ebm-papst A3G560-AP68-35 User Manual

A3G560-AP68-35
Operating instructions
ebm-papst Mulfingen GmbH & Co. KG
Bachmühle 2 D-74673 Mulfingen Phone +49 (0) 7938 81-0 Fax +49 (0) 7938 81-110 info1@de.ebmpapst.com www.ebmpapst.com
CONTENTS
Translation of the original operating instructions
CAUSES AND REMEDIES
1. SAFETY REGULATIONS AND NOTES
Please read these operating instructions carefully before starting to work with the device. Observe the following warnings to prevent malfunctions or physical damage to both property and people. These operating instructions are to be regarded as part of this device. If the device is sold or transferred, the operating instructions must accompany it. These operating instructions may be duplicated and forwarded for information about potential dangers and their prevention.
11. SAFETY REGULATIONS AND NOTES
11.1 Levels of hazard warnings
11.2 Staff qualification
11.3 Basic safety rules
11.4 Electrical voltage
21.5 Safety and protective functions
21.6 Electromagnetic radiation
21.7 Mechanical movement
21.8 Emission
21.9 Hot surface
21.10 Transport
21.11 Storage
31.12 Disposal
32. PROPER USE
43. TECHNICAL DATA
43.1 Product drawing
53.2 Nominal data
53.3 Data according to ErP directive
53.4 Technical features
53.5 Mounting data
53.6 Transport and storage conditions
63.7 Electromagnetic compatibility
64. CONNECTION AND START-UP
64.1 Connecting the mechanical system
64.2 Connecting the electrical system
74.3 Connection in terminal box
84.4 Factory settings
94.5 Connection screen
104.6 Checking the connections
104.7 Switch on device
104.8 Switching off the device
105. INTEGRATED PROTECTIVE FUNCTIONS
116. MAINTENANCE, MALFUNCTIONS, POSSIBLE
116.1 Cleaning
116.2 Safety test
1.1 Levels of hazard warnings
These operating instructions use the following hazard levels to indicate potentially hazardous situations and important safety regulations:
DANGER
Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. Compliance with the measures is mandatory.
WARNING
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. Exercise extreme caution while working.
CAUTION
Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury or damage of property.
NOTE
A potentially harmful situation can occur and, if not avoided, can lead to property damage.
1.2 Staff qualification
The device may only be transported, unpacked, installed, operated, maintained and otherwise used by qualified, trained and authorised technical staff. Only authorised specialists are permitted to install the device, to carry out a test run and to perform work on the electrical installation.
1.3 Basic safety rules
Any safety hazards stemming from the device must be re-evaluated once it is installed in the end device. Observe the following when working on the unit:
; Do not make any modifications, additions or conversions to the
device without the approval of ebm-papst.
1.4 Electrical voltage
; Check the electrical equipment of the device at regular intervals, refer
to chapter 6.2 Safety test.
; Replace loose connections and defective cables immediately.
DANGER Electrical load on the device
Risk of electric shock
→ Stand on a rubber mat if you are working on an electrically
charged device.
WARNING Terminals and connections have voltage even with a unit that is shut off
Electric shock
→ Wait five minutes after disconnecting the voltage at all poles
before opening the device.
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A3G560-AP68-35
Operating instructions
CAUTION In the event of failure, there is electric voltage at the rotor and impeller
The rotor and impeller are base insulated.
→ Do not touch the rotor and impeller once they are installed.
CAUTION If control voltage is applied or a speed setpoint is stored, the motor automatically restarts, e.g. after a power failure.
Danger of injury
→ Keep out of the danger zone of the device.
→ When working on the device, switch off the mains
supply voltage and secure the latter from being switched on again.
→ Wait until the device stops.
→ After working on the device, remove any used tools or
other objects from the device.
1.5 Safety and protective functions
DANGER Missing safety device and non-functioning safety device
If there is no safety device, you could be seriously injured, for example if you reach into the running device or your hands are sucked into it.
→ Operate the device only with a fixed and isolating safety
protection and a fixed guard grille. The guard must withstand the kinetic energy of a fan blade detaching at maximum speed.
→ The device is a built-in component. You, the owner/
operator, are responsible for providing adequate protection for the device.
→ Shut down the device immediately if you detect a
missing or ineffective protective feature.
DANGER Flying parts
Missing safety devices may cause balancing weights or broken fan blades to be ejected at high speeds, causing bodily harm.
→ Take appropriate safety measures.
WARNING Rotating device
Long hair, loose items of clothing and jewellery could become entangled and pulled into the device. You could be injured.
→ Do not wear any loose clothing or jewellery while working
on rotating parts.
→ Protect long hair by wearing a cap.
1.8 Emission
WARNING Depending on the installation and operating conditions, a sound pressure level greater than 70 dB(A) may arise.
Danger of noise-induced hearing loss
→ Take appropriate technical safety measures.
→ Protect operating personnel with appropriate safety
equipment, e.g. hearing protection.
→ Also observe the requirements of local agencies.
1.9 Hot surface
CAUTION High temperature at the electronics enclosure
Danger of burn injuries
→ Ensure that sufficient protection against accidental contact is
provided.
1.10 Transport
1.6 Electromagnetic radiation
Interference from electromagnetic radiation is possible, e.g. in conjunction with open and closed-loop control devices. If unacceptable emission intensities occur when the fan is installed, appropriate shielding measures have to be taken by the user.
NOTE Electrical or electromagnetic interferences after integrating the device in installations on the customer's side.
→ Verify that the entire setup is EMC compliant.
1.7 Mechanical movement
DANGER Rotating device
Body parts that come into contact with the rotor and impeller can be injured.
Translation of the original operating instructions
→ Secure the device against accidental contact.
→ Before working on the system/machine, wait until all
parts have come to a standstill.
WARNING Transport of fan
Injuries from slipping or falling.
→ Only transport the fan in its original packaging. # Transport
the fan "lying flat", in other words with the axis vertical.
→ Secure the fan(s) so that nothing can slip or fall, for
example using a lashing strap.
1.11 Storage
; Store the device, partially or fully assembled, in a dry and
weatherproof manner in the original packing in a clean environment.
; Protect the device from environmental impacts and dirt until the final
installation.
; We recommend storing the device for a maximum up to one year to
guarantee proper operation and longest possible service life.
; Even devices explicitly suited for outdoor use are to be stored as
described prior to being commissioned.
; Maintain the storage temperature, see
chapter 3.6 Transport and storage conditions.
; Please make sure that all screwed cable glands are fitted with
dummy plugs.
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A3G560-AP68-35
Operating instructions
1.12 Disposal
When disposing of the device, please comply with all relevant requirements and regulations applicable in your country.
2. PROPER USE
The device is exclusively designed as a built-in device for moving air according to its technical data. Any other or secondary use is deemed improper and constitutes a misuse of the device. Installations on the customer's side must meet the mechanical, thermal and service life-related stresses that can occur.
Proper use also includes:
Only using the device in stationary systems.
Carrying out all maintenance.
Moving air with a density of 1.2 kg/m³.
Using the device in accordance with the permitted ambient
temperature, see chapter 3.6 Transport and storage conditions and chapter 3.2 Nominal data.
Operating the device with all protective features in place.
Minding the operating instructions.
Improper use
Using the device in the following ways is particularly prohibited and may cause hazards:
Operating the device with an imbalance, e.g. caused by dirt deposits
or icing.
Operation in medical equipment with a life-sustaining or lifesaving
function.
Operation with external vibrations.
Moving solids content in flow medium.
Painting the device
Connections (e.g. screws) coming loose during operation.
Opening the terminal box during operation.
Moving air that contains abrasive particles.
Moving highly corrosive air, e.g. salt spray mist. Exceptions are
devices that are intended for salt spray mist and protected accordingly.
Moving air that contains dust pollution, e.g. suctioning off saw dust.
Operating the device close to flammable materials or components.
Operating the device in an explosive atmosphere.
Using the device as a safety component or for taking on safety-
related functions.
Operation with completely or partially disassembled or modified
protective features.
In addition, all application options that are not listed under proper use.
Translation of the original operating instructions
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A3G560-AP68-35
3. TECHNICAL DATA
3.1 Product drawing
Operating instructions
All measures have the unit mm.
1 Direction of air flow "A" 2 Cable diameter: min. 4 mm, max. 10 mm; tightening torque: 2.5±0.4 Nm 3 Thread reach max. 16 mm 4 Tightening torque 3.5±0.5 Nm
Translation of the original operating instructions
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A3G560-AP68-35
Operating instructions
3.2 Nominal data
Motor M3G112-EA
Phase 1~ Nominal voltage / VAC 230 Nominal voltage
200 .. 277
range / VAC Frequency / Hz 50/60
Type of data definition ml Speed / min
-1
1000
Power input / W 400 Current draw / A 1.8 Max. back pressure / Pa 100 Min. ambient temperature
-25
/ °C Max. ambient
60
temperature / °C
ml = Max. load · me = Max. efficiency · fa = Running at free air cs = Customer specs · cu = Customer unit
Subject to alterations
3.3 Data according to ErP directive
Installation category A Efficiency category Static Variable speed drive Yes Specific ratio
*
Specific ratio = 1 + pfs / 100 000 Pa
Overall efficiency ηes / % 41.1 27.2 31.2 Efficiency grade N 49.9 36 40 Power input Ped / kW 0.4 Air flow qv / m³/h 5245 Pressure increase total psf / Pa 102 Speed n / min
Data definition with optimum efficiency.
The ErP data is determined using a motor-impeller combination in a standardised measurement configuration.
*
-1
1.00
Actual Request
2013
995
Request 2015
Condensate discharge
On the stator side
holes Operation mode S1 Motor bearing Ball bearing Technical features - Output 10 VDC, max. 10 mA
- Output 20 VDC, max. 50 mA
- Output for slave 0-10 V
- Operation and alarm display
- Direction of rotation selection counter­clockwise / clockwise
- Input for sensor 0-10 V or 4-20 mA
- External 24 V input (programming)
- Alarm relay
- Integrated PID controller
- Motor current limit
- PFC, active
- RS485 MODBUS RTU
- Soft start
- Control input 0-10 VDC / PWM
- Control interface with SELV potential safely disconnected from the mains
- Over-temperature protected electronics / motor
- Line undervoltage / phase failure detection
Touch current acc.
<= 3.5 mA
IEC 60990 (measuring network Fig. 4, TN system) Electrical leads Via terminal box Motor protection Thermal overload protector (TOP) wired
internally
Protection class I (if protective earth is connected by
customer)
Product conforming
EN 61800-5-1; CE
to standard Approval EAC
For cyclic speed loads, note that the rotating parts of the device are designed for maximum one million load cycles. If you have specific questions, contact ebm-papst for support.
3.4 Technical features
Mass 8.8 kg Size 560 mm Surface of rotor Coated in black Material of electronics housing Material of blades Aluminium sheet insert (coated in black),
Die-cast aluminium, coated in black
3.5 Mounting data
; Secure the mounting screws against accidentally coming loose (e.g.
by using self-locking screws).
Strength class for mounting screws
You can obtain additional mounting data from the product drawing if necessary.
8.8
sprayed with PP plastic
Number of blades 5 Blade angle -5°
Translation of the original operating instructions
Direction of air flow "A" Direction of rotation Clockwise, seen on rotor Type of protection IP 54 Insulation class "B" Humidity class F4-2 Mounting position Shaft horizontal or rotor on top
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3.6 Transport and storage conditions
; Use the device in accordance with its protection type.
Max. permissible ambient motor temp. (transp./ storage) Min. permissible ambient motor temp. (transp./storage)
80 °C
-40 °C
A3G560-AP68-35
Operating instructions
3.7 Electromagnetic compatibility
EMC interference immunity EMC harmonics Acc. to EN 61000-3-2/3 EMC interference emission
Translation of the original operating instructions
Acc. to EN 61000-6-2 (industrial environment)
Acc. to EN 55022 (Class A, industrial environment)
4. CONNECTION AND START-UP
4.1 Connecting the mechanical system
CAUTION Cutting and crushing hazard when removing the fan from the packaging
→ Carefully remove the device from its packaging, holding it
by the centre of the blades only. Make sure to avoid any shock.
→ Wear safety shoes and cut-resistant safety gloves.
; Check the device for transport damage. Damaged devices must no
longer be installed.
; Install the undamaged device according to your application.
4.2 Connecting the electrical system
DANGER Electric voltage on the device
Electric shock
→ Always install a protective earth first.
→ Check the protective earth.
DANGER Incorrect insulation
Risk of fatal injury from electric shock
→ Use only cables that meet the specified installation
requirements for voltage, current, insulation material, load etc.
→ Route cables such that they cannot be touched by any
rotating parts.
DANGER Electrical load (>50 µC) between mains wire and protective earth connection after switching of the supply when switching multiple devices in parallel.
Electric shock, risk of injury
→ Make sure that sufficient protection against accidental contact
is provided. Before working on the electrical connection, the connections to the mains supply and PE must be shorted.
CAUTION Electrical voltage
The fan is a built-in component and features no electrically isolating switch.
→ Only connect the fan to circuits that can be switched off with
an all-pole separating switch.
→ When working on the fan, you must switch off the
installation/machine in which the fan is installed and secure it from being switched on again.
NOTE Water penetration into leads or wires
Water enters at the cable end on the customers side and can damage the device.
→ Make sure that the cable end is connected in a dry
environment.
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A3G560-AP68-35
Operating instructions
Connect the device only to circuits that can be switched off using an all-pole disconnecting switch.
4.2.1 Prerequisites
; Check whether the data on the type plate agree with the connection
data.
; Before connecting the device, ensure that the supply voltage matches
the operating voltage of the device.
; Only use cables designed for current according to the type plate.
For determining the cross-section, follow the basic principles in accordance with EN 61800-5-1. The protective earth must have a cross-section equal to or greater than the outer conductor cross­section. We recommend the use of 105°C cables. Ensure that the minimum cable cross-section is at least AWG26/0.13 mm².
Earth wire contact resistance to EN 61800-5-1
Compliance with the impedance specifications to EN 61800-5-1 for the protective earth circuit must be verified in the end application. Depending on the installation situation, it may be necessary to install an additional protective earthing conductor via the additional protective earth connection point available on the device. The protective earth connection point is located on the housing and has a protective earth symbol and a bore hole.
4.2.2 Idle current
Because of the EMC filter integrated for compliance with EMC limits (interference emission and interference immunity), idle currents in the mains cable can be measured even when the motor is at a standstill and the mains voltage is switched on.
The values lie in a range of typical < 250 mA.
The effective power in this operating state (readiness for operation) is
simultaneously at typical < 4 W.
4.2.3 Residual current operated device
Only universal (type B or B+) RCD protective devices are permitted. Like frequency inverters, RCD protective devices cannot provide personal safety while operating the device. When switching on the power supply of the device, pulsed charge currents from the capacitors in the integrated EMC filter can lead to the RCD protective devices triggering without delay. We recommend residual current devices with a trigger threshold of 300 mA and delayed triggering (super-resistant, characteristic K).
4.3 Connection in terminal box
4.3.1 Preparing connection lines for the connection
Strip the cable just enough so that the screwed cable gland is tight and the terminals are relieved of strain. Tightening torque, see chapter 3.1 Product drawing.
Fig. 1: Recommended stripping lengths in mm (inside the terminal box) Legend: CL = control lines
4.3.2 Connecting cables with terminals
WARNING Terminals and connections have voltage even with a unit that is shut off
Electric shock
→ Wait five minutes after disconnecting the voltage at all poles
before opening the device.
; Remove the cap from the screwed cable gland.
Remove the cap only in those places where cables are inserted.
; Mount the screwed cable glands with the seal inserts provided in the
terminal box.
; Insert the line(s) (not included in the standard scope of delivery) into
the terminal box.
; First connect the "PE" (protective earth) connection.
; Connect the lines to the corresponding terminals.
Use a screwdriver to do so. During the connection work, ensure that no cables splice off.
4.2.4 Locked-rotor protection
Due to the locked-rotor protection, the start-up current (LRA) is equal to or less than the nominal current (FLA).
Translation of the original operating instructions
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A3G560-AP68-35
Operating instructions
4.4 Factory settings
Factory settings with which the device is pre-set by ebm-papst.
Control mode parameter set 1 Control mode parameter set 2 Fan / device adress 01 Max. PWM / % 100 Min. PWM / % 8,0 Save set value to EEPROM Set value control Analogue (linear) Control function parameter set 1 Control function parameter set 2
PWM controlling
PWM controlling
No
Positive (heating)
Positive (heating)
Fig. 2: Connecting the wires to terminals
; Seal the terminal box.
4.3.3 Cable routing
No water may penetrate along the cable in the direction of the cable gland.
Fans installed in upright position
When routing the cable, ensure that the screwed cable glands are arranged at the bottom. The cables must always be routed downwards.
Translation of the original operating instructions
Fig. 3: Cable routing for fans installed upright.
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A3G560-AP68-35
4.5 Connection screen
Operating instructions
No. Conn. Designation Function / assignment PE - PE Protective earth connection KL1 1, 2 N, L Supply voltage, 50/60 Hz KL2 1 NC Floating status message contact, break for failure KL2 2 COM Floating status message contact, changeover contact, common connection
(2 A, max. 250 VAC, min. 10 mA, AC1)
KL2 3 NO Floating status message contact, normally open, make for failure KL3 1 OUT Analogue output, 0-10 VDC, max. 3 mA, SELV,
Output of the current motor level control coefficient: 1 V corresponds to 10% level control coefficient, 10 V correspond to 100% level control coefficient.
KL3 2, 8 GND Reference mass for control interface, SELV KL3 3, 7 0-10 V Use control / actual value input 0-10 VDC, impedance 100 kΩ only as alternative to 4-20 mA input, SELV KL3 4 +10 V Voltage output 10 VDC (+/- 3%), max. 10 mA,
Supply voltage for ext. devices (e.g. potentiometer), SELV
KL3 5 +20 V Voltage output 20 VDC (+25%/-10%), max. 50 mA
Supply voltage for ext. devices (e.g. sensors), SELV
KL3 6 4-20 mA Use control / actual value input 4-20 mA, impedance 100 Ω, only as alternative to 0-10 V input, SELV KL3 9, 11 RSB RS485 interface for MODBUS, RSB KL3 10, 12 RSA RS485 interface for MODBUS, RSA
Translation of the original operating instructions
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A3G560-AP68-35
Operating instructions
4.6 Checking the connections
; Make sure that the power is off (all phases).
; Secure it from being switched on again.
; Check the correct fit of the connection lines.
; Screw the terminal box cover closed again. Terminal box tightening
torque, see chapter 3.1 Product drawing.
; Route the connecting cables in the terminal box so that the terminal
box cover closes without resistance.
; Use all plug screws (the entire number). In doing so, insert the
screws manually to avoid damage to the thread.
; Make sure that the terminal box is correctly closed and sealed and
that all screws and screwed cable glands are properly tightened.
4.7 Switch on device
The device may only be switched on if it has been installed properly and in accordance with its intended use, including the required safety mechanisms and professional electrical connection. This also applies for devices which have already been equipped with plugs and terminals or similar connectors by the customer.
WARNING Hot motor housing
Fire hazard
→ Ensure that no combustible or flammable materials are
located close to the fan.
; Inspect the device for visible external damage and the proper function
of the protective features before switching it on.
; Check the air flow paths of the fan for foreign objects and remove any
that are found.
; Apply the nominal voltage to the voltage supply.
; Start the device by changing the input signal.
5. INTEGRATED PROTECTIVE FUNCTIONS
The integrated protective functions cause the motor to switch off automatically in case of faults described in the table.
Malfunctions Description / Function of
safety feature
Rotor position detection error An automatic restart occurs. Locked rotor ; After the blockage is
removed, the motor restarts
automatically. Line under-voltage (mains input voltage outside of permitted nominal voltage)
; If the mains supply voltage
returns to permitted values, the
motor restarts automatically.
4.8 Switching off the device
Switching off the device during operation:
; Switch off the device via the control input.
; Do not switch the motor (e.g. in cyclic operation) on and off via power
supply.
Switching off the device for maintenance work:
; Switch off the device via the control input.
; Do not switch the motor (e.g. in cyclic operation) on and off via power
supply.
; Disconnect the device from the supply voltage.
; When disconnecting, be sure to disconnect the earth wire connection
last.
Translation of the original operating instructions
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A3G560-AP68-35
Operating instructions
6. MAINTENANCE, MALFUNCTIONS, POSSIBLE CAUSES AND REMEDIES
Do not perform any repairs on your device. Return the device to ebm­papst for repair or replacement.
WARNING Terminals and connections have voltage even with a unit that is shut off
Electric shock
→ Wait five minutes after disconnecting the voltage at all poles
before opening the device.
CAUTION If control voltage is applied or a speed setpoint is stored, the motor automatically restarts, e.g. after a power failure.
Danger of injury
→ Keep out of the danger zone of the device.
→ When working on the device, switch off the mains
supply voltage and secure the latter from being switched on again.
→ Wait until the device stops.
→ After working on the device, remove any used tools or
other objects from the device.
If the device remains out of use for some time, e.g. when in storage, we recommend switching the device on for at least two hours to allow any condensate to evaporate and to move the bearings.
Malfunction/error Possible cause Possible remedy Impeller running roughly
Motor does not turn Mechanical blockage Switch off, de-
Translation of the original operating instructions
Imbalance in rotating parts
Mains supply voltage faulty
Faulty connection De-energise, correct
Thermal overload protector responded
Clean the device; if imbalance is still evident after cleaning, replace the device. If you have attached any weight clips during cleaning, make sure to remove them afterwards.
energise, and remove mechanical blockage. Check mains supply voltage, restore power supply, apply control signal.
connection, see connection diagram. Allow motor to cool off, locate and rectify cause of error, if necessary cancel restart lock-out
Overtemperature of electronics/motor
If you have any other problems, contact ebm-papst.
6.1 Cleaning
NOTE Damage to the device during cleaning.
Malfunction possible
→ Do not clean the device using a water jet or high-pressure
washer.
→ Do not use any cleaners containing acids,
bases or solvents.
→ Do not use any pointed or sharp-edged objects to clean.
6.2 Safety test
NOTE High-voltage test
The integrated EMC filter contains Y capacitors. Therefore, the trigger current is exceeded when AC testing voltage is applied.
→ Test the device with DC voltage when you carry out the
high-voltage test required by law. The voltage to be used corresponds to the peak value of the AC voltage required by the standard.
What has to be tested?
Check the protective casing against accidental contact for damage and to ensure that it is intact Check the device for damage to blades and housing Mounting the connection lines
Insufficient cooling Improve cooling. Let
the device cool down. To reset the error message, switch off the mains supply voltage for a min. of 25 s and switch it on
again. Ambient temperature too high
Unacceptable operating point
How to test? Frequency Which
Visual inspection At least every
6 months
Visual inspection At least every
6 months
Visual inspection At least every
6 months
Reduce the ambient
temperature.
Reset by reducing
control input to 0.
Correct the operating
point. Let the device
cool down.
measure?
Repair or replacement of the device
Replacement of the device
Fasten
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A3G560-AP68-35
Operating instructions
Check the insulation of the wires for damage Tightness of screwed cable gland Condensate discharge holes for clogging, as necessary Weld seams for crack formation
Visual inspection At least every
6 months
Visual inspection At least every
6 months
Visual inspection At least every
6 months
Visual inspection At least every
6 months
Replace wires
Retighten, replace if damaged Open bore holes
Replace device
Translation of the original operating instructions
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