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.

•Text with a preceding dot (•) indicates a list which is introduced by a heading.

–– 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 avoided.

ff 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 WARNING avoided.

ff 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
Caution	if it is not avoided.
	ff 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

2Safety Instructions

2.6Electrical / 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 externalrotor 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	Function
	K1	Motor with rotor position encoder	external	Detection of the rotor position
	K4	Motor with enhanced motor control basic	Sinus commutation with field-orientated	Speed controller
				Current controller
		features	control up to n = 0
				Position controller
				Speed controller
				Current controller
	K5	Motor with enhanced motor control	Sinus commutation with field-orientated	Position controller
			control up to n = 0	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

	ECI 63.20-K4
Product No.	9326320400
Nominal voltage	24 VDC	425 mNm	4000 U/min
Class of protection	IP 54	E	8,5 A
	US-Pat. 7230359B2
	ebmpapst St. Georgen		04/13
	DE (S)		xx

Company logo

Motor type, ECI = Electronically Commutated Internal Rotor Motor Diameter of motor housing = 63 mm

Overall length Electronic class Nominal torque Nominal speed

Power consumption

Thermal class

US patent No.

Production date MM/YY

Serial number

Production plant

Country code

3.4.2 Typenschild VDC-3-49.15-K4

Company logo

Product number

		937 4915 400
24 VDC	04/2014	2465 5497

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	1	2	3

4

3

4

1Motor output side with fixing option or transmission attachment

2Output shaft

3Integrated power and control electronics

4Power, signal and RS485 link

15

4 Technical Specifications

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 (UZK)		V DC		20 … 28		40 … 53
Nominal speed (nN)		rpm		4000		4000
Nominal torque (MN)		mNm		425		450
Nominal current (IN)		A		8.5		5.4
Nominal output power (PN)		W		178		188
Free-running speed (nL) (no-load speed)		rpm		5600		6000
Free-running current (IL) (no-load current)		A		0.50		0.30
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 × MN		4.2 × MN
Rotor moment of inertia (J	)	kgm2 × 10-6		19		19
R
Thermal resistance (Rth)		K / W		3.6		3.6
Degree of protection (IP rating)				IP 40 / IP 54*		IP 40 / IP 54*
Allowable ambient temperature range (TU)		°C		0 … +40		0 … +40
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
				seal on the flange side.

Fradial			Faxial	150 N
		Faxial	Fradial	150 N	L1 20 mm
			Allowable shaft load at nominal speed and life
L1			expectancy L10 about 20000 h**.

		ECI-63.20-K4-B00
5000				15,0
	M				[A]
4000				12,0
					Current intensity
3000				9,0
2000				6,0
Speed[min–1]	I
1000				3,0
				0
100	200	300	400	500

Dimensions ECI-63.20-K4,
Connector type
	16,3	118,5±0,3	20 ±0,3
Ø63,5			g5	Ø63
				+0,1 0,3-
			Ø6
	5,8
500±10	18,4

Torque [mNm]

Stranded wire type (cable harness is supplied separately)

16

4 Technical Specifications

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 (UZK)		V DC		20 … 28		40 … 53
Nominal speed (nN)		rpm		4000		4000
Nominal torque (MN)		mNm		600		750
Nominal current (IN)		A		12.3		7.2
Nominal output power (PN)		W		251		314
Free-running speed (nL) (no-load speed)		rpm		5600		5400
Free-running current (IL) (no-load current)		A		0.90		0.46
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 × MN		4 × MN
Rotor moment of inertia (J	)	kgm2 × 10-6		38		38
R
Thermal resistance (Rth)		K / W		2.9		2.9
Degree of protection (IP rating)				IP 40 / IP 54*		IP 40 / IP 54*
Allowable ambient temperature range (TU)		°C		0 … +40		0 … +40
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
				seal on the flange side.

Fradial			Faxial	150 N
		Faxial	Fradial	150 N	L1 20 mm
			Allowable shaft load at nominal speed and life
L1			expectancy L10 about 20000 h**.

	ECI-63.40-K4-B00
5000			25,0
		M		[A]
4000			20,0
				Currentintensity
3000			15,0
		I
2000			10,0
[minSpeed–1]
1000			5,0
			0
200	400	600	800

Dimensions ECI-63.40-K4,
Connector type
	16,3	138,5±0,3	20 ±0,3
Ø63,5			g5	Ø63
				+0,1 0,3-
			Ø6
	5,8
500±10	18,4

Torque [mNm]

Stranded wire type (cable harness is supplied separately)

17

4 Technical Specifications

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 (UZK)		V DC		40 … 53
Nominal speed (nN)		rpm		4000
Nominal torque (MN)		mNm		850
Nominal current (IN)		A		8.6
Nominal output power (PN)		W		356
Free-running speed (nL) (no-load speed)		rpm		5800
Free-running current (IL) (no-load current)		A		0.60
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 × MN
Rotor moment of inertia (J	)	kgm2 × 10-6		57
R
Thermal resistance (Rth)		K / W		2.5
Degree of protection (IP rating)				IP 40 / IP 54*
Allowable ambient temperature range (TU)		°C		0 … +40
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
				seal on the flange side.

Fradial			Faxial	150 N
		Faxial	Fradial	150 N	L1 20 mm
			Allowable shaft load at nominal speed and life
L1			expectancy L10 about 20000 h**.

		ECI-63.60-K4-D00
5000				12,5
		M			[A]
4000				10,0
					Currentintensity
3000				7,5
2000		I		5,0
[minSpeed–1]
1000				2,5
				0
200	400	600	800	1000

Dimensions ECI-63.60-K4
Connector type
	16,3	158,5±0,3	20 ±0,3
Ø63,5			Ø10g5	Ø63
				+0,1 0,3-
	5,8
500±10	18,4

Torque [mNm]

Stranded wire type (cable harness is supplied separately)

Extended technical data is available on request.

Note

18

4 Technical Specifications

4.4 VDC-3-49.15-K4

	Nenndaten
	Typ																		Einheit
	Nominal voltage (UN)																		V DC
	Allowable supply voltage range (UZK)																		V DC
	Nominal speed (nN)																		rpm
	Nominal torque (MN)																		mNm
	Nominal current (IN)																		A
	Nominal output power (PN)																		W
	Free-running speed (nL)																		rpm
	Free-running current (IL)																		A
	Max. reverse voltage																		V DC
	Set value input
	Recommended speed control range																		rpm
	Function for motor protection at stall
	Overload protection
	Starting torque																		mNm
	Rotor moment of inertia (J											)							kgm2 × 10-6
											R
	Protetcion class
	Ambient temperature range (TU)																		°C / °F
	Motor mass (m)																		kg
	Order No.
	Subject to change without notice
				VDC-3-49.15-K4 B00, 24V (at 25°C / 77° F)
	5500																									22
	5000								Mn														Mmax			20
	4500																									18	[%]
	4000																									16
									Operating																		*10
	3500																									14
nSpeed[min-1]									point																		η
	1500																									6	Efficiency[A];I
	3000																									12
	2500																									10
	2000																									8	Current
	500				Continous																					2
	1000																									4
	0				operation							Short-time operation														0
	0			50	100	150		200	235	300		350	400	450	500	550	600		650	700		750	800	850
											Torque M [mNm]
				n = Speed, f (M)							I = Current, f (M)							η = Efficiency, f (M)
				VDC-3-49.15-K4 D00, 48V (at 25°C / 120°F)
	5500																									22
	5000						Mn																Mmax			20
	4500																									18	[%]
	4000																									16
							Operating																				*10
	3500																									14
[minnSpeed-1]							point																				Efficiency[A];η
																										6
	3000																									12
	2500																									10
	2000																									8
	1500																										I
				Continuous
	500																									2	Current
	1000																									4
	0			operation								Short-time operation														0
	0			100	200	300		400		500	600		700	800	900	1000	1100		1200		1300		1400	1500
										Torque M [mNm]
				n = Speed, f (M)							I = Current, f (M)							η = Efficiency, f (M)

VDC-3-49.15-K4 B00	VDC-3-49.15-K4 D00
24	48
20 … 28	40 … 53
4000**	4000**
235**	300**
5**	3,2**
100**	125**
5000	5000
1.0	0.6
35	58
Analog / PWM / Frequency / Digital	Analog / PWM / Frequency / Digital
0 … 4500	0 … 4500
thermal	thermal
yes	yes
850	1500
108	108
IP 54*	IP 54*
0 … +40 / -22 … +104	0 … +40 / -22 … +104
0.56	0.56
937 4915 400	937 4915 402

*Classification of protection class refers to installed state with sealing on the flange side.

**TU max. 40 °C / 104 °F

Dimensions VDC-3-49.15-K4

Connector type

500±10

+ 0,01 Ø 8 + 0,006 Ø 25 h8

	2,5±0,1
52±0,5	20±0,3

Protective cap in aluminium natural.

Fradial			Faxial	20 N
		Faxial	Fradial	60 N	L1 10 mm
			Allowable shaft load at nominal speed and life
L1			expectancy L10 about 20000 h**.

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
					IN A or B = 1 = output stage switched on
Subject to change without notice
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 ULogic
					(logic supply)
Low level		V			Open source
High level		V			> ULogic - 2
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 @ Iout = 100 mA		kHz			≤ 1
Subject to change without notice

20

4 Technical Specifications

Analog inputs “Analog IN 1…2” (signal connector, differential to GNDAnalog)

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
				•	Under and overvoltage monitoring of the
					system voltages incl. UB overcurrent
					limitation
				•	Overload protection through I²t
Temperature cut-out point output stage (PC software)		°C		120
(Hysteresis: 10 K),
Error must be acknowledged again by means of software
UZK overvoltage cut-out		V		63
(Hardware, hysteresis: 1V)
UZK undervoltage auto restart		V		18
(software, cut-off ULogic at 16V),
The error must be acknowledged.
Overload protection I²t (software)		–		yes
Hardware overcurrent protection circuit as max. current per winding		A		45 for VDC-3-49.15-K4
limitation				53 for ECI-63.XX-K4
Resolution of single turn absolute encoder		Bit / revolution		10 (accuracy approx. 3°)
Subject to change without notice

21

5 Installation

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

Caution

Caution

Risk of damage!

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.

ff Do not load the motor shaft, either radially or axially, with more than 150 N. ff Tighten fixing screws M4 with 3±0.2 Nm maximum, M5 with 4±0.2 Nm maximum.

ff 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. ff Use ESD protective equipment during installation.

5.2.1 Determine screw length

A minimum screw length Smin is required for safe and reliable fixing of the motors. The maximum allowable screw length Smax prevents damage to the motor.

Minimum screw length Smin=

Minimum depth of engagement Emin 6.5 mm + material thickness X of the mounting plate.

Maximum screw length Smax =

Maximum depth of engagement Emin 8.0 mm + material thickness X of the mounting plate.

X	Emax
	Emin
	Smin
	Smax

5.2.2 Prepare the mounting plate

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).

3x

120˚

Ø3,7 ±0,04

44,65 ±0,5

24 ±0,2

Ø40

Ø50

Ø63 ±0,2

Sketch of fixing holes, motor housing VDC-3-49.15-K4

Sketch of fixing holes, motor housing ECI-63.XX-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:

1Connection 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.

Danger

Note

Health hazard!

The drive systems are installed in design applications in which electrical and electromagnetic components are used. These can affect pacemakers, metallic implants or hearing aids and cause severe personal harm.

ff Avoid the immediate vicinity, especially areas identified by the warning symbol , if you have a pacemaker, metal 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.

5.3.1Safety 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

5.4Connection descriptions

•The connection cable of the VDC-3-49.15-K4 motors is pre-installed on the motor in the factory.

•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 Note connector variant connector cable or for the separately supplied cable harness of the Litz wire variant.

5.4.1 Connection cable VDC-3-49.15-K4

The pin assignment of the connection socket is as follows:

		Litz	Connection		ID	AWG	Cross-section
		Blue	Ballast		Ballast resistance	16	1,3 mm2
	AWG 16	Brown	UZK		Power supply	16	1,3 mm2
		Black	GND		Power / signal GND	16	1,3 mm2
		Green	U	Logic	Logic supply + (24 V)	24	0,22 mm2
	AWG 24	White	RS485 +		Progr. Bus	24	0,22 mm2
		Grey	RS485 -		Progr. Bus	24	0,22 mm2
		red	Analog IN 1		0 …10 V (differential)	24	0,22 mm2
		Yellow	Analog GND		GND for analog IN 1 (differential)	24	0,22 mm2
		Violet	IN 1		NPN 24V	24	0,22 mm2
		Black	IN 2		NPN 24V / Analog	24	0,22 mm2
		Red-blue	IN A		NPN 24V	24	0,22 mm2
		Grey-pink	IN B		NPN 24V	24	0,22 mm2
		Brown	OUT 1		PNP 24V	24	0,22 mm2
		Pink	OUT 2		PNP 24V	24	0,22 mm2
		Blue	GND		Signal-GND	24	0,22 mm2

5.4.2 Motor connection socket ECI-63.XX-K4

The pin assignment of the connector is as follows:

	12		B		Pin	Connection	ID
		C	A	1	1	IN A	NPN 24 V
	11			2	2	IN B	NPN 24 V
	10			3	3	IN 1	NPN 24 V
					4	IN 2 *	NPN 24 V
	9			4	5	OUT 1	PNP 24 V
					6	OUT 2	PNP 24 V
	8			5	7	OUT 3	PNP 24 V
		7		6	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	ULogic	Logic supply + (24 V)
					A	Ballast	Ballast resistance
					B	UZK	Power supply
					C	GND	Power / signal GND

* Can also be parameterised as analog IN 2.

24

5Installation

5.4.3Connection 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	992 0160 025
3 m	992 0160 026
10 m	992 0160 027

Cable: CF-C11Y (3 x 1.5² / 12 x 0.34²)

Shielding: Complete shield

L

L =  1 000 ±30		Crimp insert series M16
3 000 ±30
10 000 ±30			15-pin (12 + 3)
		See below for pin
Cable plug-in connector M16			assignment
for cable Ø 8 – 11 mm
5	4 3 A 2 1 12
		45°

6 B 7 8 9 C 10 11

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
grey / pink	11	RS485 –	Progr. Bus
red / blue	12	ULogic	Logic supply + (24 V)
grey	A	Ballast	Ballast resistance
brown	B	UZK	Power supply
black	C	GND	Power / signal GND

* Can also be parameterised as analog IN 2.

Ballast, UZK and GND are the 1.5 mm² stranded wires. Please note! The colours are assigned twice.

Other cable types available on request.

Note

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		24 V systems: >= 3.75 ohm
		48 V systems: >= 5.6 ohm
	Braking resistor not included in the scope of supply.
Note	The braking resistor must be tested and designed according to the use of the drive.
	(Note maximum power loss!)

5.6 Functional ground connection

A functional ground connection must be provided for equipotential bonding.

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
		red	•	No assignment.
	Data	green	• Active data transfer via the USB CAN-RS485
				adapter.
		red	• No response following request to K4.
	Error		• Receipt of a faulty data package.
		green	• Received data is ok.
	microSD	red	•	No assignment.
		green	• Access to the memory card.

26

5 Installation

Pin assignment (D-SUB pin 9 pole):

Adapter electrically isolated

Pin	Connection
1	n. c.
2	optional – CAN L bus cable
3	GND
4	RS485 +
5	n. c.
6	GND
7	optional – CAN H bus cable
8	RS485 –
9	n. c.

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.

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 Installation

5.10 Circuit diagram
							ebmpapst	Laptop
							RS485-Controller
Motor VDC-3-49.15-K4						Ballast	Ballast - Resistor
Motor ECI-63.XX-K4
			+		-
			RS485		RS485	µC
								Power Supply
								„Power“
			Powerstage			UZK		(+24 V / +48 V DC)
						GND		+
								GND
		Enable
	or							Power Supply
								„Logic“
						ULogic		(+24 V DC)
								+
		Control		Logic-
				SMPS
								GND
			2			OUT 1
			Analog IN			OUT 2
		IN 2				OUT 3*
				IN 1	GND
IN A	IN B	IN 1	IN 2	Analog	Analog
	24 V (SPS)			0…10 V

* The OUT 3 connection is only available for the ECI-63.XX-K4 drive systems.

The user is responsible for external fusing of the power supply.

Note

28

5Installation

5.11Schematic 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

-K4 USB

ebmpapst

USB
microSD	Adapter

ECI-63.XX-K4 drive

KICKSTART

PC with “Kickstart” software

Control

SPS	Power supply

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.

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 performance.

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