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Ensure that the system is disconnected. Ensure, through a supervisory person, that the system is not able to be restarted while inspecting. Open the inspection lid (see Section, 9.4 Inspection lid opening and closing). WARNING Danger of head injuries due to protruding flap stopper when inspection lid is opened! Please watch out for the protruding flap blade stopper while working inside the inlet isolation device.
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Level sensor adjustment DANGER for any type of dust There is a risk that material deposits in the inlet isolation device might not be detected if the level sensor is not properly adjusted! This could lead to malfunction of the inlet isolation device if the flap blade does not close properly in the event of an explosion.
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Turn the level sensor's potentiometer slowly clockwise until the LED ring at the level sensor lights up. Potentiometer LED ring Level sensor Turn the potentiometer another rotation counter clockwise. Remove the material accumulation on the level sensor and clean the interior of the inlet isolation device.
Beveled pipe socket Level sensor (optional) Closed-position sensor Ball flange bearing Locking mechanism Locking lever Wear & Tear Sensor (Q-FlapCompact II Plus model only) ® ® Spare parts ordering Please contact REMBE , Inc. or your local REMBE , Inc.
11.2 Technical Data Shotbolt Lock Unit SPECIALIST FOR ELECTROMAGNETIC ACTUATORS AND SENSORS QUALITY SINCE 1912 Electromagnetically Actuated Shotbolt Lock Unit Product group G SC E 037 According to DIN VDE 0580 and RL 94/9/EC (ATEX 95) Almost linear force vs. stroke characteristic ...
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QUALITY SINCE 1912 Technical data G SC E 037 A MX A03 / A04 Operating mode S1 (100 %) -20 up to +40 Ambient temperature T (°C) Stroke s (mm) Magnetic force F Limit power P 10,5 Admissible lateral force in normal position(N) Spring Solenoid weight m (kg)
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QUALITY SINCE 1912 Dimensional drawing cable end sleeve DIN 46228 A 1,5-7 connection cable Li12Y11Y 3x1,5 mm² br/bl/gnye earth connection o-ring 19x2,5 70Sh-A NBR fastening nut hex nut tightening moment 5 Nm suitable socket wrench SW 26 (12kt DIN 3124) connection diagram labelling according tube...
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QUALITY SINCE 1912 Key for type designation Designation Design Cable length standard G SC E 037 A MX A03 pull type (de-energized locked) G SC E 037 A MX A04 push type (de-energized unlocked) Order example Type G SC E 037 AMX A03 Voltage 24 V DC Operating mode S1 (100 %) Cable length...
Annex 12.1 Q-FlapCompact II/Plus Inlet isolation device sequence ® of operation with REMBE , Inc. Monitoring Panel Before start up: Flap is locked closed (no voltage on release mechanism), closed-position (formerly known as deposit sensor) reads flap as closed, wear and tear sensor (Plus models only) reads normal. Green light is illuminated indicating system normal.
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