ebm-papst D3G180-AB62-01 Operating Instructions Manual

D3G180-AB62-01

Operating instructions

ebm-papst Mulfingen GmbH & Co. KG

Bachmühle 2
D-74673 Mulfingen
Phone [phone]
Fax [phone]
[e-mail]
www.ebmpapst.com

CONTENTS

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

32. PROPER USE

43. TECHNICAL DATA

43.1 Product drawing

53.2 Nominal data

53.3 Technical features

53.4 Mounting data

53.5 Transport and storage conditions

53.6 Electromagnetic compatibility

64. CONNECTION AND START-UP

64.1 Connecting the mechanical system

64.2 Connecting the electrical system

64.3 Connection of the cables

74.4 Connection screen

84.5 Checking the connections

84.6 Switch on device

84.7 Switching off the device

85. INTEGRATED PROTECTIVE FUNCTIONS

86. MAINTENANCE, MALFUNCTIONS, POSSIBLE

96.1 Cleaning

96.2 Safety test

106.3 Disposal

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.
The local industrial safety regulations must always be observed when
working on the device.
Keep the workplace clean and tidy. Untidiness in the working area
increases the risk of injury.
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.

Translation of the original operating instructions

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DANGER
Electrical load on the device

Risk of electric shock

→ Stand on a rubber mat if you are working on an electrically

charged device.

D3G180-AB62-01

Operating instructions

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
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 will restart automatically, e.g. after a mains
failure.

Risk of injury

→ Keep out of the device hazard zone.

→ When working on the device, switch off the mains power

and ensure that it cannot be switched back on.

→ Wait until the device stops.

→ After working on the device, remove any tools used or

other objects from the device.

1.5 Safety and protective functions

DANGER
Protective device missing and protective device not
functioning

Without a protective device there is a risk of serious injury, for
instance when reaching into the device during operation.

→ Operate the device only with a fixed protective device and

guard grille.

→ The fixed protective device must be able to withstand the

kinetic energy of a fan blade that becomes detached at
maximum speed. There must not be any gaps which it is
possible to reach into with the fingers, for example.

→ The device is a built-in component. As the operator, you

are responsible for ensuring that the device is secured
adequately.

→ Stop the device immediately if a protective device is

found to be missing or ineffective.

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

Translation of the original operating instructions

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.

→ Secure the device against accidental contact.

→ Before working on the system/machine, wait until all

parts have come to a standstill.

WARNING
Rotating device

Long hair, dangling items of clothing, jewellery and similar items
can become entangled and be pulled into the device. Risk of
injury.

→ Do not wear any loose-fitting or dangling clothing or jewellery

while working on rotating parts.

→ Protect long hair with 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 housing

Risk of burns

→ Ensure sufficient contact protection.

1.10 Transport

NOTE
Transporting the device

→ Transport the device in its original packaging only.

1.11 Storage

; Store the device, partially or fully assembled, in the original

packaging in a clean, dry and weatherproof place free of vibrations.

; Protect the device against environmental effects and dirt until final

installation.

; We recommend storing the device for no longer than one year in

order to guarantee trouble-free operation and longest possible service
life.

; Even devices explicitly intended for outdoor use are to be stored as

described prior to commissioning.

; Maintain the storage temperature, see

chapter 3.5 Transport and storage conditions.

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D3G180-AB62-01

Operating instructions

2. PROPER USE

The device is exclusively designed as a built-in device for conveying
air according to its technical data.
Any other usage above and beyond this does not conform with the
intended purpose and constitutes misuse of the device.
Customer equipment must be capable of withstanding the mechanical
and thermal stresses that can arise from this product. This applies for the
entire service life of the equipment in which this product is installed.

Proper use also includes:

● Use of the device in stationary systems only.

● Carrying out all maintenance.

● Conveying of air at an ambient air pressure of 800 mbar to 1050 mbar.

● Using the device in accordance with the permitted ambient

temperature, see chapter 3.5 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.

● Resonance mode, operation with heavy vibrations. These also

include vibrations that are transmitted from the customer system to the
fan.

● Operation in medical equipment with a life-sustaining or lifesaving

function.

● Moving solids content in flow medium.

● Painting the device

● Connections (e.g. screws) coming loose 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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D3G180-AB62-01

3. TECHNICAL DATA

3.1 Product drawing

Operating instructions

All measures have the unit mm.

1 Connection line PVC AWG22

4x core-end sleeve

2 Connection line PVC AWG18

3x core-end sleeve

Translation of the original operating instructions

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D3G180-AB62-01

Operating instructions

3.2 Nominal data

Motor M3G074-CF

Phase 1~
Nominal voltage / VAC 230
Nominal voltage
range / VAC
Frequency / Hz 50/60

Type of data definition ml
Speed (rpm) / min
Power input / W 170
Current draw / A 1.25
Min. ambient
temperature / °C
Max. ambient
temperature / °C

ml = Max. load · me = Max. efficiency · fa = Running at free air
cs = Customer specs · cu = Customer unit

Subject to alterations

-1

200 .. 277

1130

-25

60

3.3 Technical features

Mass 7.0 kg
Size 180 mm
Motor size 74
Surface of rotor Thick layer passivated
Material of electronics
housing
Material of impeller Sheet steel, galvanised
Housing material Sheet steel, galvanised
Motor suspension Motor mounted with anti-vibration on both

Direction of rotation Clockwise, seen on rotor
Type of protection IP44
Insulation class "B"
Humidity (F) /
environmental
protection class (H)
Mounting position Shaft horizontal
Condensation
drainage holes
Operation mode S1
Motor bearing Ball bearing
Technical features - Output 10 VDC, max. 1.1 mA

Touch current acc.

Translation of the original operating instructions

IEC 60990 (measuring
network Fig. 4, TN
system)
Motor protection Thermal overload protector (TOP) wired

Cable exit Variable

Die-cast aluminum

sides

H1

None

- Tach output

- Output limit

- Motor current limit

- Soft start

- Control input 0-10 VDC/PWM

- Control interface with SELV potential
safely disconnected from the mains

- Motor excess temperature protection
< 3.5 mA

internally

Protection class I (if protective earth is connected by

customer)

Product conforming
to standard

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.

; Use the device in accordance with its protection type.

Notes on surface quality

The surfaces of the products conform to the generally applicable industrial
standard. The surface quality may vary during the production period.
Strength, dimensional stability and dimensional accuracy are not affected
by this.
The colour pigments of the paints used react perceptibly to UV light over
the course of time. This does not however have any influence on the
technical properties of the products. To prevent the formation of patches
and fading, the product is to be protected against UV radiation. Changes
in colour are not a reason for complaint and are not covered by the
warranty.

EN 60950-1; EN 60335-1; EN 61800-5­1; CE

3.4 Mounting data

For depth of screw, see chapter 3.1 Product drawing

Strength class for
mounting screws

; Secure the mounting screws against accidentally coming loose (e.g.

by using self-locking screws).

Any further mounting data required can be taken from the product
drawing or Section chapter 4.1 Connecting the mechanical system.

8.8

3.5 Transport and storage conditions

Max. permissible
ambient motor temp.
(transp./ storage)
Min. permissible
ambient motor temp.
(transp./storage)

+80 °C

-40 °C

3.6 Electromagnetic compatibility

EMC interference
immunity
EMC harmonics Acc. to EN 61000-3-2/3
EMC interference
emission

Acc. to EN 61000-6-1

Acc. to EN 61000-6-3

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D3G180-AB62-01

Operating instructions

4. CONNECTION AND START-UP

4.1 Connecting the mechanical system

CAUTION
Cutting and crushing hazard when removing blower
from packaging

→ Carefully remove the blower from its packaging by grasping

hold of the housing. Never subject to impact.

→ Wear safety shoes and cut-resistant safety gloves.

NOTE
Damage to device from vibration

Bearing damage, reduced service life

→ Forces or impermissibly high vibration levels must not be

transmitted to the fan from system components.

→ If the fan is connected to air ducts, it should isolated from

vibrations, for example using compensators or similar
elements.

→ Fasten the fan to the substructure without distorting it.

; Check the device for transport damage. Damaged devices must no

longer be installed.

; Install the undamaged device according to your application.

CAUTION
Possibility of damage to the device

Serious damage may result if the device slips during assembly.

→ Keep the device fixed in position at the installation location

until all attachment screws have been tightened.

● The fan must not be strained on fastening.

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

Translation of the original operating instructions

is provided.
Before working on the electrical connection, the
connections to the mains supply and PE must be shorted.

CAUTION
Electrical voltage

The device is a built-in component and features no electrically
isolating switch.

→ Connect the device only to circuits that can be switched off

using an all-pole disconnecting switch.

→ When working on the device, you must switch off the

system/machine in which the device is installed and secure
it from being switched on again.

NOTE
Interferences and failures are possible

Maintain a distance to the power supply line when routing the
control lines of the device.

→ Ensure a sufficiently large clearance.

Recommendation: clearance > 10 cm (separate cable
routing)

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.

Connect the device only to circuits that can be switched off
using an all-pole disconnecting switch.

4.2.1 Prerequisites

; Check that the data on the type plate match 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.

Protective earth contact resistance as per EN 60335

Compliance with the resistance specifications as per EN 60335 for the
protective earth connection circuit must be verified in the application.
Depending on the installation situation, it may be necessary to connect
an additional protective earth conductor by way of the extra protective
earth terminal provided on the device.

4.2.2 Locked-rotor protection

Due to the locked-rotor protection, the start-up current (LRA) is
equal to or less than the nominal current (FLA).

4.3 Connection of the cables

External leads are brought out of device.

; First connect the "PE" (protective earth) connection.

● Connect the lines according to your application. When doing so,

observe chapter 4.4 Connection screen.

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D3G180-AB62-01

4.4 Connection screen

Operating instructions

No. Conn. Designation Colour Function / assignment

4 L black Power supply 230 VAC, 50-60 Hz, see type plate for voltage range
3 N blue Neutral conductor
1 PE green/

yellow

8 0-10 V PWM yellow Control input 0 - 10 V or PWM, electrically isolated
9 Tach white Tach output: open collector, 1 pulse per revolution, electrically isolated
11 10V / max 1.1mAred Voltage output 10 V / max. 1.1 mA, electrically isolated

12 GND blue GND - Connection for control interface

Translation of the original operating instructions

Protective earth

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D3G180-AB62-01

Operating instructions

4.5 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.

4.6 Switch on device

The device is not to be switched on until it has been installed properly
and in accordance with its intended use, including the required protective
devices and professional electrical connection. This also applies to
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 blower.

; 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.

NOTE
Damage to device by vibrations

Bearing damage, reduced service life

→ The fan must operate free of vibrations throughout its speed

control range.

→ Strong vibrations can result from improper handling,

imbalance resulting from damage during transport, or
component-induced or structural resonances.

→ When putting the fan into service, determine the speed

ranges with excessive vibration levels and also any
resonance frequencies that may be present.

→ When regulating the speed, pass through resonance

ranges as quickly as possible or find another remedy.

→ Operation at excessive vibration levels can lead to

premature failure.

4.7 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.

Translation of the original operating instructions

; When disconnecting, be sure to disconnect the earth wire connection

last.

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.

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 will restart automatically, e.g. after a mains
failure.

Risk of injury

→ Keep out of the device hazard zone.

→ When working on the device, switch off the mains power

and ensure that it cannot be switched back on.

→ Wait until the device stops.

→ After working on the device, remove any tools used or

other objects from the device.

NOTE

If the device is not operated for a lengthy period in installed
condition in a dry environment, it is to be started up and
operated at full speed for one hour at least every four months. If
the device is not operated for a lengthy period in installed
condition in a damp environment (e.g. outdoors), it is to be
started up and operated at full speed for at least two hours once
a month to move the bearings and allow any condensate that
may have ingressed to evaporate.

Malfunction/error Possible cause Possible remedy
Impeller running
roughly

Motor does not turn Mechanical blockage Switch off, de-

Imbalance in rotating
parts

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.

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D3G180-AB62-01

Operating instructions

Overtemperature of
electronics/motor

If you have any other problems, contact ebm-papst.

Mains supply voltage
faulty

Faulty connection De-energise, correct

Insufficient cooling Improve cooling. Let

Thermal overload
protector responded

Ambient temperature
too high

Unacceptable
operating point

Check mains supply
voltage,
restore power
supply,
apply control signal.

connection, see
connection diagram.

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.
Allow motor to cool
off, locate and rectify
cause of error, if
necessary cancel
restart lock-out
Reduce the ambient
temperature.
Reset by reducing
control input to 0.
Correct the operating
point. Let the device
cool down.

6.1 Cleaning

To ensure a long service life, the fans have to be regularly checked for
proper operation and degree of soiling. The frequency of the checks is to
be adapted to the occurrence of soiling.

DANGER
Risk of injury from rotating fan.

→ Only clean when not in motion. Do not disconnect the fan

from the power supply, just switch it off via the control input.
This will prevent start-up of the fan.

; Dirt deposits on the motor housing could lead to overheating of the

motor.

; Dirt on the impeller can cause vibration which would shorten the

service life of the fan.

; Severe vibration could destroy the fan.

; In such cases immediately switch off and clean the fan.

; The preferred method of cleaning is dry cleaning, e.g. using

compressed air.

; Use is never to be made of corrosive cleaning agents!

Translation of the original operating instructions

; Completely remove any cleaning agents used.

NOTE
Damage to the device during cleaning

Malfunction possible

→ Do not clean the device using a water jet or high-pressure

cleaner.

→ Do not use any acid, alkali or solvent-basedcleaning

agents.

→ Do not use any pointed or sharp-edged objects for cleaning

; Immediately switch off and replace the device if severe corrosion is

apparent at load-bearing or rotating parts.

; Repairs to load-bearing or rotating parts are not permissible!

; Operate the fan for 2 hours at maximum speed to permit the

evaporation of any moisture which may have ingressed.

; If cleaning does not eliminate vibration, the fan may have to be re-

balanced. In such cases please contact ebm-papst.

; The fan is provided with maintenance-free ball bearings. The lifetime

lubrication of the ball bearings is designed for a service life of at least
40,000 hours.

; Please contact ebm-papst if bearing replacement is required after this

period.

; Adapt the maintenance intervals to the dust pollution occurring.

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
Mounting of
protective earth
connection
Check the
insulation of the
wires for damage
Impeller for
wear/deposits/
corrosion and
damage
Abnormal
bearing noise

How to test? Frequency Which

measure?

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

Visual inspection At least every

6 months

Visual inspection At least every

6 months

acoustic At least every

6 months

Repair or
replacement of
the device

Replacement of
the device

Fasten

Fasten

Replace wires

Clean impeller
or replace device

Replace device

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D3G180-AB62-01

Operating instructions

6.3 Disposal

For ebm-papst, environmental protection and resource preservation are
top priority corporate goals.
ebm-papst operates an environmental management system which is
certified in accordance with ISO 14001 and rigorously implemented
around the world on the basis of German standards.
Right from the development stage, ecological design, technical safety
and health protection are fixed criteria.
The following section contains recommendations for ecological disposal
of the product and its components.

6.3.1 Country-specific legal requirements

NOTE
Country-specific legal requirements

Always observe the applicable country-specific legal
regulations with regard to the disposal of products or waste
occurring in the various phases of the life cycle. The
corresponding disposal standards are also to be heeded.

6.3.2 Disassembly

Disassembly of the product must be performed or supervised by
qualified personnel with the appropriate technical knowledge.
The product is to be disassembled into suitable components for disposal
employing standard procedures for motors.

WARNING
Heavy parts of the product may drop off. Some of the
product components are heavy. These components
could drop off during disassembly.

This can result in fatal or serious injury and material damage.

→ Secure components before unfastening to stop them falling.

Dispose of electronic components employing the proper procedures for
electronic scrap.

→ Please contact ebm-papst for any other questions on disposal.

6.3.3 Component disposal

The products are mostly made of steel, copper, aluminium and plastic.
Metallic materials are generally considered to be fully recyclable.
Separate the components for recycling into the following categories:

● Steel and iron

● Aluminium

● Non-ferrous metal, e.g. motor windings

● Plastics, particularly with brominated flame retardants, in accordance

with marking

● Insulating materials

● Cables and wires

● Electronic scrap, e.g. circuit boards

Only ferrite magnets and not rare earth magnets are used in external
rotor motors from ebm-papst Mulfingen GmbH & Co. KG.

; Ferrite magnets can be disposed of in the same way as normal iron

and steel.

Electrical insulating materials on the product, in cables and wires are
made of similar materials and are therefore to be treated in the same
manner.

Translation of the original operating instructions

The materials concerned are as follows:

● Miscellaneous insulators used in the terminal box

● Power lines

● Cables for internal wiring

● Electrolytic capacitors

Item no. 50035-5-9970 · ENG · Revision 200166 · Release 2019-06-17 · Page 10 / 10

ebm-papst Mulfingen GmbH & Co. KG · Bachmühle 2 · D-74673 Mulfingen · Phone [phone] · Fax [phone] · [e-mail] · www.ebmpapst.com