ebm-papst M3G112-GA53-72 User Manual

Page 1
M3G112-GA53-72
Operating instructions
ebm-papst Mulfingen GmbH & Co. KG
Bachmühle 2 D-74673 Mulfingen Phone +49 (0) 7938 81-0 Fax +49 (0) 7938 81-110 info1@de.ebmpapst.com www.ebmpapst.com
CONTENTS
CAUSES AND REMEDIES
Translation of the original operating instructions
1. SAFETY REGULATIONS AND NOTES
Please read these operating instructions carefully before starting to work with the device. Observe the following warnings to prevent malfunctions or physical damage to both property and people. These operating instructions are to be regarded as part of this device. If the device is sold or transferred, the operating instructions must accompany it. These operating instructions may be duplicated and forwarded for information about potential dangers and their prevention.
11. SAFETY REGULATIONS AND NOTES
11.1 Levels of hazard warnings
11.2 Staff qualification
11.3 Basic safety rules
11.4 Electrical voltage
21.5 Electromagnetic radiation
21.6 Mechanical movement
21.7 Hot surface
21.8 Transport
21.9 Storage
21.10 Disposal
32. PROPER USE
43. TECHNICAL DATA
43.1 Product drawing
53.2 Nominal data
53.3 Technical features
53.4 Mounting data
53.5 Transport and storage conditions
64. CONNECTION AND START-UP
64.1 Connecting the mechanical system
64.2 Connecting the electrical system
74.3 Connection in terminal box
74.4 Factory settings
84.5 Connection screen
94.6 Checking the connections
94.7 Switch on device
94.8 Switching off the device
95. INTEGRATED PROTECTIVE FUNCTIONS
106. MAINTENANCE, MALFUNCTIONS, POSSIBLE
106.1 Cleaning
106.2 Safety test
1.1 Levels of hazard warnings
These operating instructions use the following hazard levels to indicate potentially hazardous situations and important safety regulations:
DANGER
Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. Compliance with the measures is mandatory.
WARNING
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. Exercise extreme caution while working.
CAUTION
Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury or damage of property.
NOTE
A potentially harmful situation can occur and, if not avoided, can lead to property damage.
1.2 Staff qualification
Only specialised electrical personnel may install the device, perform the test run and work on the electrical system. Only trained and authorised specialist personnel are permitted to transport, unpack, assemble, operate or maintain the device, or to use it in any other manner.
1.3 Basic safety rules
Any safety hazards stemming from the device must be re-evaluated once it is installed in the end device. Observe the following when working on the unit:
; Do not make any modifications, additions or conversions to the
device without the approval of ebm-papst.
1.4 Electrical voltage
; Check the electrical equipment of the device at regular intervals, refer
to chapter 6.2 Safety test.
; Replace loose connections and defective cables immediately.
DANGER Electrical load on the device
Risk of electric shock
→ Stand on a rubber mat if you are working on an electrically
charged device.
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.
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Page 2
M3G112-GA53-72
Operating instructions
CAUTION If control voltage is applied or a speed setpoint is stored, the motor automatically restarts, e.g. after a power failure.
Danger of injury
→ Keep out of the danger zone of the device.
→ When working on the device, switch off the mains
supply voltage and secure the latter from being switched on again.
→ Wait until the device stops.
→ After working on the device, remove any used tools or
other objects from the device.
CAUTION The motor restarts automatically when operating voltage is applied, e.g. after a power failure.
Danger of injury
→ Keep out of the danger zone of the motor.
→ When working on the motor, switch off the mains supply
voltage and secure the latter from being switched on again.
→ Wait until the motor stops.
1.5 Electromagnetic radiation
Interference from electromagnetic radiation is possible, e.g. in conjunction with open and closed-loop control devices. If unacceptable emission intensities occur when the fan is installed, appropriate shielding measures have to be taken by the user.
NOTE Electrical or electromagnetic interferences after integrating the device in installations on the customer's side.
→ Verify that the entire setup is EMC compliant.
1.6 Mechanical movement
DANGER Flying parts
Missing safety devices may cause balancing weights or broken fan blades to be ejected at high speeds, causing bodily harm.
→ Take appropriate safety measures.
WARNING Rotating device
Long hair, loose items of clothing and jewellery could become entangled and pulled into the device. You could be injured.
→ Do not wear any loose clothing or jewellery while working
on rotating parts.
→ Protect long hair by wearing a cap.
WARNING Flying parts
If the motor is operated with attached fan blades, missing safety
Translation of the original operating instructions
devices may cause balancing weights or broken fan blades to be ejected and cause bodily injuries.
→ Take the appropriate safety measures; e.g. install guard
grilles.
→ Keep out of the exhaust zone.
1.7 Hot surface
CAUTION High temperature at the electronics enclosure
Danger of burn injuries
→ Ensure that sufficient protection against accidental contact is
provided.
1.8 Transport
CAUTION Transport of motor
Crushing hazard
→ Wear safety shoes and cut-resistant safety gloves.
→ Transport the motor in its original packaging only.
→ Secure the device so that it does not slip, e.g. by using a
clamping strap.
1.9 Storage
; Store the device, partially or fully assembled, in a dry and
weatherproof manner in the original packing in a clean environment.
; Protect the device from environmental impacts and dirt until the final
installation.
; We recommend storing the device for a maximum up to one year to
guarantee proper operation and longest possible service life.
; Even devices explicitly suited for outdoor use are to be stored as
described prior to being commissioned.
; Maintain the storage temperature, see
chapter 3.5 Transport and storage conditions.
; Please make sure that all screwed cable glands are fitted with
dummy plugs.
1.10 Disposal
When disposing of the device, please comply with all relevant requirements and regulations applicable in your country.
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M3G112-GA53-72
Operating instructions
2. PROPER USE
The device is designed exclusively for use as a drive motor. Any other or secondary use is deemed improper and constitutes a misuse of the device. Installations on the customer's side must meet the mechanical, thermal and service life-related stresses that can occur.
Proper use also includes:
Only using the device in stationary systems.
Carrying out all maintenance.
Using the device in accordance with the permitted ambient
temperature, see chapter 3.5 Transport and storage conditions and chapter 3.2 Nominal data.
Operating the device with all protective features in place.
Minding the operating instructions.
Improper use
Using the device in the following ways is particularly prohibited and may cause hazards:
Operation in medical equipment with a life-sustaining or lifesaving
function.
Operation with external vibrations.
Moving solids content in flow medium.
Painting the device
Connections (e.g. screws) coming loose during operation.
Opening the terminal box during operation.
Moving air that contains abrasive particles.
Moving highly corrosive air, e.g. salt spray mist. Exceptions are
devices that are intended for salt spray mist and protected accordingly.
Moving air that contains dust pollution, e.g. suctioning off saw dust.
Operating the device close to flammable materials or components.
Operating the device in an explosive atmosphere.
Using the device as a safety component or for taking on safety-
related functions.
Operation with completely or partially disassembled or modified
protective features.
In addition, all application options that are not listed under proper use.
Translation of the original operating instructions
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M3G112-GA53-72
3. TECHNICAL DATA
3.1 Product drawing
Operating instructions
All measures have the unit mm.
1 Direction of rotation counter-clockwise, seen on shaft 2 Through-hole for screw M10 3 Depth of screw max. 12 mm 4 Depth of screw max. 16 mm 5 Cable diameter: min. 4 mm, max. 10 mm, tightening torque: 2±0.3 Nm 6 Tightening torque 3.5±0.5 Nm 7 Groove depth 3.5 mm
Translation of the original operating instructions
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ebm-papst Mulfingen GmbH & Co. KG · Bachmühle 2 · D-74673 Mulfingen · Phone +49 (0) 7938 81-0 · Fax +49 (0) 7938 81-110 · info1@de.ebmpapst.com · www.ebmpapst.com
Page 5
M3G112-GA53-72
Operating instructions
3.2 Nominal data
Motor M3G112-GA
Phase 1~ Nominal voltage / VAC 230 Nominal voltage range / VAC Frequency / Hz 50/60
Type of data definition ml State prelim. Speed / min Power input / W 1330 Power output / W 1100 Current draw / A 5.8 Rated torque / Ncm 350 Min. ambient temperature / °C Max. ambient temperature / °C
ml = Max. load · me = Max. efficiency · fa = Running at free air cs = Customer specs · cu = Customer unit
Subject to alterations
-1
200 .. 277
3000
-25
40
3.3 Technical features
Mass 14.8 kg Size 112 mm Material of electronics housing Housing material Die-cast aluminium Direction of rotation Counter-clockwise, seen on shaft Type of protection IP 55 Insulation class "B" Humidity class F3-1 Mounting position Any Cooling bore / aperture Rotor-side Operation mode S1 Motor bearing Ball bearing Technical features - Output 10 VDC, max. 10 mA
Translation of the original operating instructions
Die-cast aluminium
- Output 20 VDC, max. 50 mA
- Output for slave 0-10 V
- Tach output
- Input for sensor 0-10 V or 4-20 mA
- Alarm relay
- Integrated PID controller
- Motor current limit
- PFC, active
- RS485 MODBUS RTU
- Soft start
- Control input 0-10 VDC / PWM
- Control interface with SELV potential safely disconnected from the mains
- Over-temperature protected electronics / motor
- Line undervoltage / phase failure detection
Touch current acc. IEC 60990 (measuring network Fig. 4, TN system) Electrical leads Via terminal box Motor protection Thermal overload protector (TOP) wired
Protection class I (if earth wire is connected by customer) Product conforming to standard
For cyclic speed loads, note that the rotating parts of the device are designed for maximum one million load cycles. If you have specific questions, contact ebm-papst for support.
<= 3.5 mA
internally
EN 61800-5-1; CE
3.4 Mounting data
; Secure the mounting screws against accidentally coming loose (e.g.
by using self-locking screws).
Strength class for mounting screws
You can obtain additional mounting data from the product drawing if necessary.
8.8
3.5 Transport and storage conditions
; Use the device in accordance with its protection type.
Max. permissible ambient motor temp. (transp./ storage) Min. permissible ambient motor temp. (transp./storage)
+ 80 °C
- 40 °C
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M3G112-GA53-72
Operating instructions
4. CONNECTION AND START-UP
4.1 Connecting the mechanical system
WARNING Hot motor housing
Fire hazard
→ Ensure that no combustible or flammable materials are
located close to the motor.
CAUTION Cutting and crushing hazard when removing the motor from the packaging
→ Carefully remove the device from its packaging. Make sure
to avoid any shock.
→ 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.
; Check the device for transport damage. Damaged devices must no
longer be installed.
; Install the undamaged device according to your application.
4.2 Connecting the electrical system
DANGER Electric voltage on the device
Electric shock
→ Always install a protective earth first.
→ Check the protective earth.
DANGER Incorrect insulation
Risk of fatal injury from electric shock
→ Use only cables that meet the specified installation
requirements for voltage, current, insulation material, load etc.
→ Route cables such that they cannot be touched by any
rotating parts.
DANGER Electrical load (>50 µC) between mains wire and protective earth connection after switching of the supply when switching multiple devices in parallel.
Electric shock, risk of injury
→ Make sure that sufficient protection against accidental contact
is provided. Before working on the electrical connection, the connections to the mains supply and PE must be shorted.
CAUTION Electrical voltage
Translation of the original operating instructions
The motor is a built-in component and features no electrically isolating switch.
→ Only connect the motor to circuits that can be switched off
with an all-pole separating switch.
→ When working on the motor, you must switch off the
system/machine in which the motor is installed and secure it from being switched on again.
NOTE Water penetration into leads or wires
Water enters at the cable end on the customers side and can damage the device.
→ Make sure that the cable end is connected in a dry
environment.
Connect the device only to circuits that can be switched off using an all-pole disconnecting switch.
4.2.1 Prerequisites
; Check whether the data on the type plate agree with the connection
data.
; Before connecting the device, ensure that the supply voltage matches
the operating voltage of the device.
; Only use cables designed for current according to the type plate.
For determining the cross-section, follow the basic principles in accordance with EN 61800-5-1. The protective earth must have a cross-section equal to or greater than the outer conductor cross­section. We recommend the use of 105°C cables. Ensure that the minimum cable cross-section is at least AWG26/0.13 mm².
Earth wire contact resistance to EN 61800-5-1
Compliance with the impedance specifications to EN 61800-5-1 for the protective earth circuit must be verified in the end application. Depending on the installation situation, it may be necessary to install an additional protective earthing conductor via the additional protective earth connection point available on the device. The protective earth connection point is located on the housing and has a protective earth symbol and a bore hole.
4.2.2 Idle current
Because of the EMC filter integrated for compliance with EMC limits (interference emission and interference immunity), idle currents in the mains cable can be measured even when the motor is at a standstill and the mains voltage is switched on.
The values lie in a range of typical < 250 mA.
The effective power in this operating state (readiness for operation) is
simultaneously at typical < 4 W.
4.2.3 Residual current operated device
Only universal (type B or B+) RCD protective devices are permitted. Like frequency inverters, RCD protective devices cannot provide personal safety while operating the device. When switching on the power supply of the device, pulsed charge currents from the capacitors in the integrated EMC filter can lead to the RCD protective devices triggering without delay. We recommend residual current devices with a trigger threshold of 300 mA and delayed triggering (super-resistant, characteristic K).
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M3G112-GA53-72
4.2.4 Locked-rotor protection
Due to the locked-rotor protection, the start-up current (LRA) is equal to or less than the nominal current (FLA).
Operating instructions
4.3 Connection in terminal box
4.3.1 Preparing connection lines for the connection
Strip the cable just enough so that the screwed cable gland is tight and the terminals are relieved of strain. Tightening torque, see chapter 3.1 Product drawing.
4.3.2 Connecting cables with terminals
; Remove the cap from the screwed cable gland.
Remove the cap only in those places where cables are inserted.
; Mount the screwed cable glands with the seal inserts provided in the
terminal box.
; Insert the line(s) (not included in the standard scope of delivery) into
the terminal box.
; First connect the "PE" (protective earth) connection.
; Connect the lines to the corresponding terminals.
Use a screwdriver to do so. During the connection work, ensure that no cables splice off.
; Insert the strands until they meet resistance.
; Seal the terminal box.
4.3.3 Cable routing
No water may penetrate along the cable in the direction of the cable gland. When routing the cable, ensure that the screwed cable glands are arranged at the bottom. The cables must always be routed downwards.
4.4 Factory settings
Factory settings with which the device is pre-set by ebm-papst.
Control mode parameter set 1 Control mode parameter set 2 Fan / device adress 1 Max. PWM / % 100 Min. PWM / % 5 Save set value to EEPROM Set value control Analogue (linear) Control function parameter set 1 Control function parameter set 2
Translation of the original operating instructions
PWM controlling
PWM controlling
Yes
Positive (heating)
Positive (heating)
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M3G112-GA53-72
Operating instructions
4.5 Connection screen
No. Pin Signal Function / assignment KL1 1 L1 Mains supply connection, supply voltage 1~200-277 V AC; 50/60 Hz KL1 2 N Mains supply connection, supply voltage 1~200-277 V AC; 50/60 Hz PE PE Earth connection, PE connection KL2 1 NO Status relay, floating status contact; option 1: close with error; option 2: close with run monitor error message KL2 2 COM Status relay; floating status contact; changeover contact; common connection; contact rating 250 VAC / max.
2 A (AC1) / min. 10 mA
KL2 3 NC Status relay, floating status contact; option 1: break with error; option 2: break with error for run monitor error
message
KL3 1 RSA Bus connection RS485; RSA; MODBUS RTU KL3 2 RSB Bus connection RS485; RSB; MODBUS RTU KL3 3 GND Signal ground for control interface KL3 4 Ain1 U Analog input 1 (set value); 0-10 V; Ri= 100kOhm; parametrisable curve; only usable as alternative to input
Ain1 I
KL3 5 +10 V Fixed voltage output 10 VDC; + 10 V +/-3%; max. 10 mA; short circuit proof; power supply for ext. devices
(e.g. potentiometer)
KL3 6 Ain1 I Analog input 1 (set value); 4-20 mA; Ri= 100 Ohm; parametrisable curve; only usable as alternative to input
Ain1 U
KL3 7 Din1 Digital input 1: enabling of electronics; enabling: open pin or applied voltage 5 to 50 VDC; disabling: bridge to
GND or applied voltage < 0.8 VDC; reset function: triggers software reset after a level change to <0.8 V
KL3 8 Din2 Digital input 2: parameter set switch 1/2; according to EEPROM setting, the valid/used parameter set is
selectable per BUS or per digital input DIN2. Parameter set 1: open pin or applied voltage 5 to 50 VDC; parameter set 2: bridge to GND or applied voltage < 0.8 VDC
KL3 9 Din3 Digital input 3: control characteristic of the integrated controller; according to EEPROM setting, the control
characteristic of the integrated controller is normally/inversely selectable per BUS or per digital input; normal: open pin or applied voltage 5 to 50 VDC; inverse: bridge to GND or applied voltage < 0.8 VDC
KL3 10 GND Signal ground for control interface KL3 11 Ain2 U Analog input 2; actual sensor value 0-10 V; Ri= 100kOhm; parametrisable curve; only usable as alternative to
input Ain2 I
KL3 12 +20 V Fixed voltage output 20 VDC; + 20V +25/-10%; max. 50 mA; short circuit proof; power supply for ext.
devices (e.g. sensors)
KL3 13 Ain2 I Analog input 2; actual sensor value 4-20 mA; Ri= 100 Ohm; parametrisable curve; only alternative to input
Translation of the original operating instructions
KL3 14 Aout Analogue output 0-10 V; max. 5 mA; output of the actual motor control factor (output voltage of electronics)/ of
Ain2 U
the actual motor speed. Parametrisable curve.
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M3G112-GA53-72
Operating instructions
4.6 Checking the connections
; Make sure that the power is off (all phases).
; Secure it from being switched on again.
; Check the correct fit of the connection lines.
; Screw the terminal box cover closed again. Terminal box tightening
torque, see chapter 3.1 Product drawing.
; Route the connecting cables in the terminal box so that the terminal
box cover closes without resistance.
; Use all plug screws (the entire number). In doing so, insert the
screws manually to avoid damage to the thread.
; Make sure that the terminal box is correctly closed and sealed and
that all screws and screwed cable glands are properly tightened.
4.7 Switch on device
; 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.
4.8 Switching off the device
Switching off the device during operation:
; Switch on the device via the control input.
; Do not switch the motor (e.g. in cyclic operation) on and off via power
supply.
Switching off the device for maintenance work:
; Switch on the device via the control input.
; Do not switch the motor (e.g. in cyclic operation) on and off via power
supply.
; Disconnect the device from the supply voltage.
; When disconnecting, be sure to disconnect the earth wire connection
last.
5. INTEGRATED PROTECTIVE FUNCTIONS
The integrated protective functions cause the motor to switch off automatically in case of faults described in the table.
Malfunctions Description / Function of
safety feature
Rotor position detection error An automatic restart occurs. Locked rotor ; After the blockage is
removed, the motor restarts
automatically. Line under-voltage (mains input voltage outside of permitted nominal voltage)
; If the mains supply voltage
returns to permitted values, the
motor restarts automatically.
Translation of the original operating instructions
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M3G112-GA53-72
Operating instructions
6. MAINTENANCE, MALFUNCTIONS, POSSIBLE CAUSES AND REMEDIES
Do not perform any repairs on your device. Return the device to ebm­papst for repair or replacement.
CAUTION The motor restarts automatically when operating voltage is applied, e.g. after a power failure.
Danger of injury
→ Keep out of the danger zone of the motor.
→ When working on the motor, switch off the mains supply
voltage and secure the latter from being switched on again.
→ Wait until the motor stops.
CAUTION If control voltage is applied or a speed setpoint is stored, the motor automatically restarts, e.g. after a power failure.
Danger of injury
→ Keep out of the danger zone of the device.
→ When working on the device, switch off the mains
supply voltage and secure the latter from being switched on again.
→ Wait until the device stops.
→ After working on the device, remove any used tools or
other objects from the device.
If the device remains out of use for some time, e.g. when in storage, we recommend switching the device on for at least two hours to allow any condensate to evaporate and to move the bearings.
Malfunction/error Possible cause Possible remedy Rotor running roughly
Motor does not turn Mechanical blockage Switch off, de-
Translation of the original operating instructions
Imbalance in rotating parts
Mains supply voltage faulty
Faulty connection De-energise, correct
Thermal overload protector responded
Clean the device, if imbalance still evident after cleaning, replace device
energise, and remove mechanical blockage. Check mains supply voltage, restore power supply, apply control signal.
connection, see connection diagram. Allow motor to cool off, locate and rectify cause of error, if necessary cancel restart lock-out
Overtemperature of electronics/motor
If you have any other problems, contact ebm-papst.
6.1 Cleaning
NOTE Damage to the device during cleaning.
Malfunction possible
→ Do not clean the device using a high-pressure washer.
→ Do not use any cleaners containing acids, bases or
solvents.
→ Do not use any pointed or sharp-edged objects to clean.
6.2 Safety test
NOTE High-voltage test
The integrated EMC filter contains Y capacitors. Therefore, the trigger current is exceeded when AC testing voltage is applied.
→ Test the device with DC voltage when you carry out the
high-voltage test required by law. The voltage to be used corresponds to the peak value of the AC voltage required by the standard.
What has to be tested?
Device for damage Mounting the connection lines Check the insulation of the wires for damage Condensate discharge holes for clogging, as necessary
Insufficient cooling Improve cooling. Let
the device cool down. To reset the error message, switch off the mains supply voltage for a min. of 25 s and switch it on
again. Ambient temperature too high
Unacceptable operating point
How to test? Frequency Which
Visual inspection At least every
6 months
Visual inspection At least every
6 months
Visual inspection At least every
6 months
Visual inspection At least every
6 months
Reduce the ambient
temperature.
Reset by reducing
control input to 0.
Correct the operating
point. Let the device
cool down.
measure?
Replace device
Fasten
Replace wires
Open bore holes
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