ebm-papst ECI-63.XX-K4 User Manual
VDC-3-49.15-K4
ECI-63.XX-K4
Operating manual
Imprint
Dated 08.2014
Copyright
ebm-papst
St. Georgen GmbH & Co. KG
Hermann-Papst-Straße 1
78112 St. Georgen
Germany
Disclaimer
Contents of the operating manual
This operating manual has been compiled with the greatest possible care. Nonetheless, ebm-papst does not provide any guarantee for the
up-to-dateness, correctness, completeness or quality of the information provided. Liability claims against ebm-papst, which relate to
material or non-material damage or losses, and which were caused by use or non-use of the information provided or by use of incorrect and
incomplete information, are excluded, provided ebm-papst is not verifiably culpable of deliberate or grossly negligent act.
Copyright and trademark law
ebm-papst remains the sole holder of the copyright. Reproduction or use without the express consent of the author is not permitted.
Use
The safety regulations must be noted and followed when using the motors. Read through this operating manual carefully, before you start
working on the drive system. Please note and follow the hazard signs and warnings to avoid personal risk and malfunctions.
This operating manual is to be treated as part of the drive system.
If the drive system is sold or passed on the operating manual must be handed over with it.
Copies can be made of the safety, assembly and installation instructions and passed on for the purpose of informing about potential hazards
and their prevention.
Subject to change without notice.
The respective current version of this operating manual is available on the ebm-papst internet site: www.ebmpapst.com
2
Contents
1 Introduction 8
1.1 Foreword 8
1.2 Target group 8
1.3 Notation used in this document 8
1.4 Warnings and notes 9
1.5 Picture symbols 9
2 Safety Instructions 10
2.1 General safety instructions 10
2.2 Documentation 10
2.3 Standards, guidelines and directives 10
2.4 Personnel qualifications 10
2.5 Personal safety 10
2.6 Electrical / electromagnetic safety 11
2.7 Mechanical safety 11
2.8 Intended use 11
2.8.1 Type-related exclusion 11
2.9 Maintenance / repair 12
2.10 Cleaning 12
2.11 Transport / storage 12
2.12 Disposal 12
2.13 Liability and warranty 12
3 Product Description 13
3.1 Description VDC-3-49.15-K4 13
3.2 Description of the ECI-63.XX modular system K4 13
3.3 Description of the electronic classes 13
3.3.1 Functional scope of “K classes 1, 4 and 5” 13
3.4 Rating plate 14
3.4.1 Rating plate ECI-63.XX-K4 14
3.4.2 Typenschild VDC-3-49.15-K4 14
3.5 Basic configuration 15
4 Technical Specifications 16
4.1 ECI-63.20-K4 16
4.2 ECI-63.40-K4 17
4.3 ECI-63.60-K4 18
4.4 VDC-3-49.15-K4 19
4.5 Electronic properties 20
3
Contents
5 Installation 22
5.1 Notes 22
5.2 Installing the drive 22
5.2.1 Determine screw length 22
5.2.2 Prepare the mounting plate 22
5.3 Electrical connection 23
5.3.1 Safety check 23
5.4 Connection descriptions 24
5.4.1 Connection cable VDC-3-49.15-K4 24
5.4.2 Motor connection socket ECI-63.XX-K4 24
5.4.3 Connection cable with connector ECI-63.XX-K4 25
5.4.4 Harness for Litz wire version ECI-63.XX-K4 25
5.5 Braking chopper K4 26
5.6 Functional ground connection 26
5.7 RS485 interface 26
5.8 USB-CAN-RS485 adapter 26
5.9 Connection to the USB-CAN-RS485 adapter 27
5.10 Circuit diagram 28
5.11 Schematic layout: parameterisation, commissioning (startup) and automatic operation 29
5.11.1 Parameterisation and commissioning 29
5.11.2 Automatic operation 29
5.11.3 Connecting connector at the motor 29
6 Parameterisation 30
6.1 Memory management 30
6.1.1 “RAM” memory area 30
6.1.2 “custom” memory area 30
6.1.3 “default” memory area 31
6.2 Parameter 32
7 Parameterisation of the Operating Modes 35
7.1 Application example 35
7.2 Parameterisation of the speed regulation characteristic 37
7.3 Parameterisation of the maximum current characteristic 38
7.4 Operating mode 11: Speed setpoint N1, N2, N3; Analog IN 1 40
7.5 Operating mode 12: Speed setpoints N1, A1; dynamic current limitation via A1 41
7.6 Operating mode 13: Speed setpoints A1, N1; distance 42
7.7 Operating mode 16: Speed setpoints A1, N1; rotational direction 43
7.8 Operating mode 17: Speed setpoints A1, N1; dynamic current limit via A2 44
7.9 Operating mode 18: Speed setpoints A1, N1; brake 45
4
Contents
7.10 Operating mode 21: dynamic current limit via A1; speed setpoints A1, N2 46
7.11 Operating mode 23: dynamic current limit via A1; distance 47
7.12 Operating mode 26: dynamic current limit via A1; rotational direction 48
7.13 Operating mode 28: dynamic current limit via A1; brake 49
7.14 Operating mode 31: Distance; speed setpoints A1, N2 50
7.15 Operating mode 32: Distance; dynamic current limit via A1 51
7.16 Operating mode 34: Distance; teach 52
7.17 Operating mode 36: Distance; rotational direction 53
7.18 Operating mode 37: Distance; dynamic current limit A2 54
7.19 Operating mode 38: Distance; brake 55
7.20 Operating mode 43: Teach; distance 56
7.21 Operating mode 55: IN A / B logic via IN 1, IN 2; IN A / IN B as release (enable) 57
7.22 Operating mode 61: Rotational direction; speed setpoints A1, N2 58
7.23 Operating mode 62: Rotational direction; dynamic current limit via A1 59
7.24 Operating mode 63: Rotational direction; distance 60
7.25 Operating mode 67: Rotational direction; dynamic current limit via A2 61
7.26 Operating mode 68: Rotational direction; brake 62
7.27 Operating mode 71: Speed setpoint PWM, N2 63
7.28 Operating mode 72: Speed setpoint PWM; dynamic current limitation via PWM 64
7.29 Operating mode 73: Speed setpoint PWM, distance 65
7.30 Operating mode 76: Speed setpoint PWM; rotational direction 66
7.31 Operating mode 77: Speed setpoint PWM; dynamic current limit via A2 67
7.32 Operating mode 78: Speed setpoint PWM; brake 68
7.33 Operating mode 81: Speed setpoint frequency, N2 69
7.34 Operating mode 82: Speed setpoint frequency; dynamic current limitation via frequency 70
7.35 Operating mode 83: Speed setpoint frequency, distance 71
7.36 Operating mode 86: Speed setpoint frequency, rotational direction 72
7.37 Operating mode 87: Speed setpoint frequency; dynamic current limit via A2 73
7.38 Operating mode 88: Speed setpoint frequency, brake 74
7.39 Operating mode 91: Operation via RS485; distance / speed 75
7.40 Operating mode 98: Operation via RS485; distance / speed; brake 76
8 Inputs and Outputs 77
8.1 Input circuit 77
8.1.1 IN A / IN B control inputs 77
8.1.2 Input IN 1 and Input IN 2 78
8.1.3 Analog IN A1 79
8.2 Output circuit 79
8.2.1 Output OUT 1 / Output OUT 2 / Output OUT 3 79
5
Contents
9 RS485 Communication 81
9.1 Communication method 81
9.2 Cycle time 81
9.3 Commands 81
9.3.1 Commands (RX) 81
9.3.2 Answer commands (TX) 82
9.4 Status byte 82
9.5 Motor status byte 83
9.6 Checksum 83
9.7 “Speed” run command 83
9.7.1 Requirements 83
9.7.2 Answer 84
9.8 “Position” run command 84
9.8.1 Requirements 84
9.8.2 Answer 85
9.9 Save parameters 85
9.9.1 Request 85
9.9.2 Answer 85
9.9.3 Error flags 86
9.10 Write parameter 86
9.10.1 Request 86
9.10.2 Answer 86
9.10.3 Error flags 87
9.11 Read parameter 87
9.11.1 Request 87
9.11.2 Answer 87
9.11.3 Error flags 88
9.12 Read status word 88
9.12.1 Request 88
9.12.2 Answer 88
9.13 Load “Parameter default values” 88
9.13.1 Request 88
9.13.2 Answer 89
9.13.3 Error flags 89
9.14 Read software ID 89
9.14.1 Request 89
9.14.2 Response (without / with bootloader) 90
6
Contents
9.15 Read bootloader ID 90
9.15.1 Request 90
9.15.2 Answer 90
9.16 Full write access to parameters 91
9.16.1 Request 91
9.16.2 Answer 91
9.16.3 Error flags 91
9.17 Request jump back to bootloader 91
9.17.1 Request 91
9.17.2 Answer 92
9.17.3 Error flags 92
9.18 Reset customer password 92
9.18.1 Request 92
9.18.2 Answer 92
9.18.3 Error flags 93
9.19 Undefined telegrams 93
10 Parameter Description 94
10.1 Safety functions 107
11 Troubleshooting 108
11.1 Error handling 108
11.2 Operation 109
11.3 Parameterisation 110
7
1 Introduction
1.1 Foreword
This operating manual describes the possible uses, the assembly and/or installation, operation and programming of the products listed on
the front page.
All the safety instructions listed under Chapter 2 must be followed at all times during the installation and operation of the drive system;
outside of Germany the relevant laws, directives, guidelines and regulations of the respective country also apply.
Read through this operating manual carefully before starting any work on the drive system. Note and follow the following warnings in order
to avoid personal risk or product malfunctions.
This operating manual is to be thought of and handled as part of the drive system and must be handed over with the drive system if it is sold
or passed on.
The safety instructions can be copied and passed on to provide information about potential hazards and their prevention.
Depending on the version or revision status of the products, differences may exist compared to this operating manual. The user must check
this before using the manual and take into account any such differences.
1.2 Target group
This operating manual is solely directed at qualified and trained skilled personnel with knowledge of electronics and mechanics.
1.3 Notation used in this document
In this operating manual the significance of texts is denoted by different presentation forms.
Descriptive text is presented without preceding symbol.
• Textwithaprecedingdot(•)indicatesalistwhichisintroducedbyaheading.
– Text with a preceding dash (–) is on a lower level below the list with a dot.
Underlined blue text denotes a cross-reference, which can be clicked in the PDF document. The part of the document named in the text is
then displayed.
Text in Courier font
is used to represent command sequences in software programs.
8
1 Introduction
1.4 Warnings and notes
Warnings and notices are always positioned before the instruction, implementation of which can result in a hazard or property damage.
The following warnings are used in this document:
Hazard.
This notice denotes a hazard with high risk, which will result in imminent fatality or serious physical injuries if it is not
DANGER
WARNING
CAUTION
avoided.
f This arrow indicates the appropriate precaution to take to avert the hazard.
Hazard.
This notice denotes a hazard with moderate risk, which can possibly result in fatality or serious physical injuries if it is not
avoided.
f This arrow indicates the appropriate precaution to take to avert the hazard.
Hazard.
This notice denotes a hazard with low risk, which can result in minor or moderate physical injuries or property to damage
if it is not avoided.
f This arrow indicates the appropriate precaution to take to avert the hazard.
Notices contain information, which are particularly important in the corresponding position or which facilitate the described operating steps,
are highlighted as follows:
This notice gives you use recommendations and helpful tips.
NOTE
1.5 Picture symbols
The following pictograms, where applicable in combination, are used on the ebm-papst products and packagings as hazard warnings.
General warning.
High voltage sign (Electric shock).
Hot surface warning sign.
Crushing hazard / hand injury warning sign.
9
2 Safety Instructions
The VDC-3-49.15-K4 and ECI-63.XX-K4 drive systems have been developed to the latest electronic and electrical engineering standards as
well as recognised guidelines for the safety and protection of users.
The drive systems may only be operated and serviced by authorised skilled personnel, who have read through and understood the complete
operating manual. The drive systems must be used with the necessary care, in compliance with all safety instructions described in this
operating manual and the local company-specific regulations.
Read all safety information and instructions and keep notices and the operating manual in the same place as the drive systems.
2.1 General safety instructions
• Before starting work, disconnect the drive system or the design application using suitable devices provided and secure it against being
switched back on again.
• Before opening the units or entering the danger zone, safely bring all drives to a standstill and secure them against being switched back
on again.
• Do not make any changes, add attachments or make modifications to the drive system without ebm-papst's approval.
• If the motor is subjected to unapproved loads, check it for damage and if necessary repair or replace it.
• Do not commission or start up the design application until it has been fully checked for compliance with all relevant legal requirements,
directives and guidelines and the safety provisions relevant for its intended use (e.g. accident prevention regulations and technical
standards).
• Re-assess any safety risks caused by the drive system after it has been installed in the design application.
2.2 Documentation
In addition to this operating manual, the “Kickstart” PC software is required for making settings and parameterisation (configuration) of the
motors. The “ebm-papst Kickstart” software manual describes how it functions.
2.3 Standards, guidelines and directives
• The product does not fall under the Low Voltage Directive 2006/95/EC, as the nominal operating voltage is not within the voltage range
from 75 V DC and 1500 V DC.
• The Machinery Directive MD is applicable, as the product is “partly completed machinery” in accordance with Article 2, paragraph g),
MD 2006/42/EC. A “CE” marking does not have to be provided on the rating plate. However, a Declaration of Incorporation must be drawn
up in accordance with Annex II, Part 1, Section B, MD 2006/42/EC.
2.4 Personnel qualifications
• Only qualified electricians may install the drive system and carry out the trial run and work on the electrical system.
• The drive system may only be transported, unpacked, operated and serviced by instructed and authorised skilled personnel.
2.5 Personal safety
• Provide adequate safeguards / contact protection.
• Wear suitable clothing.
• Do not wear loose clothing or jewellery.
• Keep hair, clothing and gloves away from rotating components.
• Wear personal protective equipment (hearing protection, thermal protection gloves).
10
2 Safety Instructions
2.6 Electrical / electromagnetic safety
• Check the electrical equipment of the drive system regularly.
• Only use cables and connectors approved by ebm-papst.
• Remove defective cables and loose connections immediately.
• Take suitable measures to avoid impermissible electromagnetic interference emissions.
• Take suitable measures against high-frequency EMC radiation.
• Ensure EMC capability in the terminal device / installation state.
• Use control devices to control the electromagnetic radiation.
2.7 Mechanical safety
• Only carry out work when the system / machine is at a standstill.
• Provide adequate cooling of the drive.
• Remove protective devices and guards on the drive system and design application only for the purpose of carrying out repair and
assembly work.
2.8 Intended use
• The drives of the VDC-3-49.15-K4 and ECI-63.XX-K4 series are intended for installation in stationary industrial design applications and
machines and may only be operated electrically when installed!
• Commissioning or starting up is therefore prohibited until it has been established that the drive system together with the design
application, in which the drive is installed, satisfy the safety and protection requirements of the Machinery Directive.
• This product is not intended for consumers! Use in a home environment is not planned, without further testing and deployment of
appropriately adapted EMC protection measures!
• The electronic module is an installation product. It is only intended for use within other equipment or units and has no independent
function. It is not intended for passing on to end users or consumers.
• All motor - electronic combinations must be qualified by the end manufacturer within their intended application and validated for overload
and blocking safety. The application manufacturer is responsible for the end product and must ensure that adequate safety precautions
are taken.
2.8.1 Type-related exclusion
Due to its type or design, the drive system must not be used in the following areas of use; this could result in and hazards and equipment
damage:
• In case of special fail-safe requirements.
• In aircraft and space vehicles.
• In rail and motor vehicles.
• In boats and ships.
• In potentially explosive atmospheres (EX protection area).
• For operation near flammable materials or components.
• For use as a safety component or for carrying out safety-relevant functions.
11
2 Safety Instructions
2.9 Maintenance / repair
• The control electronics are maintenance-free for the period of the planned life.
• Repairs on the product may only be made by qualified personnel or ebm-papst.
2.10 Cleaning
Damage or malfunction if the unit is cleaned by
• cleaning with a water spray or high-pressure (jet) cleaner.
• Use of acids, alkalis and solvent-based cleaning agents.
• Use of pointed and sharp-edged objects.
2.11 Transport / storage
• Transport the motor only in its original packaging.
• Secure the transport goods.
• Do not exceed the vibration values, temperature and climate ranges during the whole transport (refer to technical data from page 16).
• Store the drive system, dry and protected in its original packaging, in a clean environment.
• Do not store the drive system for longer than 1 year.
• Keep to the specified ambient temperature range (refer to technical data from page 16).
2.12 Disposal
On disposing of the product, note and follow all legal and local regulations and requirements applicable in your country.
2.13 Liability and warranty
ebm-papst GmbH & Co. KG does not accept any liability or provide any warranty whatsoever for incidents due to
• Failure to follow this operating manual.
• Incorrect handling and use of the drive system.
• Improper handling.
• Incorrect storage.
• Unsecured transport.
• Use of accessories and spare parts of other manufacturers without the express and written approval of ebm-papst GmbH & Co. KG.
• Changes to the drive system without the express and written approval of ebm-papst GmbH & Co. KG.
12
3 Product Description
3.1 Description VDC-3-49.15-K4
The VDC-3-49.15-K4 motor is a 3-phase EC drive with a multi-pole magnetised neodymium magnet. The electronically commuted external-
rotor motor has an astonishingly high power density and a compact design. Excellent control action is achieved due to the field-orientated
control with sinus commutation. The VDC-3-49.15-K4 has fully integrated control electronics with high-performance DSP and extensive
interfaces. This enables particularly flexible control of the drive and the drive can therefore be adapted to different applications. The
integrated temperature cut-out provides reliable protection against overload.
Rated wattages from 100 to 150 watt are available to choose from.
3.2 Description of the ECI-63.XX modular system K4
The ECI-63.20-K4, 63.40-K4 and 63.60-K4 motors are EC drives. The Series ECI electronically commutated internal rotor motors excel with
large power density and dynamic performance. The ECI-63.XX modular system K4 has fully integrated class 4 control electronics with several
analog and digital interfaces. These can be parameterised via an RS485 interface. This enables particularly flexible control of the drive and
the drive can therefore be adapted to different applications.
Nominal outputs from 150 to 400 W with corresponding packet lengths from 20 to 60 mm are available to choose from.
3.3 Description of the electronic classes
ebm-papst uses the designation “K class” to describe the functional scope of an ebm-papst motor system. The higher the digit the greater
the functional scope. Of the planned classes 1 – 6, to date classes K1, K4 and K5 are in use.
Intelligence
16-bit DSP
8-bit processor
No processor
Functions
Overview of the electronic classes
3.3.1 Functional scope of “K classes 1, 4 and 5”
Class Motor type Commutation
K1
K4
K5
Motor with rotor position encoder external Detection of the rotor position
Motor with enhanced motor control basic
features
Motor with enhanced motor control
Sinus commutation with field-orientated
control up to n = 0
Sinus commutation with field-orientated
control up to n = 0
Function
Speed controller
Current controller
Position controller
Speed controller
Current controller
Position controller
Enhanced safety functions
Bus system, e.g. CANopen, parameterisable
Firmware download, etc.
13
3 Product Description
3.4 Rating plate
The rating plate with the respective features of the ECI-63.XX-K4 and VDC-3-49.15-K4 motors is attached to the housing.
3.4.1 Rating plate ECI-63.XX-K4
Company logo
Motor type, ECI = Electronically Commutated Internal Rotor Motor
Diameter of motor housing = 63 mm
Overall length
Electronic class
Nominal torque
Nominal speed
ECI 63.20-K4
Product No.
Nominal voltage
Class of protection
9326320400
24 VDC 425 mNm 4000 U/min
IP 54 E 8,5 A
US-Pat. 7230359B2
ebm- papst St. Georgen 04/13
DE (S) xx
Power consumption
Thermal class
US patent No.
Production date MM/YY
3.4.2 Typenschild VDC-3-49.15-K4
937 4915 400
24 VDC 04/2014 2465 5497
Serial number
Production plant
Country code
Company logo
Product number
Serial number
Production date MM/YY
Nominal voltage
14
3 Product Description
3.5 Basic configuration
In the VDC-49.15-K4 drive system the control electronics (3) is attached on the motor output end (1). The connection cable is preinstalled in
the control electronics (3) in the factory. The motor housing on the output shaft (2) is formed as a flange with various drillholes for fixing and
attaching the transmission.
In the drive systems of the ECI-63.XX modular system K4 series, the motor housing and control electronics (3) are configured with same
diameter. All necessary electrical connections (4) are integrated in the control electronics (3). The motor housing is formed as a flange at the
output shaft (2) with various drillholes for fixing and attaching the transmission.
VDC-49.15-K4 ECI-63.XX-K4
1
2
3
2
1
3
4
4
1 Motor output side with fixing option or transmission attachment
2 Output shaft
3 Integrated power and control electronics
4 Power, signal and RS485 link
15
4 Technical Specifications
F
This chapter contains the nominal technical data of the following motors:
• ECI-63.20-K4 / ECI-63.40-K4 / ECI-63.60-K4 and
• VDC-3-49.15-K4
and extended technical data for all sizes (see page 20).
4.1 ECI-63.20-K4
Nominal data
Type Unit ECI-63.20-K4-B00 ECI-63.20-K4-D00
Nominal voltage (UN) V DC 24 48
Allowable supply voltage range (U
Nominal speed (n
Nominal torque (M
Nominal current (I
Nominal output power (P
Free-running speed (n
Free-running current (I
) rpm 4000 4000
N
) mNm 425 450
N
) A 8.5 5.4
N
N
) (no-load speed) rpm 5600 6000
L
) (no-load current) A 0.50 0.30
L
Max. reverse voltage V DC 35 58
Setpoint input – Analog / PWM / Frequency / Digital Analog / PWM / Frequency / Digital
Recommended speed control range rpm 0 … 5000 0 … 5000
Locked rotor protection – thermal thermal
Protection on overload – yes yes
Starting torque mNm 3.5 × M
Rotor moment of inertia (JR) kgm2 × 10
Thermal resistance (R
) K / W 3.6 3.6
th
Degree of protection (IP rating) IP 40 / IP 54* IP 40 / IP 54*
Allowable ambient temperature range (T
Motor mass (m) kg 0.85 0.85
Order No. (ECI-63.20-K4-S) Connector type 932 6320 400 932 6320 402
Order No. (ECI-63.20-K4-L) Stranded (litz) wire type 932 6320 403 932 6320 405
Subject to change without notice * The degree of protection (IP 54) given refers to the connector type and the installed condition with
) V DC 20 … 28 40 … 53
ZK
) W 178 188
-6
) °C 0 … +40 0 … +40
U
N
19 19
seal on the flange side.
4.2 × M
N
F
radial
F
axial
150 N
axial
F
150 N L
radial
1
20 mm
Allowable shaft load at nominal speed and life
L
1
expectancy L10 about 20000 h**.
ECI-63.20-K4-B00
5000
4000
]
–1
3000
2000
Speed [min
1000
M
I
100 200 300 400 500
Torque [mNm]
16
15,0
12,0
9,0
6,0
Current intensity [A]
3,0
0
Dimensions ECI-63.20-K4,
Connector type
16,3
Ø63,5
5,8
18,4500±10
118,5
±0,3
Stranded wire type (cable harness is supplied separately)
±0,3
20
+0,1
-0,3
g5
Ø63
Ø6
4 Technical Specifications
F
4.2 ECI-63.40-K4
Nominal data
Type Unit ECI-63.40-K4-B00 ECI-63.40-K4-D00
Nominal voltage (UN) V DC 24 48
Allowable supply voltage range (U
Nominal speed (n
Nominal torque (M
Nominal current (I
Nominal output power (P
Free-running speed (n
Free-running current (I
) rpm 4000 4000
N
) mNm 600 750
N
) A 12.3 7.2
N
N
) (no-load speed) rpm 5600 5400
L
) (no-load current) A 0.90 0.46
L
Max. reverse voltage V DC 35 58
Setpoint input Analog / PWM / Frequency / Digital Analog / PWM / Frequency / Digital
Recommended speed control range rpm 0 … 5000 0 … 5000
Locked rotor protection – thermal thermal
Protection on overload – yes yes
Starting torque mNm 2.5 × M
Rotor moment of inertia (JR) kgm2 × 10
Thermal resistance (R
) K / W 2.9 2.9
th
Degree of protection (IP rating) IP 40 / IP 54* IP 40 / IP 54*
Allowable ambient temperature range (T
Motor mass (m) kg 1.15 1.15
Order No. (ECI-63.40-K4-S) Connector type 932 6340 400 932 6340 402
Order No. (ECI-63.40-K4-L) Stranded (litz) wire type 932 6340 403 932 6340 405
Subject to change without notice * The degree of protection (IP 54) given refers to the connector type and the installed condition with
) V DC 20 … 28 40 … 53
ZK
) W 251 314
-6
) °C 0 … +40 0 … +40
U
N
38 38
seal on the flange side.
4 × M
N
F
radial
F
axial
150 N
axial
F
150 N L
radial
1
20 mm
Allowable shaft load at nominal speed and life
L
1
expectancy L10 about 20000 h**.
ECI-63.40-K4-B00
5000
4000
]
–1
3000
2000
Speed [min
1000
200 400 600 800
M
I
Torque [mNm]
25,0
20,0
15,0
10,0
Current intensity [A]
5,0
0
Dimensions ECI-63.40-K4,
Connector type
16,3
Ø63,5
5,8
18,4500±10
138,5
±0,3
Stranded wire type (cable harness is supplied separately)
±0,3
20
+0,1
-0,3
g5
Ø63
Ø6
17
4 Technical Specifications
F
4.3 ECI-63.60-K4
Nominal data
Type Unit ECI-63.60-K4-D00
Nominal voltage (UN) V DC 48
Allowable supply voltage range (U
Nominal speed (n
Nominal torque (M
Nominal current (I
Nominal output power (P
Free-running speed (n
Free-running current (I
) rpm 4000
N
) mNm 850
N
) A 8.6
N
N
) (no-load speed) rpm 5800
L
) (no-load current) A 0.60
L
Max. reverse voltage V DC 58
Setpoint input Analog / PWM / Frequency / Digital
Recommended speed control range rpm 0 … 5000
Locked rotor protection – thermal
Protection on overload – yes
Starting torque mNm 3 × M
Rotor moment of inertia (JR) kgm2 × 10
Thermal resistance (R
) K / W 2.5
th
Degree of protection (IP rating) IP 40 / IP 54*
Allowable ambient temperature range (T
Motor mass (m) kg 1.5
Order No. (ECI-63.60-K4 S) Connector type 932 6360 402
Order No. (ECI-63.60-K4 L) Stranded (litz) wire type 932 6360 405
Subject to change without notice * The degree of protection (IP 54) given refers to the connector type and the installed condition with
) V DC 40 … 53
ZK
) W 356
-6
) °C 0 … +40
U
57
N
seal on the flange side.
radial
F
L
1
5000
4000
]
–1
3000
2000
Speed [min
1000
F
150 N
axial
F
150 N L
radial
axial
1
Allowable shaft load at nominal speed and life
expectancy L10 about 20000 h**.
ECI-63.60-K4-D00
M
I
200 400 600 800 1000
Torque [mNm]
20 mm
12,5
10,0
7,5
5,0
Current intensity [A]
2,5
0
Dimensions ECI-63.60-K4
Connector type
16,3
Ø63,5
5,8
18,4500±10
158,5
±0,3
Stranded wire type (cable harness is supplied separately)
±0,3
20
+0,1
-0,3
g5
Ø63
Ø10
Extended technical data is available on request.
NOTE
18
4 Technical Specifications
500
±10
VDC-3-49.15-K4 D00, 48V (at 25°C / 120°F)
4.4 VDC-3-49.15-K4
Nenndaten
Typ Einheit VDC-3-49.15-K4 B00 VDC-3-49.15-K4 D00
Nominal voltage (UN) V DC 24 48
Allowable supply voltage range (U
Nominal speed (n
Nominal torque (M
Nominal current (I
Nominal output power (P
Free-running speed (n
Free-running current (I
) rpm 4000** 4000**
N
) mNm 235** 300**
N
) A 5** 3,2**
N
N
) rpm 5000 5000
L
) A 1.0 0.6
L
Max. reverse voltage V DC 35 58
Set value input Analog / PWM / Frequency / Digital Analog / PWM / Frequency / Digital
Recommended speed control range rpm 0 … 4500 0 … 4500
Function for motor protection at stall thermal thermal
Overload protection yes yes
Starting torque mNm 850 1500
Rotor moment of inertia (J
Protetcion class IP 54* IP 54*
Ambient temperature range (T
Motor mass (m) kg 0.56 0.56
Order No. 937 4915 400 937 4915 402
Subject to change without notice * Classification of protection class refers to installed state with sealing on the flange side.
) V DC 20 … 28 40 … 53
ZK
) W 100** 125**
) kgm2 × 10
R
) °C / °F 0 … +40 / -22 … +104 0 … +40 / -22 … +104
U
-6
108 108
max. 40 °C / 104 °F
** T
U
VDC-3-49.15-K4 B00, 24V (at 25°C / 77° F)
5500
5000
4500
4000
3500
]
-1
3000
2500
2000
1500
Speed n [min
1000
500
0
Continous
operation
n = Speed, f (M) I = Current, f (M) η = Efficiency, f (M)
5500
5000
4500
4000
]
-1
Speed n [min
3500
3000
2500
2000
1500
1000
500
0
Mn Mmax
Operating
point
Continuous
operation
300 400 500 600 700 800 900 1000 1100 1300 1400 1500
200
n = Speed, f (M) I = Current, f (M) η = Efficiency, f (M)
M
n Mmax
Operating
point
Short-time operation
350 400 450 500 550 650 700 750 800 850
6000 50 100 150 200 235 300
Torque M [mNm]
Short-time operation
12000 100
Torque M [mNm]
22
20
18
16
14
12
10
8
6
4
2
Current I [A]; Efficiency η*10 [%]
0
22
20
18
16
14
12
10
8
6
4
2
Current I [A]; Efficiency η*10 [%]
0
Dimensions VDC-3-49.15-K4
Connector type
52
±0,5
Protective cap in aluminium natural.
F
radial
L
1
F
20 N
axial
F
60 N L
radial
F
axial
Allowable shaft load at nominal speed and life
expectancy L10 about 20000 h**.
0,0 1
0,0 06
_
_
+
+
Ø 8
Ø 25 h8
2,5
±0,1
20
±0,3
10 mm
1
19
4 Technical Specifications
4.5 Electronic properties
Inputs IN A, IN B
Properties Unit Value / Comment
Input level – PLC level
Low level V < 5
High level V > 15
Protection against polarity reversal and voltages V ≤ 30
if case of cable break – Logic level “0”
Input impedance kΩ 5.4
Input frequency kHz ≤ 10
Input dynamic (Tau) ms ≤ 0.1
Applied logic level – IN A = B = 0 = output stage switched off, FK 5
Subject to change without notice
IN A or B = 1 = output stage switched on
Inputs IN 1, IN 2
Properties Unit Value / Comment
Input level – PLC level
Low level V < 5
High level V > 15
Protection against polarity reversal and voltages V ≤ 30
if case of cable break – Logic level “0”
Input impedance kΩ 5.4
Maximum input frequency for command source via PWM / frequency kHz 15
Input dynamic (Tau) ms ≤ 0.1
Subject to change without notice
Outputs (PNP)
Properties Unit Value / Comment
Output level – High side driver dependent on U
Low level V Open source
High level V > U
Protection against polarity reversal and voltages V ≤ 30
Output current / channel mA ≤ 100
Peak output current / channel A approx. 600 mA (thermally dependent)
Short-circuit proof – yes
Polarity reversal protection – no
Overload protected – yes (automatic thermal cut-out)
Output frequency @ I
Subject to change without notice
= 100 mA kHz ≤ 1
out
(logic supply)
- 2
Logic
Logic
20
4 Technical Specifications
Analog inputs “Analog IN 1…2” (signal connector, differential to GND
Analog
)
Properties Unit Value / Comment
Input voltage range (analog IN) V 0 to 10
GND reference (differential measurement) – Analog GND
Input frequency kHz ≤ 1
Internal resistance kΩ 8
Signal resolution bit 10
Measuring tolerance (relative to the end value 10 V) % ≤ 2
Protection against polarity reversal and voltages V ≤ 28
Subject to change without notice
RS485 bus interface
Properties Unit Value / Comment
Functional scope – –
Baud rate kbit/s 115
Dielectric strength V -8 V to +13 V
Internal bus termination ohm 12k
Subject to change without notice
Safety and monitoring functions
Properties Unit Value / Comment
Functional scope – • Temperature monitoring of the output stage
Temperature cut-out point output stage (PC software)
(Hysteresis: 10 K),
Error must be acknowledged again by means of software
overvoltage cut-out
U
ZK
(Hardware, hysteresis: 1V)
undervoltage auto restart
U
ZK
(software, cut-off U
The error must be acknowledged.
Overload protection I²t (software) – yes
Hardware overcurrent protection circuit as max. current per winding
limitation
Resolution of single turn absolute encoder Bit / revolution 10 (accuracy approx. 3°)
Subject to change without notice
Logic
at 16V),
°C 120
V 63
V 18
A
• Under and overvoltage monitoring of the
system voltages incl. UB overcurrent
limitation
• Overload protection through I²t
45 for VDC-3-49.15-K4
53 for ECI-63.XX-K4
21
5 Installation
3x
Ø3,7
This chapter describes the mechanical and electrical connection of the drive systems.
5.1 Notes
The drives must be checked for visible damage before installation. Damaged drive system must not be installed.
The drives must be fixed onto a flat surface with at least 4 screws. The screws must be secured with suitable measures against loosening.
Use thread-forming screws to DIN 7500 for the fixing.
5.2 Installing the drive
Risk of damage!
CAUTION
CAUTION
When the drives are installed in the motor housing it can be damaged by high radial loads, if the tightening torque applied
to the fixing screws is too high or if the fixing screws are too long.
f Do not load the motor shaft, either radially or axially, with more than 150 N.
f Tighten fixing screws M4 with 3
±0.2
Nm maximum, M5 with 4
±0.2
Nm maximum.
f Do not exceed the specified maximum length of the fixing screws (see Chapter “5.2.1 Determine screw length”).
Risk of damage to electronic components!
The discharge of static charge during installation of the drives can damage the electronic component.
f Use ESD protective equipment during installation.
5.2.1 Determine screw length
X E
A minimum screw length S
is required for safe and reliable fixing of the motors.
min
The maximum allowable screw length S
Minimum screw length S
Minimum depth of engagement E
Maximum screw length S
Maximum depth of engagement E
=
min
6.5 mm + material thickness X of the mounting plate.
min
=
max
8.0 mm + material thickness X of the mounting plate.
min
prevents damage to the motor.
max
max
E
min
S
min
S
max
5.2.2 Prepare the mounting plate
120˚
±0,04
±0,5
44,65
±0,2
24
Ø40
Ø50
±0,2
Ø63
Sketch of fixing holes, motor
housing ECI-63.XX-K4
Only use the drillholes on the output side of the motors housing to fix the drive.
To this end, transfer the necessary drillholes for the centring collar of the motor,
pitch circle and size of the fixing holes onto the mounting plate and drill (see
sketch).
Sketch of fixing holes, motor
housing VDC-3-49.15-K4
22
5 Installation
5.3 Electrical connection
The connection cable for the VDC-3-49.15-K4 drive system is attached to the motor in the factory, no additional plugs are required for the
electrical connection and parameter setting.
The following is required for the electrical connection and parameter setting of the ECI-63.XX-K4 drive system:
1 Connection cable with 15 pin connector M16 (not for the Litz wire (stranded wire) variant of the ECI-63.XX-K4, see Chapter 5.4.4 Harness
for Litz wire version ECI-63.XX-K4, page 25).
1 ebm-papst USB-CAN-RS485 adapter (screw terminal adapter board to the D-SUB 9 connection, USB connection cable to the PC).
1 ebm-papst “Kickstart” PC software.
Health hazard!
The drive systems are installed in design applications in which electrical and electromagnetic components are used.
DANGER
NOTE
These can affect pacemakers, metallic implants or hearing aids and cause severe personal harm.
f Avoid the immediate vicinity, especially areas identified by the warning symbol
implants or wear a hearing aid.
• The drive systems are built-in parts and do not have any electrical disconnecting switches.
• Connect the product to suitable electrical circuits only. Please note that the power supply units must have suitable
protection against regenerative voltage generated on the secondary side.
• When working on the drive system the system / machine must always be disconnected from the power supply and
secured against being switched back on again.
, if you have a pacemaker, metal
5.3.1 Safety check
Before connecting the drive system, check:
• Supply voltage and product voltage identical?
• Does the rating plate data match the connection data of the power supply unit?
• Connection cable suitable for the current intensity and the ambient conditions and area of use?
23
5 Installation
5.4 Connection descriptions
• The connection cable of the VDC-3-49.15-K4 motors is pre-installed on the motor in the factory.
NOTE
5.4.1 Connection cable VDC-3-49.15-K4
The pin assignment of the connection socket is as follows:
• The ECI-63.XX-K4 motors have a 15 pin connector M16 (12+3) on the motor. This is used for the connection of a
connector variant connector cable or for the separately supplied cable harness of the Litz wire variant.
Litz Connection ID AWG Cross-section
AWG 16
AWG 24
Blue
Brown
Black
Green
White
Grey
red
Yellow
Violet
Black
Red-blue
Grey-pink
Brown
Pink
Blue
Ballast Ballast resistance 16
U
ZK
GND Power / signal GND 16
U
Logic
RS485 + Progr. Bus 24
RS485 - Progr. Bus 24
Analog IN 1 0 …10 V (differential) 24
Analog GND GND for analog IN 1 (differential) 24
IN 1 NPN 24V 24
IN 2 NPN 24V / Analog 24
IN A NPN 24V 24
IN B NPN 24V 24
OUT 1 PNP 24V 24
OUT 2 PNP 24V 24
GND Signal-GND 24
Power supply 16
Logic supply + (24 V) 24
1,3 mm
1,3 mm
1,3 mm
0,22 mm
0,22 mm
0,22 mm
0,22 mm
0,22 mm
0,22 mm
0,22 mm
0,22 mm
0,22 mm
0,22 mm
0,22 mm
0,22 mm
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
5.4.2 Motor connection socket ECI-63.XX-K4
The pin assignment of the connector is as follows:
12
A
C
11
10
B
9
4
8
7
6
Pin Connection ID
1
1 IN A NPN 24 V
2
2 IN B NPN 24 V
3
3 IN 1 NPN 24 V
4 IN 2 * NPN 24 V
5 OUT 1 PNP 24 V
6 OUT 2 PNP 24 V
7 OUT 3 PNP 24 V
5
8 Analog IN 1 0 …10 V (differential)
9 Analog GND GND for analog IN 1 (differential)
10 RS485 + Progr. Bus
11 RS485 – Progr. Bus
12 U
A Ballast Ballast resistance
B U
C GND Power / signal GND
Logic
ZK
* Can also be parameterised as analog IN 2.
Logic supply + (24 V)
Power supply
24
5 Installation
5.4.3 Connection cable with connector ECI-63.XX-K4
The connection cable with connector is available only for the ECI-63.XX-K4. For the VDC-3-49.15-K4, the connecting
cable is factory-mounted to the engine, means that no plug required.
NOTE
A standard cable with classification CF-C11Y (3 x 1.5² / 12 x 0.34²) and connector M16 is required for connection of the motor. 1 m, 3 m
and 10 m cable lengths are available for the connection.
Length Order No.
1 m
3 m
10 m
992 0160 025
992 0160 026
992 0160 027
Cable: CF-C11Y (3 x 1.5² / 12 x 0.34²)
Shielding: Complete shield
L
L = 1 000 ±30
3 000 ±30
10 000 ±30
Cable plug-in connector M16
for cable Ø 8 – 11 mm
Other cable types available on request.
NOTE
Crimp insert series M16
15-pin (12 + 3)
See below for pin
5 4 3 A 2 1 12
6 B 7 8 9 C 10 11
assignment
Wire colour Pin Connection ID
white 1 IN A NPN 24 V
brown 2 IN B NPN 24 V
green 3 IN 1 NPN 24 V
yellow 4 IN 2 * NPN 24 V
grey 5 OUT 1 PNP 24 V
pink 6 OUT 2 PNP 24 V
blue 7 OUT 3 PNP 24 V
red 8 Analog IN 1 0 …10 V (differential)
black 9 Analog GND GND for analog IN 1 (differential)
violet 10 RS485 + Progr. Bus
45°
grey / pink 11 RS485 – Progr. Bus
red / blue 12 U
grey A Ballast Ballast resistance
brown B U
black C GND Power / signal GND
Logic
ZK
* Can also be parameterised as analog IN 2.
Ballast, U
and GND are the 1.5 mm² stranded wires.
ZK
Please note! The colours are assigned twice.
Logic supply + (24 V)
Power supply
5.4.4 Harness for Litz wire version ECI-63.XX-K4
The cable harness, length 500 mm, for the Litz wire variant of the ECI-63.XX-K4 can be ordered from ebm-papst under
order number 9920400001.
NOTE
For further connection details, see Chapter 5.4 Connection descriptions, page 24.
Other cable types available on request.
25
5 Installation
5.5 Braking chopper K4
The task of the braking chopper is to convert the energy not required in case of fast speed changes. If the set voltage threshold is exceeded
the external resistor is switched on.
Chopper current Recommended braking resistor
max. 10 A
Braking resistor not included in the scope of supply.
The braking resistor must be tested and designed according to the use of the drive.
NOTE
(Note maximum power loss!)
5.6 Functional ground connection
A functional ground connection must be provided for equipotential
bonding.
24 V systems: >= 3.75 ohm
48 V systems: >= 5.6 ohm
Functional ground connection
on the ECI-63.XX-K4 drive
5.7 RS485 interface
The RS485 interface is used as the parameterisation and diagnostic interface. The “Kickstart” PC software can be used for operation of the
interface. A PC and the ebm-papst USB-CAN-RS485 adapter are required for this.
The “Kickstart” PC software only operates correctly with the ebm-papst USB-CAN-RS485 adapter.
If you use another USB-CAN-RS485 adapter, you will need the relevant software.
NOTE
The bus interfaces are wired by the user. Depending on the topology, the line termination (resistors) must be realised by
the user.
NOTE
5.8 USB-CAN-RS485 adapter
The USB-CAN-RS485 adapter is required as an accessory for the ebm-papst “Kickstart” software, in order to connect the PC with the K4
drive. The adapter can be ordered under Material No. 914 0000 400.
Functional description of the LED displays
LED name Colour Function assignment
Data
Error
microSD
red • No assignment.
green
red
green • Received data is ok.
red • No assignment.
green • Access to the memory card.
• Active data transfer via the USB CAN-RS485
adapter.
• No response following request to K4.
• Receipt of a faulty data package.
26
5 Installation
Pin assignment (D-SUB pin 9 pole):
Adapter electrically isolated
Pin Connection
1
2
3
4
5
6
7
8
9
USB device drivers of the type “FTDI USB Serial Converter” are required for operation of the USB-CAN-RS485 adapter. In many cases these
are already available on the PC or can be installed using the files provided in the subdirectory of the “Kickstart PC-Software\USB-CAN-basic-
driver-files”. Detailed installation instructions (in English) for the operating systems Windows 7, Windows Vista and Windows XP are provided
as PDF files in the installation directory of the “Kickstart” PC software.
n. c.
optional – CAN L bus cable
GND
RS485 +
n. c.
GND
optional – CAN H bus cable
RS485 –
n. c.
Scope of supply:
1 USB-CAN-RS485 adapter (incl. microSD memory card)
1 Screw terminal adapter board to the D-SUB 9 connection
1 USB connection cable to the PC.
5.9 Connection to the USB-CAN-RS485 adapter
• Connect the cable at Pin 10 (violet) with connection 4 (RS485 +) of the USB-CAN-RS485 adapter.
• Connect the cable at Pin 11 (grey/pink) with connection 8 (RS485 –) of the USB-CAN-RS485 adapter.
• Switch on the “Logic” voltage at the power supply unit.
• Start the “Kickstart” tool at the PC for parameterisation.
• Load an existing project (*.kickzip or *.kicktpl) or create a new project: *.kickpro.
27
5.10 Circuit diagram
+
+
or
24 V (SPS)
ebmpapst
5 Installation
Motor VDC-3-49.15-K4
Motor ECI-63.XX-K4
Enable
IN 2
Control
LogicSMPS
RS485 -
RS485 +
U
Powerstage
GND
Analog IN 2
Ballast
µC
ZK
U
Logic
OUT 1
OUT 2
OUT 3*
RS485-Controller
Ballast - Resistor
Power Supply
„Power“
(+24 V / +48 V DC)
GND
Power Supply
„Logic“
(+24 V DC)
GND
Laptop
IN B
IN A
* The OUT 3 connection is only available for the ECI-63.XX-K4 drive systems.
IN 1
IN 2
The user is responsible for external fusing of the power supply.
NOTE
Analog IN 1 Analog GND
0…10 V
28
5 Installation
SPS
5.11 Schematic layout: parameterisation, commissioning (startup) and automatic operation
5.11.1 Parameterisation and commissioning 5.11.2 Automatic operation
Automatic operation with stored parameters and integrated control
Power supply
Control
SPS
USB-K4
ebmpapst
Data
Error
microSD
USB
microSD
Adapter
ECI-63.XX-K4 drive
5.11.3 Connecting connector at the motor
Risk of damage.
When plugging in the connector to the connection on the motor ECI-63.XX-K4, ensure that the company logo on the
CAUTION
connector is facing upwards towards the housing edge of the motor.
When connecting the Litz wires of the VDC-3-49.15-K4 motor variant, ensure that the pin assignment is precisely as
specified and not incorrectly assigned, as this causes irreparable damage to the motor electronics.
KICKSTART
Control
Power supply
PC with “Kick-
start” software
ECI-63.XX-K4 drive
VDC-3-49.15-K4
ECI-63.XX-K4
29
6 Parameterisation
82 parameters are available for parameterising the VDC-3-49.15-K4 and ECI-63.XX-K4 drive systems (from page 32). These are managed
via the electronic class K4 and are set using the ebm-papst “Kickstart” PC software.
A detailed parameter description see Chapter “10 Parameter Description”, page 94.
6.1 Memory management
The K4 has a management function for the “RAM”, “custom” and “default” memory areas.
To edit the values you will need the password “custom access key”. This is set to 0 on delivery. If you change it, please ensure that it is not
lost.
6.1.1 “RAM” memory area
The motor operates with the values in the RAM area.
The memory class “appl func” can be changed (written) if the motor is at a standstill (IN A and IN B input to LOW). If the inputs are not set to
zero you will receive an error message in the status display.
The memory class “appl value” can be changed (written) while the motor is in operation and therefore directly affects the motor's perfor-
mance.
All values can be read out during operation or while the motor is at a standstill.
Parameters that are written in the “RAM” memory area with the “write” command are no longer available if the power supply fails or is
switched off.
6.1.2 “custom” memory area
To ensure that the data is available permanently, it must be located in the “custom” memory area. The data from the “RAM” area is not
written in the “custom” area unless the “store” command is used; after it has been moved the data is then permanently available. On
switching on the voltage, the data from the “custom” area is transferred into the “RAM” area.
30
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