Ebmpapst K3G500-AP25-90 Operating Instructions Manual

Operating instructions

K3G500-AP25-90

` II 2G Ex d e ib IIB T3 Gb

IBExU14ATEX1122 X /03

`

Translation of the original operating instructions54005-4-8670

ebm-papst Mulfingen GmbH & Co. KG

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

CONTENTS

1. STANDARDS AND DIRECTIVES

11. STANDARDS AND DIRECTIVES

1.1 Applied standards and directives

11.1 Applied standards and directives

As per directive 2014/34/EU in accordance with the following standards:

EN 14986: 2007

Design of fans for use in potentially explosive atmospheres

EN 60079-0: 2012 +A11: 2013

Explosive atmospheres
Part 0: Equipment - General requirements

EN 60079-1: 2007

Explosive atmosphere Part 1: Equipment protection by pressure­resistant enclosure "d"

EN 60079-7: 2007

Explosive atmosphere Part 7: Equipment protection by increased safety
"e"

EN 60079-11: 2012

Explosive atmosphere Part 11: Equipment protection by intrinsic safety "i"

TR CU 012/2011

The fan satisfies the requirements of the Technical Regulations of the
Customs Union "On safety of equipment intended for use in explosive
atmospheres".

These operating instructions are available in other languages on
our website, www.ebmpapst.com.

22. SAFETY REGULATIONS AND NOTES

22.1 Levels of hazard warnings

22.2 Staff qualification

22.3 Basic safety rules

22.4 Electrical voltage

22.5 Safety and protective functions

32.6 Electromagnetic radiation

32.7 Mechanical movement

32.8 Emission

32.9 Hot surface

32.10 Transport

32.11 Storage (including stockkeeping of spare parts)

42.12 Disposal

43. PROPER USE

54. TECHNICAL DATA

54.1 Product drawing

64.2 Nominal data

64.3 Technical features

64.4 Mounting data

64.5 Transport and storage conditions

74.6 Electromagnetic compatibility

74.7 Ex areas

74.8 The type plate

85. CONNECTION AND START-UP

85.1 Connecting the mechanical system

85.2 Connecting the electrical system

105.3 Connection in terminal box

125.4 Factory settings

135.5 Connection screen

145.6 Checking the connections

145.7 Switch on device

145.8 Switching off the device

146. INTEGRATED PROTECTIVE FUNCTIONS

147. MAINTENANCE, MALFUNCTIONS, POSSIBLE

CAUSES AND REMEDIES

157.1 Cleaning

157.2 Safety test

157.3 Maintenance interval

167.4 Vibration check

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

Operating instructions

K3G500-AP25-90

` II 2G Ex d e ib IIB T3 Gb

IBExU14ATEX1122 X /03

`

Translation of the original operating instructions54005-4-8670

2. SAFETY REGULATIONS AND NOTES

Read the operating instructions carefully before working on the device
and every time before using it. Observe the following safety instructions
to prevent malfunctions or danger to persons. These operating
instructions are to be regarded as part of the device. Keep the operating
instructions close to the product so that users can access them at any
time. The device may only be sold or passed on together with the
operating instructions. The operating instructions must be accessible for
the operating and maintenance personnel. These operating instructions
may be duplicated and forwarded for information about potential dangers
and their prevention.

2.1 Levels of hazard warnings

These operating instructions use the following hazard levels to indicate
potentially hazardous situations and important safety regulations:

DANGER

Indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury. Compliance with
the measures is mandatory.

WARNING

Indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury. Exercise extreme
caution while working.

CAUTION

Indicates a potentially hazardous situation which, if not avoided,
may result in minor or moderate injury or damage of property.

NOTE

A potentially harmful situation can occur and, if not avoided, can
lead to property damage.

2.2 Staff qualification

Only electricians specialising in electrical explosion protection may
install the device, perform the test run and work on the electrical system.
The device may only be unpacked, operated, switched on or off, set,
used, run, disassembled and transported by suitable, qualified, trained
and authorised personnel.

2.3 Basic safety rules

A risk assessment in accordance with the Industrial Safety Regulation
(BetrSichV) must be performed before any use of the device. The safety
hazards associated with the device must be assessed again following
installation in the final product.
Observe the following when working on the unit:

; The device is only to be used in proper technical working order for its

intended purpose, in a safe manner with attention to potential dangers
and in accordance with the operating instructions.

; Any faults and defects which impair safety must be rectified

immediately.

; Do not make any modifications, additions or conversions to the

device (such as modifying the guard grille or attaching other
equipment to the wall ring) without the approval of ebm-papst.

; Modifications to the device result in loss of Ex approval. ebm-papst

Mulfingen GmbH & Co. KG does not accept any liability for resultant
damage.

2.4 Electrical voltage

; Check the electrical equipment of the device at regular intervals; see

chapter 7.2 Safety test.

; Replace loose connections and defective cables immediately.

DANGER
Live terminals and connections even with device
switched off

Electric shock, unintentional triggering of an ignition spark and
capacitive residual voltage can cause an ignition spark in the
event of a short circuit.

→ Before disconnecting the wires in the terminal box,

short-circuit the wires (L1, L2, L3) and PE outside the
explosion-hazard area, see chapter 5.8.2 Switching off
the device for maintenance work. #Wait five minutes
following all-pole disconnection of the voltage before
opening the terminal box.

CAUTION
In the event of failure, there is electric voltage at the
rotor and impeller

The rotor and impeller are base insulated.

→ Do not touch the rotor and impeller once they are installed.

CAUTION
If control voltage is applied or a speed setpoint is stored,
the motor will restart automatically, e.g. after power
failure.

Risk of injury

→ Keep out of the device danger zone.# When working on the

device, switch off the mains power and ensure that it cannot
be switched back on.

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

other objects from the device.

2.5 Safety and protective functions

DANGER
Protective device missing and protective device not
functioning

Without a protective device there is a risk of serious injury, for
instance if the hands reach or are sucked into the device during
operation.

→ Operate the device only with a fixed protective device and

guard grille.# The fixed protective device must be able to
withstand the kinetic energy of a fan blade that becomes
detached at maximum speed. There must not be any gaps
which it is possible to reach into with the fingers, for example.

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

are responsible for ensuring that the device is secured
adequately.

→ Stop the device immediately if a protective device is

found to be missing or ineffective.

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

Operating instructions

K3G500-AP25-90

` II 2G Ex d e ib IIB T3 Gb

IBExU14ATEX1122 X /03

`

Translation of the original operating instructions54005-4-8670

2.6 Electromagnetic radiation

Interference from electromagnetic radiation is possible, e.g. in conjunction
with open and closed-loop control devices.
If unacceptable emission intensities occur when the fan is installed,
appropriate shielding measures have to be taken by the user.

NOTE
Electrical or electromagnetic interferences after
integrating the device in installations on the customer's
side.

→ Verify that the entire setup is EMC compliant.

2.7 Mechanical movement

DANGER
Rotating device

Body parts that come into contact with the rotor and impeller
can be injured.

→ Secure the device against accidental contact.

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

parts have come to a standstill.

WARNING
Rotating device

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

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

while working on rotating parts.# Protect long hair with a cap.

WARNING
Flying parts

If safety devices are missing, this may cause parts to be
ejected at high speeds, causing bodily harm, or impair
explosion protection.

→ Take appropriate safety measures. The safety devices must

prevent contact with rotating and electrically live parts.

DANGER
The fan is not supplied with full protective equipment.

→ The system in which it is installed must generally be

protected against the penetration of objects (IP20 as per
EN60529/EN14986). #To ensure ignition protection, rotating
parts must be designed throughout the entire production
series such that the connection methods employed always
reliably stop parts or material working loose. In this context it
must also be ensured that loose metallic parts from the
surrounding area cannot get into the vicinity of the rotating
parts and thus impair ignition protection. #The suitability of the
protective device and its attachment must always be
assessed in the context of the overall safety concept for the
system as a whole.

2.8 Emission

WARNING
Depending on the installation and operating conditions,
a sound pressure level greater than 70 dB(A) may arise.

Danger of noise-induced hearing loss

→ Take appropriate technical safety measures.

→ Protect operating personnel with appropriate safety

equipment, e.g. hearing protection.

→ Also observe the requirements of local agencies.

2.9 Hot surface

CAUTION
High temperature at the electronics housing

Risk of burns

→ Ensure sufficient contact protection.

2.10 Transport

WARNING
Transportation of fan

Injuries from tipping or slipping.

→ Wear safety shoes and cut-resistant safety gloves. #Only

transport the fan in its original packaging. #Transport the fan
lying flat, in other words with the motor axis vertical.

→ Secure the fan(s) so that nothing can slip or tip, e.g. by

using a lashing strip.

NOTE
Packaging damaged

ebm-papst Mulfingen will not accept any liability for packaging
damages that are reported late.

→ Report damages immediately

→ Open the product as soon as it arrives.

→ Describe the damages in writing

→ Sign the description and have the shipper (driver) initial it.

NOTE
Packaging undamaged, content damaged.

In the case of covered transport damage, you have to show
that the damage occurred during transport and not afterwards.

→ Notify the supplier and ebm-papst of damages within 5

workdays in writing.

→ Keep the damaged goods with the packaging until the

situation has been clarified.

→ Operating damaged devices is prohibited.

2.11 Storage (including stockkeeping of spare parts)

; Store the device, partially or fully assembled, in a dry and

weatherproof manner in the original packing in a clean environment.

; Protect the device from environmental impacts and dirt until the final

installation.

; Protect the device from unwanted access, e.g. by unauthorised

personnel.

; We recommend storing the device for a maximum up to one year to

guarantee proper operation and longest possible service life.

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

described prior to being commissioned.

; Observe the correct storage temperature; see chapter 4.5 Transport

and storage conditions.

DANGER
Danger of explosion, ingress of dirt and humidity into
the motor

The IP type of protection is decreased.

→ Store the device in completely assembled condition only

(screwed cable gland and terminal box cover are sealed)

Item no. 54005-5-9970 · ENG · Revision 90396 · Release 2016-09-21 · Page 3 / 16

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

Operating instructions

K3G500-AP25-90

` II 2G Ex d e ib IIB T3 Gb

IBExU14ATEX1122 X /03

`

Translation of the original operating instructions54005-4-8670

2.12 Disposal

When disposing of the device, please comply with all relevant
requirements and regulations applicable in your country.

3. PROPER USE

The device is exclusively designed as a built-in device for conveying
air according to its technical data.

Note

; The motor satisfies the requirements of category II 2G Ex d e ib IIB

T3 Gb. Devices of this category are intended for use in areas in
which the occasional occurrence of an explosive atmosphere of air,
gases and vapours or mists is to be expected (category 2G). The
device-related explosion protection measures of this category must
provide the required degree of safety even in the event of frequent
system malfunctions or fault statuses normally to be taken into
consideration (foreseeable faults). This involves assessment of the
individual risks of the system as a whole and implementation of the
necessary explosion protection measures.

Any other usage above and beyond this does not conform with the
intended purpose and constitutes misuse of the device.
Customer equipment must be capable of withstanding the mechanical
and thermal stresses that can arise from this product. This applies for the
entire service life of the equipment in which this product is installed.
When used in the intended manner, explosion-proof motors cannot ignite
explosive gases or vapours.
The manufacturer who installs ebm-papst devices is responsible for
ensuring operation in accordance with the intended use, operational
safety, proper installation, and EMC properties when installed.
The fan is designed for 40,000 hours of operation and must then be
replaced.
ebm-papst accepts no liability for subsequent modifications to the fan.

Proper use also includes:

● Use the device in power systems with earthed neutral (TN/TT power

systems) only.

● Conveying of air at an ambient air pressure of 750 mbar to 1050 mbar.

● Using the device within the permitted ambient temperature range; see

chapter 4.2 Nominal data and chapter 4.5 Transport and storage
conditions.

● Device protected against weather effects at the installation location.

● Operating the device with all protective devices.

● Using the device only in Zones 1 and 2 with explosion subcategories

IIA and IIB and temperature classes T1 to T3.

● Using the device only in stationary systems.

● Using the device only in resonance-free speed ranges to avoid spark

formation.

● Punctual, complete performance of all maintenance; see chapter 7.3

Maintenance interval.

● Observance of the operating instructions.

Improper use

Using the device in the following ways is particularly prohibited and
may cause hazards:

● Operating the device with an imbalance, e.g. caused by dirt deposits

or icing.

● Moving air that contains abrasive particles.

● Conveying of highly corrosive air, such as salt spray mist. This does

not apply to devices designed for use in a salt-laden atmosphere and
accordingly protected. The same applies to all other corrosive
substances.

● Moving solids content in flow medium.

● Conveying of air with a high dust pollution level, e.g. extraction of

sawdust, flour dust etc.

● Conveying of air containing iron and rust particles, e.g. use of the

device in a welding shop.

● Operation (also when stopped) with external vibrations.

● Operation in unstable flow conditions (vibration).

● Operation with severe contamination (see maintenance instructions).

● Installation and operation of the device with exposure to weather

effects.

● Using the device as a safety component or for taking on safety-

related functions.

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

function.

● Operation with vibration transmitted to the fan from external machines

or attachments.

● Operation with externally induced mechanical loads that are in

excess of the permitted level.

● Opening of the terminal box during operation, see chapter 4.1 Product

drawing.

● Painting the fan.

● Standing or walking on the fan or ventilation unit.

● Operation with completely or partially disassembled, manipulated or

inadequate protective devices.

● Connections (e.g. screws) coming loose during operation.

● Upstream connection of frequency converters.

● Connection of attachments to the rotor housing.

● Flow medium and ambient conditions not conforming to those of Ex

marking.

● In addition, all application options that are not listed under proper use.

DANGER
Potential dangers in the event of non-compliance include
personal injury and property damage due to shaft
breakage, fatigue failure, reduced bearing service life or
explosions caused by elevated surface temperatures or
spark formation.

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

Operating instructions

K3G500-AP25-90

` II 2G Ex d e ib IIB T3 Gb

IBExU14ATEX1122 X /03

`

Translation of the original operating instructions54005-4-8670

4. TECHNICAL DATA

4.1 Product drawing

All measures have the unit mm.

1 Inlet nozzle with pressure tap
2 Screw-on position for vibration-absorbing elements
3 Cable diameter min. 10 mm, max. 16 mm, tightening torque 6±0.6 Nm; standard value depending on cable
4 Screw plug M20x1.5
5 Cable diameter min. 10 mm, max. 14 mm, tightening torque 6±0.6 Nm; standard value depending on cable
6 Attachment screws for terminal box cover, tightening torque 3.5±0.5 Nm
7 Earth connection point M8 (functional earth to dissipate electrostatic charge, no protective earth), do not unfasten the existing nut, contact is

established with another nut.

8 Axial gap dimension
9 Radial gap dimension
10 Additional type plate and warning sticker in Russian

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

Operating instructions

K3G500-AP25-90

` II 2G Ex d e ib IIB T3 Gb

IBExU14ATEX1122 X /03

`

Translation of the original operating instructions54005-4-8670

4.2 Nominal data

Motor M3G150-FF

Phase 3~
Nominal voltage / VAC 400
Nominal voltage
range / VAC

380 .. 440

Frequency / Hz 50/60

Type of data definition ml
State prelim.
Speed (rpm) / min

-1

1780

Power input / W 2970
Current draw / A 4.5
Min. ambient
temperature / °C

-25

Max. ambient
temperature / °C

50

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

Subject to alterations

4.3 Technical features

Mass 62.5 kg
Size 500 mm
Surface of rotor Coated in black
Material of electronics
housing

Die-cast aluminium, coated in black

Material of impeller Aluminium sheet
Material of inlet nozzle Aluminium sheet
Material of support
structure

Sheet steel, galvanised

Number of blades 7
Direction of rotation Clockwise, seen on rotor
Type of protection IP 44
Insulation class "F"
Humidity (F)/
environmental
protection class (H)

F4-1

Mounting position Shaft horizontal (base mounting only) or

rotor on bottom; rotor on top not permissible

Condensate discharge
holes

Rotor-side

Operation mode S1
Motor bearing Ball bearing

Technical features - Output 10 VDC, max. 10 mA

- Output 20 VDC, max. 50 mA

- Output for slave 0-10 V

- Operation and alarm display

- Input for sensor 0-10 V or 4-20 mA

- External 24 V input (programming)

- External release input

- Alarm relay

- Integrated PID controller

- Motor current limit

- PFC, passive

- RS485 MODBUS RTU

- Soft start

- Control input 0-10 VDC / PWM

- Temperature derating

- Over-temperature protected
electronics / motor

- Line undervoltage / phase failure
detection

Touch current acc.
IEC 60990 (measuring
network Fig. 4, TN
system)

<= 3.5 mA

Electrical leads Via terminal box
Motor protection Reverse polarity and locked-rotor

protection

Protection class I (if protective earth is connected by

customer)

Product conforming
to standard

EN 61800-5-1; CE

Approval II 2G; EAC

For cyclic speed loads, note that the rotating parts of the device
are designed for maximum one million load cycles. If you have
specific questions, contact ebm-papst for support.

4.4 Mounting data

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

by using self-locking screws).

Strength class for
mounting screws

10.9

You can obtain additional mounting data from the product drawing if
necessary.

4.5 Transport and storage conditions

; Use the device in accordance with its protection type.

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

+80 °C

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

Transport -40 °C / Storage -55 °C °C

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

Operating instructions

K3G500-AP25-90

` II 2G Ex d e ib IIB T3 Gb

IBExU14ATEX1122 X /03

`

Translation of the original operating instructions54005-4-8670

4.6 Electromagnetic compatibility

If several devices are switched in parallel on the mains side so
that the line current of the arrangement is in the range of 16 - 75
A, then this arrangement conforms to IEC 61000-3-12 provided
that the short-circuit power Ssc at the connection point of the
customer system to the public power system is greater than or
equal to 120 times the rated output of the arrangement.
It is the responsibility of the installation engineer or operator/
owner of the device to ensure, if necessary after consultation
with the network operator, that this device is only connected to
a connection point with a Ssc value that is greater than or equal
to 120 times the rated output of the arrangement.

4.7 Ex areas

The device may only be used according to the specifications in the
operating instructions; see chapter 3. Proper use.

Zone classification

The zones describe how long an explosive atmosphere may be present.
Zones 1 and 2 permit only gases, vapours and mist (no dust) which
occur occasionally to seldom in normal operation.

Device categories

The device is approved for Category 2 of Equipment Group II. The
categories define the degree of safety.

4.8 The type plate

Fig. 1: Specifications on the type plate

Serial number

Designation Explanation

YY Year Year, e.g. 11 for 2011,

model year

WW Week Week, calendar week of

the model year

Six-digit number, e.g. 000003 Sequential serial number

Ex identification

` II 2 G Ex d e ib IIB T3 Gb

Element Explanation

`

Ex marking according to 2014/
34/EU

II Device group (II --> use above

ground (not mining))

2 Category 2 --> Zone 1,

Category 3 --> Zone 2

G Ex atmosphere (G --> Gas) (no

dust pollution permissible)

Ex d e ib Ignition protection class (d -->

flameproof enclosure, e -->
increased safety, ib --> intrinsic
safety with protection level)

IIB Explosion group (for gases of

Group IIB)

T3 Temperature class T3, see EN

60079-0

Gb Equipment protection level

Certificate number IBExU14ATEX1123 X /xx

Element Explanation

IBExU Certification body
14 Year of approval
ATEX In accordance with ATEX

product directive 2014/34/EU
1123 Certificate number
X The "X" symbol after the

certificate number indicates

special conditions for safe use of

the motors, which can be found

in these operating instructions.
\xx Supplement to EC type

examination certificate for the

type concerned

Special conditions for safe use

● The design specifications of the manufacturer must be observed when

repairing flame-proof joints. Repair work based on the values of EN
60079-1 is not permissible.

● The cable glands used are only to be employed for fixed installation.

Appropriate strain relief must be ensured on installation.

● When replacing cable entries, make sure that these are suitable for a

sustained usage temperature of -55°C to +80°C.

● At ambient temperatures below -20°C the connection lines must be

suitable for the corresponding usage temperature.

● The heating element should only remain switched on at ambient

temperatures up to max. +30°C.

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

Operating instructions

K3G500-AP25-90

` II 2G Ex d e ib IIB T3 Gb

IBExU14ATEX1122 X /03

`

Translation of the original operating instructions54005-4-8670

5. CONNECTION AND START-UP

Before commencing work, take the measures specified in your risk
assessment, for the protection of employees.
In addition to the generally valid installation requirements for electrical
low-voltage equipment, the special requirements for setting up electrical
installations in the potentially explosive area must be observed.

5.1 Connecting the mechanical system

DANGER
Insufficient earthing

Electric shock

→ The fan must be earthed in the motor terminal box. There is

also a connection on the outside of the motor. The earthing
points on the fan frame or fan housing are no substitute for
protective earthing in the terminal box (only for dissipation of
static electricity).

CAUTION
Cutting and crushing hazard when removing device
from packaging

→ Carefully remove the device from its packaging, only

touching the housing. Strictly avoid shocks.# Wear safety
shoes and cut-resistant safety gloves.

CAUTION
Heavy load when taking out the device

Bodily harm, e.g. back injuries, are possible.

→ Two people should remove the device out of its packaging

together.

NOTE
Imbalance

Shortened device service life

→ Do not grasp or transport the device by the blades. Use

cloth cable loops, for example, to move the device using a
crane.# After installation, ensure that the impeller can
easilymove and that the impeller blades are not deformed or
bent and do not scrape anywhere.

NOTE
Mounting peripheral components

→ When mounting peripheral components or similar

attachments, make sure you use a suitable material (in terms
of contact points or contact surfaces) between rotating and
stationary parts.

→ When mounting such parts, you, the system

manufacturer, are responsible for maintaining the safety
distance in accordance with EN 14986, for example
between the impeller and housing.

NOTE
Shortened service life due to extreme loads

Examples of extreme loads include the effects of moisture,
corrosive chemical substances and vibrations. Examples of
extreme climatic stressing include extreme heat or cold or high
humidity.

→ Avoid extreme loads.

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

longer be installed.

; Install the undamaged device according to your application.

; The system may not introduce any forces into the device that place

stress on the frame structure and that affect the Ex-relevant gap (e.g.
uneven mounting level, air duct connections, or the like).

; During installation, make sure not to bend or pry the device in order to

avoid mechanical tension.

; Verify that all rotating parts can move freely. The device must be

installed such that the shaft is horizontal or vertical with the rotor facing
downwards.

; During installation, ensure that the direction of rotation of the device is

correct.

; Use suitable fastening hardware for the installation.

; Remove any objects that are located in the exhaust zone of the fan or

near the fan blades.

; After installation, ensure that the screws are tightened.

; The device must not be subjected to impermissibly high vibration from

the system (vibration measurement as per chapter 7.4 Vibration
check is required on start-up and as part of regular maintenance).

If multiple ebm-papst fans are installed in one system, please
allocate serial numbers to the project and write them down so
that in the even of a potential defect, accurate information can be
provided about the range of devices affected.

5.1.1 Gap dimension

Radial gap dimension

The gap dimension between the impeller and inlet nozzle is set
by ebm-papst and is at least 1% of the contact diameter (see
chapter 4.1 Product drawing).

Axial gap dimension

The axial distance between pressure tap and impeller must be
at least 1% of the contact diameter; (see chapter 4.1 Product
drawing).

→ Remember to always check this distance in axial and radial

direction on start-up and when performing routine checking in
accordance with chapter 7.3 Maintenance interval. Operation
of the device with less than the minimum gap dimension is
not permissible.

5.2 Connecting the electrical system

DANGER
Electric voltage on the device

Electric shock

→ Always install a protective earth first.

→ Check the protective earth.

DANGER
Explosion hazard

→ To dissipate electrostatic charges, the fan must be earthed

via the earthing point on the fan housing.# Operation of the
fan without earthing to dissipate electrostatic charges is not
permitted.

NOTE
Observe the minimum permissible temperature of -35°C
for connection of the cables at the terminals.

The terminals could be damaged.

→ Only connect the connection cables at temperatures above -

35°C.

Item no. 54005-5-9970 · ENG · Revision 90396 · Release 2016-09-21 · Page 8 / 16

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Operating instructions

K3G500-AP25-90

` II 2G Ex d e ib IIB T3 Gb

IBExU14ATEX1122 X /03

`

Translation of the original operating instructions54005-4-8670

DANGER
Faulty insulation

Risk of fatal injury from electric shock

→ Only use cables complying with the installation

specifications with regard to voltage, current, insulation
material, load rating etc.# Take care to route the wiring such
that it cannot come into contact with any rotating parts.

→ Only use cables designed for the current level indicated

on the type plate and approved for use in potentially
explosive atmospheres.

CAUTION
Electrical voltage

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

→ Only connect the fan to circuits that can be switched off with

an all-pole separating switch.

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

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

NOTE
Interferences and failures are possible

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

→ Ensure a sufficiently large clearance.

Recommendation: clearance > 10 cm (separate cable
routing)

NOTE
Water penetration into leads or wires

Water enters at the cable end on the customers side and can
damage the device.

→ Make sure that the cable end is connected in a dry

environment.

5.2.1 Prerequisites

; Check whether the data on the type plate agree with the connection

data.

; Before connecting the device, ensure that the supply voltage matches

the operating voltage of the device.

; Only use cables designed for the current level indicated on the type

plate; see chapter 5.3.3 Connecting cables with terminals. For
determining the cross-section, observe the basic principles according
to EN 61800-5-1. The protective earth must have a cross-section
equal to or greater than the phase conductor cross-section. We
recommend the use of 105°C cables.

; Only use cables approved for the corresponding ambient temperature.

; Do not subject the connection lines to impermissible strain.

; Establish a safe protective earth connection.

; Ensure compliance with the protection rating. The seals in the terminal

box from ebm-papst have been inspected for their suitability.

The motor must be connected in accordance with EN 60079-14.

Earth wire contact resistance to EN 61800-5-1

Compliance with the impedance specifications according to EN 61800-5­1 for the protective earth connection circuit must be verified in the
application. Depending on the installation situation, it may be necessary
to connect an additional protective earth conductor to the extra protective
earth terminal on the device. The protective earth terminal with an earth
conductor symbol and a hole is located on the housing.

5.2.2 Power supply connection, fuse protection

Assignment of conductor cross-sections and the fuse protection required
for them (overload protection only, no device protection).

Nominal
voltage

Safety
fuse

Automatic

circuit

breaker

Wire
cross­section

Wire
cross­section

VDE UL VDE mm² *AWG
3/PE AC
380 - 440
VAC

16 A 15 A C16A 1.5 16

3/PE AC
380 - 440
VAC

20 A 20 A C20A 2.5 14

3/PE AC
380 - 440
VAC

25 A 25 A C25A 4.0 12

* AWG = American Wire Gauge

5.2.3 Idle current

Because of the EMC filter integrated for compliance with EMC
limits (interference emission and interference immunity), idle
currents in the mains cable can be measured even when the
motor is at a standstill and the mains voltage is switched on.

● The values lie in a range of typical < 250 mA.

● The effective power in this operating state (readiness for operation) is

simultaneously at typical < 5 W.

5.2.4 Residual current operated device

Only universal (type B or B+) RCD protective devices are
permitted. Like frequency inverters, RCD protective devices
cannot provide personal safety while operating the device.
When switching on the power supply of the device, pulsed
charge currents from the capacitors in the integrated EMC filter
can lead to the RCD protective devices triggering without
delay. We recommend residual current devices with a trigger
threshold of 300 mA and delayed triggering (super-resistant,
characteristic K).

5.2.5 Leakage current

For asymmetrical power systems or if a phase fails, the
leakage current can increase to a multiple of the nominal value.

Item no. 54005-5-9970 · ENG · Revision 90396 · Release 2016-09-21 · Page 9 / 16

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

Operating instructions

K3G500-AP25-90

` II 2G Ex d e ib IIB T3 Gb

IBExU14ATEX1122 X /03

`

Translation of the original operating instructions54005-4-8670

5.3 Connection in terminal box

5.3.1 Delivery condition of terminal box

The terminal box of the fan supplied by ebm-papst is equipped with the
following screwed cable glands.

Line Outer

diameter of
wire

Terminal area
of the
terminal strip

Manufacturer
order number
(Hugro)

Mains supply
connection
M25 x 1.5

Ø 10 mm to Ø
16 mm

1.5 mm² to 4
mm²

154.2516.37

Control line
M20 x 1.5

Ø 10 mm to Ø
14 mm

0.5 mm² to 1.5
mm²

154.2014.37

Plug screw
M20 x 1.5

- - 548.20.14

5.3.2 Preparing connection lines for the connection

Use can be made of cables with or without shielding. The following two
illustrations show the lengths to which the cables are to be cut. For
correct wiring, refer to chapter 5.3.3 Connecting cables with terminals.
Only strip the cable as far as necessary, ensuring that the cable gland is
sealed and there is no strain on the connections. Tightening torques, see
chapter 4.1 Product drawing.

Fig. 2: Recommended stripping lengths in mm (inside terminal box) for
non-shielded cables. By way of example, all cable glands are used in
this illustration. The illustration may differ from the actual device design.

Fig. 3: Recommended stripping lengths in mm (inside terminal box) for
shielded cables. By way of example, all cable glands are used in this
illustration.

5.3.3 Connecting cables with terminals

; Open the terminal box.

; To do so, unscrew the seven attachment screws; for tightening

torque, see chapter 4.1 Product drawing.

Take care when opening the terminal box cover. Do not
damage the terminal box seal by using tools to open it. A
protective earth is installed on the terminal box cover. This
connection must not be broken.

If the original screws of the terminal box cover have been lost, use
metric and corrosion-resistant screws; for size see chapter 4.1 Product
drawing.

; Remove the cap from the screwed cable gland.

Only Ex e-approved plug screws may be used; see Other
types of closure, e.g. using cables, are not permitted.

; Use one sheathed cable for each screwed cable gland.

; Use copper wires only.

; Check that the wires are clean.

; Insert the line(s) (not included in the standard scope of delivery) into

the terminal box.

The mains line (PE and L1 - L3) must always be routed
separately and must not be routed together with the control line.
Pay attention to the cross-sections of the strands and cable
glands.

If using shielded cables, the shielding has to be folded back
over the wire sheath and fixed under the strain relief clamps;
see the illustration "Strain relief for shielded cables".

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

; Connect the lines to the corresponding terminals.

Use a screwdriver to do so.
During the connection work, ensure that no cables splice off.

Item no. 54005-5-9970 · ENG · Revision 90396 · Release 2016-09-21 · Page 10 / 16

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Operating instructions

K3G500-AP25-90

` II 2G Ex d e ib IIB T3 Gb

IBExU14ATEX1122 X /03

`

Translation of the original operating instructions54005-4-8670

Fig. 4: Connecting wires to terminals (example)

There must be no mechanical load applied between the terminal and the
cable gland. The cable must be relieved of strain.

Fig. 5: Secure the brackets (included in terminal box) for strain relief of
the wires

Fig. 6: Strain relief for shielded wires

The strain relief acts on the cable sheath, which eliminates load
on the single strands.

DANGER
Risk of explosion due to poorly sealed terminal box.

The terminal box cover, its seal and the contact surface on the
housing must not be soiled or damaged.

→ Clean the contact surfaces if soiled, note the section on

cleaning.# If damaged, send the device to ebm-papst for
repair/replacement.

The terminal box is only properly sealed if the terminal box
screw connections and cable glands have been tightened to the
specified torque.

5.3.3.1 Exchange of screwed cable glands and plug screws

If you would like to replace screwed cable glands or plug screws, for
example because they have been lost or become worn out, the
following characteristics must be met.

CAUTION

Required properties for cable glands and screw plugs:- Ex e
approval

- Usage temperature -40°C to 85°C

- Connection thread M20 x 1.5 mm or M25 x 1.5 mm

- Sizing corresponding to cable diameter

- Material: Nickel-plated brass or stainless steel

5.3.4 Cable routing

No water may penetrate along the cable in the direction of the cable gland.
To relieve strain on the cables, we recommend fastening the connection
lines at intervals of 10 cm.

Fans installed lying flat

Make sure the cables are routed in a U-shaped loop.

Fig. 7: Fan installed lying flat, cable routed as a water trap.

Item no. 54005-5-9970 · ENG · Revision 90396 · Release 2016-09-21 · Page 11 / 16

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

Operating instructions

K3G500-AP25-90

` II 2G Ex d e ib IIB T3 Gb

IBExU14ATEX1122 X /03

`

Translation of the original operating instructions54005-4-8670

Fans installed in upright position

When routing the cable, ensure that the screwed cable glands are
arranged at the bottom. The cables must always be routed downwards.

Fig. 8: Cable routing for fans installed upright.

5.4 Factory settings

Factory settings with which the device is pre-set by ebm-papst.

Control mode
parameter set 1

PWM controlling

Control mode
parameter set 2

PWM controlling

Fan / device adress 1
Max. PWM / % 100
Min. PWM / % 5,1
Save set value to
EEPROM

Yes

Set value control Analogue (linear)
Control function
parameter set 1

Positive (heating)

Control function
parameter set 2

Positive (heating)

Item no. 54005-5-9970 · ENG · Revision 90396 · Release 2016-09-21 · Page 12 / 16

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Operating instructions

K3G500-AP25-90

` II 2G Ex d e ib IIB T3 Gb

IBExU14ATEX1122 X /03

`

Translation of the original operating instructions54005-4-8670

5.5 Connection screen

Shading => terminals not assigned

No. Conn. Designation Function / assignment
1 PE Earth connection, PE connection
1 L1 Mains supply connection, supply voltage 3-phase, 380- 440 VAC, 50/60 Hz
1 L2 Mains supply connection, supply voltage 3-phase, 380- 440 VAC, 50/60 Hz
1 L3 Mains supply connection, supply voltage 3-phase, 380- 440 VAC, 50/60 Hz
1 HZ Not used (optional: internal heating element)
2 RSA Bus connection RS485; RSA; MODBUS RTU; double terminal (SELV)
2 RSB Bus connection RS485; RSB; MODBUS RTU; double terminal (SELV)
2 GND Signal ground for control interface (SELV)
2 Ain1 U Analogue input 1, set value: 0-10 V, Ri = 100 kΩ, parametrisable curve, only for use as alternative to input

Ain1; SELV

2 +10 V Fixed voltage output 10 VDC, +10 V +/-3%, max. 10 mA, short-circuit-proof, power supply for ext. devices

(e.g. potentiometer); SELV

2 Ain1 I Analogue input 1, set value: 4-20 mA; Ri = 100 Ω, parametrisable curve, only for use as alternative to input

Ain1 U; SELV

2 Din 1 Digital input 1: Enabling of electronics,

Enabling: Pin open or applied voltage 5-50 VDC
Disabling: Bridge to GND or applied voltage <1 VDC
Reset function: Triggers software reset after a level change to <1 VDC; SELV

2 Aout Analogue output 0-10 VDC, max. 5 mA, output of the current motor level control coefficient / motor speed

parametrisable curve; SELV

2 Din 2 Digital input 2: Parameter set 1/2 switching, depending on EEPROM setting, the valid/used parameter set can

be selected via the bus or via the digital input DIN2.
Parameter set 1: Pin open or applied voltage 5-50 VDC
Parameter set 2: bridge to GND or applied voltage <1 VDC; SELV

2 Din 3 Digital input 3: Controller function of integrated controller; depending on EEPROM setting, normal / inverse can

be selected for the controller function of the integrated controller via the bus or the digital input
Normal: Pin open or applied voltage 5-50 VDC
Inverse: bridge to GND or applied voltage <1 VDC; SELV

2 Ain2 U Analogue input 2, actual value: 0-10 V, Ri = 100 kΩ, parametrisable curve, only usable as alternative to input

Ain2; SELV

2 +20 V Fixed voltage output 20 VDC, +20 V +25/-10%, max. 50 mA, short-circuit-proof, power supply for ext.

devices (e.g. sensors); SELV
Alternatively: +24 V DC input for parametrisation via MODBUS without mains power

2 Ain2 I Analogue input 2, actual value: 4-20 mA, Ri = 100 Ω, parametrisable curve, only for use as alternative to input

Ain2 U; SELV

2 NO Status relay; floating status contact; make for failure
2 COM Status relay, floating status contact, common connection, contact rating 250 VAC / max. 2 A (AC1) / min. 10

mA

2 NC Status relay; floating status contact; break for failure

Item no. 54005-5-9970 · ENG · Revision 90396 · Release 2016-09-21 · Page 13 / 16

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Operating instructions

K3G500-AP25-90

` II 2G Ex d e ib IIB T3 Gb

IBExU14ATEX1122 X /03

`

Translation of the original operating instructions54005-4-8670

5.6 Checking the connections

; Make sure that the power is off (all phases).

; Secure it from being switched on again.

; Check the correct fit of the connection lines.

; Route the connecting cables in the terminal box so that the terminal

box cover closes without resistance. The strands must not be trapped
between the terminal box cover and housing.

; Screw the terminal box cover back on again. Terminal box tightening

torque, see chapter 4.1 Product drawing.

; Use all plug screws (the entire number). In doing so, insert the

screws manually to avoid damage to the thread.

; Make sure that the terminal box is correctly closed and sealed and

that all screws and screwed cable glands are properly tightened.

; The supply lines to the add-on unit, e.g. exchanger, must conform to

the IP protection rating (see type plate). Do not route the cables over
any sharp-edged objects.

5.7 Switch on device

The device may only be switched on if it has been installed properly and
in accordance with its intended use, including the required safety
mechanisms and professional electrical connection. This also applies for
devices which have already been equipped with plugs and terminals or
similar connectors by the customer.

; Inspect the device for visible external damage and the proper function

of the protective features before switching it on.

; Check the air flow paths of the fan for foreign objects and remove any

that are found.

; Apply the nominal voltage to the voltage supply.

; Start the device by changing the input signal.

5.8 Switching off the device

5.8.1 Switch off device during operation

; Switch off the device via the control input.

; Do not switch the motor (e.g. in cyclic operation) on and off via power

supply.

5.8.2 Switching off the device for maintenance work

; Switch off the device via the control input.

; Disconnect the device from the supply voltage.

If the device (terminal box cover) has to be opened and disconnected
from the supply line, observe the following:

DANGER
Electrical load (>50 µC, 60 µJ) between mains wire and
protective earth connection after switching off the supply
when switching multiple devices in parallel.

Electric shock, risk of injury

→ Important! The terminal box cover must not be

opened within a potentially explosive area before the
wires (L1, L2, L3) and PE are short-circuited outside
the potentially explosive area (e.g. on the main switch).

; Disconnect the connection line on the device.

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

last.

6. INTEGRATED PROTECTIVE FUNCTIONS

The integrated protective functions cause the motor to switch off
automatically in case of faults described in the table.

Malfunctions Description / Function of

safety feature

Rotor position detection error No automatic restart occurs.
Locked rotor ; After the blockage is

removed, the motor restarts

automatically.
Line under-voltage (mains input
voltage outside of permitted
nominal voltage)

; If the mains supply voltage

returns to permitted values, the

motor restarts automatically.
Phase failure A phase of the supply voltage

fails for at least 5 s.

; If all phases are correctly

supplied again, the motor

automatically restarts after 10 -

40 s.
Overtemperature of motor,
electronics interior and power
electronics

No automatic restart. Reset the

instrument manually.

7. MAINTENANCE, MALFUNCTIONS, POSSIBLE
CAUSES AND REMEDIES

Do not perform any repairs on your device. Send the device to ebm­papst for repair or replacement.
When performing maintenance work on the fan, e.g. when cleaning the
fan impeller, the fan must be stationary and the circuit must be interrupted
and safeguarded against unintentional re-starting.

; Wait until the device stops.

WARNING
Live terminals and connections even with device
switched off

Electric shock

→ When shutting off the device, note chapter 5.8 Switching off

the device.# Wait five minutes after disconnecting the
voltage at all poles before opening the device.

CAUTION
If control voltage is applied or a speed setpoint is stored,
the motor will restart automatically, e.g. after power
failure.

Risk of injury

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

and ensure that it cannot be switched back on.# Wait until
the device stops.

→ Keep out of the device hazard zone.

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

other objects from the fan air paths.

If the device remains out of use for over four months, we
recommend switching the device on for at least three hours at
full speed to allow any condensate to evaporate and to move
the bearings.

; Carry out inspections and cleanings according to the Ex protection

class so that no dirt deposits form.

Malfunction/error Possible cause Possible remedy

Item no. 54005-5-9970 · ENG · Revision 90396 · Release 2016-09-21 · Page 14 / 16

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

Operating instructions

K3G500-AP25-90

` II 2G Ex d e ib IIB T3 Gb

IBExU14ATEX1122 X /03

`

Translation of the original operating instructions54005-4-8670

Impeller running
roughly

Imbalance in rotating
parts

Clean the device;
replace if unbalance
is still found after
cleaning. Make sure
no weight clips are
moved, damaged or
removed during
cleaning.

Motor does not turn Mechanical blockage Switch off, de-

energise, and
remove mechanical

blockage.
Mains supply voltage
faulty

Check mains power,

restore power

supply. Attention! The

error message resets

automatically. The

device starts up

again automatically

without advance

warning.
Faulty connection De-energise, correct

connection, see

connection diagram.
Motor winding broken Replace device
Insufficient cooling Improve cooling. Let

the device cool down.

To reset the error

message, switch off

the mains supply

voltage for a min. of

25 s and switch it on

again.

Alternatively, reset

the error message by

applying a control

signal of <0.5 V to

DIN1 or by short

circuiting Din1 to

GND.
Ambient temperature
too high

Reduce the ambient

temperature. Let the

device cool down.

To reset the error

message, switch off

the mains supply

voltage for a min. of

25 s and switch it on

again.

Alternatively, reset

the error message by

applying a control

signal of <0.5 V to

DIN1 or by short

circuiting Din1 to

GND.

Impermissible
operating point (e.g.
excessive load, back
pressure too high)

Correct the operating
point. Let the device
cool down.
To reset the error
message, switch off
the mains supply
voltage for a min. of
25 s and switch it on
again.
Alternatively, reset
the error message by
applying a control
signal of <0.5 V to
DIN1 or by short
circuiting Din1 to
GND.

Mounting screws
of terminal box
broken during
closing

Replace device

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

7.1 Cleaning

NOTE
Damage to the device during cleaning

Malfunction possible

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

cleaner.# Do not use any acid, alkali or solvent­basedcleaning agents.# Do not use any pointed or sharp­edged objects for cleaning

Regular cleaning of the device prevents unbalance caused by
deposits for example.

7.2 Safety test

NOTE
High-voltage test

The integrated EMC filter contains Y capacitors. Therefore, the
trigger current is exceeded when AC testing voltage is applied.

→ Test the device with DC voltage when you carry out the

high-voltage test required by law. The voltage to be used
corresponds to the peak value of the AC voltage required by
the standard.

7.3 Maintenance interval

What has to
be tested?

How to test? Frequency Which

measure?

Corrosion Visual inspection At least every

3 months

When there is
strong
corrosion that
impairs the EX
protection, e.g.
in gap
surfaces,
replace the
device.

Item no. 54005-5-9970 · ENG · Revision 90396 · Release 2016-09-21 · Page 15 / 16

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Operating instructions

K3G500-AP25-90

` II 2G Ex d e ib IIB T3 Gb

IBExU14ATEX1122 X /03

`

Translation of the original operating instructions54005-4-8670

Check the
protective
casing against
accidental
contact for
damage and to
ensure that it is
intact

Visual inspection At least every

6 months

Repair or
replacement of
the device

Check the
device for
damage to
blades and
housing

Visual inspection At least every

6 months

Replacement of
the device

Mounting the
connection lines

Visual inspection At least every

6 months

Fasten

Check the
insulation of the
wires for damage

Visual inspection At least every

6 months

Replace wires

Impeller for
wear/deposits/
corrosion and
damage

Visual inspection At least every

6 months

Clean or
replace impeller

Tightness of
screwed cable
gland

Visual inspection At least every

6 months

Retighten,
replace if

damaged
Drain holes to
prevent
clogging, as
necessary

Visual inspection At least every

6 months

Open bore holes

Weld seams for
crack formation

Visual inspection At least every

6 months

Replace device

Cable routing
(fastening)

Visual inspection At least every

6 months

Fasten cables

Cleaning and
preventive
maintenance

Visual inspection At least every

3 months

Remove dirt,

clean the device

Check the ball
bearings to
ensure they are
quiet, can
move easily
and are free of
play

Acoustic and/or
manual check
by turning the
rotor whilst
switched off,
vibration test

At least every
3 months

Replace the

device in the

event of noise,

stiffness or

bearing play.

Have the motor

bearings

replaced by

ebm-papst.
Vibration test See Vibration

test section

At least every
6 months

Cleaning,

repair or

replacement of

device
Check gap
dimensions

See Gap
dimensions
section

At least every
3 months

Replacement of

device

7.4 Vibration check

Regular checks must be made to ensure that the fan is not operated with
impermissibly high vibration values. On the basis of ISO 14694, the
maximum permissible vibration velocities are specified as follows:

Fan connected to system
with isolation from vibration

Fan connected to system
without isolation from
vibration

Vibration velocity Vibration velocity
Max. 6.3 mm/s Max. 4.5 mm/s

Fig. 9: The vibration velocities are measured in radial direction at the
stator bush.

The motor bearings are provided with lifetime lubrication at the factory.
Experience has shown that under normal operating conditions the grease
therefore only has to be renewed after several years. The motor must be
deactivated in the event of bearing noise. To remedy this, the motor has
to be exchanged or the defective bearings replaced by the ebm-papst
Service department.
A record is to be kept of the routine inspections performed.

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