ebm-papst R3G160-AC50-01 Operating Instructions Manual

Operating instructions

R3G160-AC50-01

Translation of the original operating instructions

ebm-papst Mulfingen GmbH & Co. KG

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

CONTENTS

1. SAFETY REGULATIONS AND INFORMATION

11. SAFETY REGULATIONS AND INFORMATION

Read these operating instructions carefully before starting work on the
device. Observe the following warnings to prevent malfunctions or
danger to persons.
These operating instructions are to be regarded as part of the device.
The device is only to be sold or passed on together with the operating
instructions.
These operating instructions may be duplicated and distributed to inform
about potential dangers and their prevention.

1.1 Hazard levels for warnings

11.1 Hazard levels for 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 will result in
death or serious injury if the specified actions are not taken.
Compliance with the instructions is imperative.

WARNING

Indicates a potentially hazardous situation which can result in
death or serious injury if the specified actions are not taken.
Exercise extreme caution while working.

CAUTION

Indicates a potentially hazardous situation which can result in
minor or moderate injury or damage to property if the specified
actions are not taken.

NOTE

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

1.2 Staff qualifications

11.2 Staff qualifications

The device may only be transported, unpacked, installed, operated,
maintained and otherwise used by suitably qualified, trained and
authorized technical staff.
Only authorized specialists are permitted to install the device, to carry
out a test run and to perform work on the electrical installation.

1.3 Basic safety rules

11.3 Basic safety rules

The safety hazards associated with the device must be assessed again
following installation in the final product.
The locally applicable industrial safety regulations are always to be
observed when working on the device.
Keep the workplace clean and tidy. Untidiness in the work area
increases the risk of accidents.
Note the following when working on the device:

; Do not perform any modifications, additions or conversions on the

device without the approval of ebm-papst.

1.4 Voltage

11.4 Voltage

; Check the device's electrical equipment at regular intervals; see

Chapter 6.2 Safety inspection.

; Replace loose connections and defective cables immediately.

DANGER
Electrically charged device

Risk of electric shock

→ When working on an electrically charged device, stand on a

rubber mat.

21.5 Safety and protective features

21.6 Electromagnetic radiation

21.7 Mechanical movement

21.8 Emissions

21.9 Hot surface

21.10 Transport

21.11 Storage

32. INTENDED USE

43. TECHNICAL DATA

43.1 Product drawing

63.2 Nominal data

63.3 Technical description

63.4 Mounting data

63.5 Transport and storage conditions

74. CONNECTION AND STARTUP

74.1 Mechanical connection

74.2 Electrical connection

74.3 Connecting the cables

84.4 Connection diagram

94.5 Checking connections

94.6 Switching on the device

94.7 Switching off the device

95. INTEGRATED PROTECTIVE FEATURES

96. MAINTENANCE, MALFUNCTIONS, POSSIBLE

CAUSES AND REMEDIES

106.1 Cleaning

106.2 Safety inspection

106.3 Disposal

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Operating instructions

R3G160-AC50-01

Translation of the original operating instructions

WARNING
Live terminals and connections even with device
switched off

Electric shock

→ Wait five minutes after disconnecting the voltage at all poles

before opening the device.

CAUTION
In the event of a fault, the rotor and the impeller will be
energized

The rotor and the impeller have basic insulation.

→ Do not touch the rotor and impeller once installed.

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

Risk of injury

→ Keep out of the device’s danger zone.

→ When working on the device, switch off the line voltage

and ensure that it cannot be switched back on.

→ Wait until the device comes to a stop.

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

objects from the device.

1.5 Safety and protective features

DANGER
Protective device missing and protective device not
functioning

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

→ Operate the device only with a fixed protective device and

guard grille.

→ The fixed protective device must be able to withstand the

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

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

are responsible for ensuring that the device is secured
adequately.

→ Stop the device immediately if you notice a missing or

ineffective protective device.

1.6 Electromagnetic radiation

Interference from electromagnetic radiation is possible, e.g. in conjunction
with open- and closed-loop control devices.
If impermissible radiation levels occur following installation, appropriate
shielding measures have to be taken by the user.

NOTE
Electrical or electromagnetic interference after installing
the device in customer equipment.

→ Verify that the entire setup is EMC-compliant.

1.7 Mechanical movement

DANGER
Rotating device

Risk of injury to body parts coming into contact with the rotor or
the impeller.

→ 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 and dangling items of clothing, jewelry and the like
can become entangled and be pulled into the device. Injuries
can result.

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

while working on rotating parts.

→ Protect long hair with a cap.

1.8 Emissions

WARNING
Depending on the installation and operating conditions,
the sound pressure level may exceed 70 dB(A).

Risk of noise-induced hearing loss

→ Take appropriate technical safety measures.

→ Protect operating personnel with appropriate safety

equipment such as hearing protection.

→ Also observe the requirements of local agencies.

1.9 Hot surface

CAUTION
High temperature on electronics housing

Risk of burns

→ Ensure sufficient protection against accidental contact.

1.10 Transport

NOTE
Transporting the device

→ Transport the device in its original packaging only.

1.11 Storage

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

protected against the weather and free from vibration, in the original
packaging in a clean environment.

; Protect the device against environmental effects and dirt until final

installation.

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

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

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

described prior to commissioning.

; Maintain the storage temperature, see

Chapter 3.5 Transport and storage conditions.

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Operating instructions

R3G160-AC50-01

Translation of the original operating instructions

2. INTENDED USE

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

Intended use also includes

● Use of the device in stationary systems only.

● Conveying air at an ambient air pressure between 800 mbar and

1050 mbar.

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

Chapter 3.5 Transport and storage conditions and
Chapter 3.2 Nominal data.

● Operating the device with all protective devices.

● Following the operating instructions.

Improper use

In particular, operating the device in the following ways is prohibited and
could be hazardous:

● Operating the device in an unbalanced state, e.g. due to dirt deposits

or ice formation.

● Resonant operation, operation with severe vibration. This also

includes vibration transmitted to the fan from the customer installation.

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

function.

● Conveying solids in the flow medium.

● Painting the device

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

● Conveying air that contains abrasive particles.

● Conveying highly corrosive air, e.g. salt spray. Exception: devices

designed for salt spray and correspondingly protected.

● Conveying air with high dust content, e.g. suctioning off sawdust.

● Operating the device close to flammable materials or components.

● Operating the device in an explosive atmosphere.

● Using the device as a safety component or to perform safety-related

functions.

● Operation with completely or partially disassembled or manipulated

protective devices.

● In addition, all applications not listed among the intended uses.

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Operating instructions

R3G160-AC50-01

Translation of the original operating instructions

3. TECHNICAL DATA

3.1 Product drawing

All dimensions in mm.

1 Accessory part: inlet ring 09588-2-4013 not included in scope of delivery
2 Tapping hole prepared for self-tapping M4 thread, max. screw-in depth 8 mm
3 Tapping hole prepared for self-tapping M4 thread, max. screw-in depth 6 mm
4 Screw-in depth 8-10 mm; tightening torque 2.5±0.2 Nm; gluing the screws is recommended
5 Cable PVC AWG18

3x wire-end ferrule

6 Cable PVC AWG22

4x wire-end ferrule

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Operating instructions

R3G160-AC50-01

Translation of the original operating instructions

All dimensions in mm.

Accessory part: inlet ring 09588-2-4013 not included in scope of delivery

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Operating instructions

R3G160-AC50-01

Translation of the original operating instructions

3.2 Nominal data

Motor M3G074-CF

Phase 1~
Nominal voltage / VAC 230
Nominal voltage
range / VAC

200 .. 277

Frequency / Hz 50/60

Method of obtaining
data

ml

Speed (rpm) / min

-1

2150

Power consumption / W 170
Current draw / A 1.25
Min. ambient
temperature / °C

-25

Max. ambient
temperature / °C

60

ml = Max. load · me = Max. efficiency · fa = Free air
cs = Customer specification · ce = Customer equipment

Subject to change

3.3 Technical description

Weight 2.0 kg
Size 160 mm
Motor size 74
Rotor surface Thick-film passivated (electroplated with

nickel)

Impeller material Sheet steel, galvanized
Direction of rotation Clockwise, viewed toward rotor
Degree of protection IP44; installation- and position-dependent
Insulation class "B"
Moisture (F) /
Environmental (H)
protection class

H1

Installation position Any
Condensation
drainage holes

None

Mode S1
Motor bearing Ball bearing
Technical features - Output 10 VDC, max. 1.1 mA

- Tach output

- Power limiter

- Motor current limitation

- Soft start

- Control input 0-10 VDC / PWM

- Control interface with SELV potential
safely disconnected from the mains

- Thermal overload protection for motor

Touch current
according to IEC
60990 (measuring
circuit Fig. 4, TN
system)

<= 3.5 mA

Motor protection Thermal overload protector (TOP)

internally connected

with cable Variable
Protection class I (with customer connection of protective

earth)

Conformity with
standards

EN 60335-1; CE

Approval CCC; UL 1004-7 + 60730-1; CSA

C22.2 No. 77 + CAN/CSA-E60730-1

With regard to cyclic speed loads, note that the rotating parts of
the device are designed for a maximum of one million load
cycles. If you have special questions, consult ebm-papst for
support.

; Use the device in accordance with its degree of protection.

Information on surface quality

The surfaces of the products conform to the generally applicable industrial
standard. The surface quality may change during the production period.
This has no effect on strength, dimensional stability and dimensional
accuracy.
The color pigments in the paints used perceptibly react to UV light over
the course of time. This does not however in any way affect the
technical properties of the products. The product is to be protected against
UV radiation to prevent the formation of patches and fading. Changes in
color are not a reason for complaint and are not covered by the warranty.

3.4 Mounting data

; Secure the screws against unintentional loosening (e.g. use self-

locking screws).

For screw clearance, see Chapter 3.1 Product drawing

Any further mounting data required can be taken from the product
drawing or Section Chapter 4.1 Mechanical connection.

3.5 Transport and storage conditions

Max. permitted
ambient temp. for
motor (transport/
storage)

+ 80 °C

Min. permitted
ambient temp. for
motor (transport/
storage)

- 40 °C

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Operating instructions

R3G160-AC50-01

Translation of the original operating instructions

4. CONNECTION AND STARTUP

4.1 Mechanical connection

CAUTION
Cutting and crushing hazard when removing fan from
packaging

→ Carefully remove the device from its packaging, by the fan

impeller. Strictly avoid shocks.

→ Wear safety shoes and cut-resistant safety gloves.

NOTE
Damage to the device from vibration

Bearing damage, shorter service life

→ The fan must not be subjected to force or excessive vibration

from sections of the installation.

→ If the fan is connected to air ducts, the connection should

be isolated from vibration, e.g. using compensators or similar
elements.

→ Ensure stress-free attachment of the fan to the

substructure.

; Check the device for transport damage. Damaged devices are not to

be installed.

; Install the undamaged device in accordance with your application.

CAUTION
Possible damage to the device

If the device slips during installation, serious damage can result.

→ Ensure that the device is securely positioned at its place of

installation until all fastening screws have been tightened.

● The fan must not be strained on fastening.

4.2 Electrical connection

DANGER
Voltage on the device

Electric shock

→ Always connect a protective earth first.

→ Check the protective earth.

DANGER
Faulty insulation

Risk of fatal injury from electric shock

→ Use only cables that meet the specified installation

regulations for voltage, current, insulation material, capacity,
etc.

→ Route cables so that they cannot be touched by any

rotating parts.

DANGER
Electrical charge (>50 µC) between phase conductor and
protective earth connection after switching off supply
with multiple devices connected in parallel.

Electric shock, risk of injury

→ Ensure sufficient protection against accidental contact.

Before working on the electrical hookup, short the supply
and PE connections.

CAUTION
Voltage

The fan is a built-in component and has no disconnecting switch.

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

an all-pole disconnection switch.

→ When working on the fan, secure the system/machine in

which the fan is installed so as to prevent it from being
switched back on.

NOTE
Device malfunctions possible

Route the device's control lines separately from the supply line.

→ Maintain the greatest possible clearance.

Recommendation: clearance > 10 cm (separate cable
routing)

NOTE
Water ingress into wires or cables

Water ingress at the customer end of the cable can damage the
device.

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

environment.

Only connect the device to circuits that can be switched off with
an all-pole disconnection switch.

4.2.1 Requirements

; Check whether the information on the nameplate matches the

connection data.

; Before connecting the device, make sure the power supply matches

the device voltage.

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

nameplate.
For determining the cross-section, note the sizing criteria according
to EN 61800-5-1. The protective earth must have a cross-section
equal to or greater than that of the phase conductor.
We recommend the use of 105 °C cables. Ensure that the minimum
cable cross-section is at least
AWG 26 / 0.13 mm².

Protective earth contact resistance according to EN 60335

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

4.2.2 Locked-rotor protection

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

4.3 Connecting the cables

The device has external leads.

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

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

observe Chapter 4.4 Connection diagram.

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Operating instructions

R3G160-AC50-01

Translation of the original operating instructions

4.4 Connection diagram

Drawing preliminary!

No. Conn. Designation Color Function/assignment

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

yellow

Protective earth

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

12 GND blue GND connection for control interface

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Operating instructions

R3G160-AC50-01

Translation of the original operating instructions

4.5 Checking connections

; Ensure isolation from supply (all phases).

; Make sure a restart is impossible

; Check the cables for proper fit.

4.6 Switching on the 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 hookup. This also applies for
devices which have already been equipped with plugs and terminals or
similar connectors by the customer.

WARNING
Hot motor housing

Risk of fire

→ Ensure that no combustible or flammable materials are

located close to the fan.

; Before switching on, check the device for visible external damage

and make sure the protective devices are functional.

; Check the fan's air flow paths for foreign matter and remove any

foreign matter found.

; Apply the nominal supply voltage.

; Start the device by changing the input signal.

NOTE
Damage to the device from vibration

Bearing damage, shorter service life

→ Low-vibration operation of the fan must be ensured over the

entire speed control range.

→ Severe vibration can arise for instance from inexpert

handling, transportation damage and resultant imbalance or
be caused by component or structural resonance.

→ Speed ranges with excessively high vibration levels and

possibly resonant frequencies must be determined in the
course of fan commissioning.

→ Either run through the resonant range as quickly as

possible with speed control or find another remedy.

→ Operation with excessively high vibration levels can

lead to premature failure.

4.7 Switching off the device

Switching off the device during operation:

; Switch off the device via the control input.

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

supply.

Switching off the device for maintenance:

; Switch off the device via the control input.

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

supply.

; Disconnect the device from the power supply.

; When disconnecting, be sure to disconnect the ground connection last.

5. INTEGRATED PROTECTIVE FEATURES

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

Fault Safety feature description/

function

Rotor position detection error An automatic restart follows.
Blocked rotor ; After the blockage is

removed, the motor restarts
automatically.

6. MAINTENANCE, MALFUNCTIONS, POSSIBLE
CAUSES AND REMEDIES

Do not perform any repairs on your device. Send the device to ebm­papst for repair or replacement.

WARNING
Live terminals and connections even with device
switched off

Electric shock

→ Wait five minutes after disconnecting the voltage at all poles

before opening the device.

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

Risk of injury

→ Keep out of the device’s danger zone.

→ When working on the device, switch off the line voltage

and ensure that it cannot be switched back on.

→ Wait until the device comes to a stop.

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

objects from the device.

NOTE

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

Malfunction/fault Possible cause Possible remedy
Impeller not
running smoothly

Imbalance in rotating
parts

Clean the device;
replace it if imbalance
persists after cleaning.
Make sure no
weight clips are
removed during
cleaning.

Motor not turning Mechanical blockage Switch off, isolate

from supply and
remove mechanical
blockage.

Line voltage faulty Check line voltage,

restore power
supply, apply control
signal.

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Operating instructions

R3G160-AC50-01

Translation of the original operating instructions

Faulty connection Isolate from supply,

correct connection;
see connection
diagram.

Motor/electronics
overtemperature

Deficient cooling Improve cooling. Let

the device cool down.
To reset the error
message, switch off
the line voltage for at
least 25 s and then

switch it on again.
Thermal overload
protector activated

Allow motor to cool

off, locate and rectify

cause of error,

release restart lockout

if necessary
Ambient temperature
too high

Reduce the ambient

temperature.

Reset by reducing

control input to 0.
Impermissible point of
operation

Correct the operating

point. Let the device

cool down.

In the event of further malfunctions, contact ebm-papst.

6.1 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 solvent-basedcleaning

agents.

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

6.2 Safety inspection

NOTE
High-voltage test

The integrated EMC filter has Y capacitors. The tripping current
is exceeded when AC testing voltage is applied.

→ Test the device with DC voltage when you perform the

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

What to check How to check How often What action?

Contact
protection
cover for
intactness or
damage

Visual inspection At least every

6 months

Repair or
replacement of
device

Device for
damage to
blades and
housing

Visual inspection At least every

6 months

Replacement of
device

Fastening the
cables

Visual inspection At least every

6 months

Fasten

Fastening the
protective earth
terminal

Visual inspection At least every

6 months

Fasten

Insulation of
cables for
damage

Visual inspection At least every

6 months

Replace cables

Impeller for
wear/deposits/
corrosion and
damage

Visual inspection At least every

6 months

Clean impeller
or replace device

Abnormal
bearing noise

acoustic At least every

6 months

Replace device

6.3 Disposal

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

6.3.1 Country-specific legal requirements

NOTE
Country-specific legal requirements

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

6.3.2 Disassembly

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

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

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

→ Secure components before unfastening to stop them falling.

6.3.3 Component disposal

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

● Steel and iron

● Aluminum

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

● Plastics, particularly with brominated flame retardants, in accordance

with marking

● Insulating materials

● Cables and wires

● Electronic scrap, e.g. circuit boards

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

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Operating instructions

R3G160-AC50-01

Translation of the original operating instructions

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

and steel.

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

● Miscellaneous insulators used in the terminal box

● Power cables

● Cables for internal wiring

● Electrolytic capacitors

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

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

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