ebm-papst VDC-3-49.15 User Manual

VDC-3-49.15

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Assembly instructions

ebm-papst St. Georgen GmbH & Co. KG

Hermann-Papst-Straße 1
78112 St. Georgen
Phone: [phone]
Fax: [phone]
www.ebmpapst.com

[e-mail]

3-phase external rotor motor in EC technology with

integrated electronic operation and control .

CONTENTS

1 Safety regulations and instructions 1

1.1 Warnings 1

1.2 Information symbols 2

1.3 Type plate 2

1.4 Staff qualification 2

1.5 Basic safety rules 2

1.6 Electrical voltage 2

1.7 Electromagnetic radiation 2

1.8 Mechanical movement 2

1.9 Noise emissions 3

1.10 Hot surface 3

1.11 Transport/storage/unpacking 3

1.12 Disposal 3

2 Use 3

2.1 Proper use 3

2.2 Reasonably foreseeable misuse 3

3 Technical data 4

3.1 Product drawing 4

3.2 Performance data 4

3.3 Technical description 5

3.4 Transport and storage conditions 5

4 Connection description 5

4.1 Pin configuration 5

4.2 Specification of the interface 5

4.3 Requirements for the drive power supply 8

5 Functional description 8

inal installation

5.1 Speed set value input function 8

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5.2 Torque set value input function 8

5.3 Actual value output/encoder signal function 8

5.4 Overvoltage/undervoltage protection function 9

5.5 Overtemperature protection function 9

5.6 I2t peak current limitation function 9

5.7 Acceleration and braking ramp function 9

5.8 Safe braking operation 9

5.9 "Zero speed" function 9

5.10 Optional functions 9

6 Connection and start-up 10

6.1 Connecting the mechanical system 10

6.2 Connecting the electrical system 10

6.3 Switching on and operating the drive 11

6.4 Integrated protective functions 11

7 MAINTENANCE, MALFUNCTIONS, POSSIBLE CAUSES

AND REMEDIES 12

7.1 Troubleshooting 12

7.2 Restarting after an error 13

7.3 Cleaning 13

7.4 Safety inspection 13

7.5 Service and support 13

8 Declaration of Incorporation 14

1 SAFETY REGULATIONS AND INSTRUCTIONS

Please read these assembly instructions carefully before starting to work
with the drive system. Observe the following warnings to prevent
malfunctions or physical damage to both property and people.

These assembly instructions are to be regarded as part of this drive system.

If the drive system is sold or transferred, the assembly instructions must
accompany it.

These assembly instructions may be duplicated and forwarded for
information about potential dangers and their prevention.

1.1 Warnings

1.1.1 Hazard levels of warnings

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

DANGE

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.

NOTE

potentially harmful situation can occur and, if not avoided,

can lead to property damage.

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VDC-3-49.15

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Assembly instructions

1.1.2 Pictograms

These pictograms are used in these assembly instructions and on the motor
if necessary.

Warning of a general hazard.

This warning sign appears in front of activities for which
hazards can be caused by multiple reasons.

Warning of hazardous electrical voltage

This warning sign appears in front of activities that carry a risk
of electric shock, possibly resulting in death.

Warning of hot surface

This warning sign appears in front of activities in which
hazards from hot surfaces exist.

Warning of property damage.

This warning sign appears in front of activities for which a risk
of property damage exists.

1.2 Information symbols

• For bulleted lists.

Æ Measures to avoid dangers.

⇒ Instructs you to take action.

1.6 Electrical voltage

⇒ Check the electrical equipment of the drive system on a regular basis.
⇒ Remove loose connections and defective cables immediately.

1.7 Electromagnetic radiation

Interference from electromagnetic radiation is possible, e.g. in conjunction
with open and closed-loop control devices.

If unacceptably high interference emission occurs when the device is
installed, the user must take suitable measures.

The product emits high-frequency EMC radiation.

For the respective data, refer to the specification.

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

When operating the drive system, interference may occur due
to the high switching frequencies and the switching process.
The electromagnetic compatibility of a machine depends on
the type of installation and the care exercised during
installation.

Æ Pay particular attention to design, filtering, shielding and

earthing.

Æ Ensure the electromagnetic compatibility in the end

device/installed condition.

1.3 Type plate

The type plate is installed on the edge of the motor flange.

1.3.1 Design of type plate

1

2

937 4915 6XX

XXVDC WW/YY XXXX XXXX

5

Fig.1 Design of type plate

1. Manufacturer

2. Product number

3. Serial number

4. Date code

5. Nominal voltage

1.4 Staff qualification

Only specialised electrical personnel may install the drive system, perform
the test run and work on the electrical system.

inal installation

Only trained and authorised specialist personnel are permitted to transport,

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unpack, assemble, operate or maintain the drive system, or to use it in any
other manner.

4

3

1.8 Mechanical movement

WARNING
Rotating shaft.

Body parts that come into contact with the shaft can be injured.

Æ Secure the drive system against accidental contact.
Æ Before working on the installation/machine, wait until all

parts have come to a standstill.

WARNING
Rotating shaft.

Long hair, loose items of clothing and jewellery could become
entangled and pulled into the drive system.
Danger of severe injuries.

Æ Do not wear any loose clothing or jewellery while working

on rotating parts.

Æ Protect long hair with a hood.

1.5 Basic safety rules

The safety hazards originating from the drive system must be re-evaluated
after installation in the end drive system.

When working on the drive system, observe the following information:

⇒ Do not make any modifications, additions or conversions to the drive

system without the approval of ebm-papst.

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ebm-papst St. Georgen GmbH & Co. KG · Hermann-Papst-Straße 1 · 78112 St. Georgen · Phone: [phone] · Fax: [phone] · www.ebmpapst.com · [e-mail]

VDC-3-49.15

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Assembly instructions

1.9 Noise emissions

Sound pressure level, SPL Lp < 63 db(A) (measured at free-running speed
and at a measuring distance of 250 mm).

Reference value valid for product number 937 4915 600.

1.10 Hot surface

CAUTION
High temperature on the motor.

Danger of burn injuries from hot surface.

Æ Ensure that sufficient protection against accidental

contact is provided.

1.11 Transport/storage/unpacking

⇒ Transport the motor in its original packaging only.
⇒ Check the motor after receipt to ensure that it is complete and

undamaged.

⇒ Store the drive system in the original packaging, in a dry and clean

place protected against weather conditions.

⇒ Protect the drive system from environmental impacts and dirt until the

final installation.

⇒ We recommend storing the drive system for a maximum of one year.
⇒ Observe the transport and storage conditions (refer to Chapter 3.4).

CAUTION
Motor is heavy.

The motor can fall down and cause crushing injuries.

Æ Wear safety shoes.

1.12 Disposal

⇒ When disposing of the drive system, comply with all relevant

requirements and regulations applicable in your country.

By request, a materials list can be created for various purposes. (Ex. RoHS,
REACH, overview of insulation materials)

2 USE

2.1 Proper use

The drive systems of the VDC-3-49.15 series are determined for installation
in stationary end devices and machines in the industrial area and must be
operated on electricity only when in installed condition!

Therefore, it must not be put into service until the machinery into which this
product is to be incorporated has been found and declared to be in
conformity with the protection requirements of the Machinery Directive.

This product is not intended for the end consumer. No provision is made for
use in a residential environment without further testing and the use of
correspondingly adapted EMC protective measures.

2.2 Reasonably foreseeable misuse

In particular, the following uses of the drive system are prohibited and can
lead to dangerous situations:

• Operating the drive system in the vicinity of flammable materials or

components.

• Operating the drive system in an explosive atmosphere.

• Using the drive system as a safety system component or for the

assumption of safety-related functions.

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

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Article No.: 194 0005 008 · Version: V1.0 · dated 08.11.2011 · Page 3 of 14
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VDC-3-49.15

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3 TECHNICAL DATA

3.1 Product drawing

Assembly instructions

Reference example (product number: 9374915600) All measurements in mm

Fig.2: Product drawing

3.2 Performance data

Designation Unit

Nominal voltage (UN) VDC 24 48
Permitted supply voltage range (UZK) VDC (XX to XX) 18 to 30 18 to 55
Nominal speed (nN) rpm 4 000 4 000
Nominal torque (MN) mNm 150 250

inal installation

Nominal current (IN)
Nominal output power (PN) W 63 105

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Free-running speed (nL) rpm 4 000 4 000
Free-running current (IL)
Max. reverse voltage VDC 36.7 63
Set value input VDC 0 to 10 0 to 10
Meximum speed rpm 0 to 4000 0 to 4000
Recomm. speed control range rpm 0 to 4000 0 to 4000
Locked-rotor protection thermal
Locked-rotor protection pulsing No
Protection from overload Yes
Starting torque mNm 300 500
Rotor moment of inertia (JR) kgm2x10
Thermal resistance (Rth) K/W - ­Protection class IP 54* IP 54*

mbient temperature range (TU) °C 0 to 40 0 to 40

Motor mass (m) kg 0.59 0.59

* Sealing on the flange side (towards the ball bearing) must be ensured in installed condition.

–6

DC-3-49.15 B00 VDC-3-49.15 D00

3.5 2.75

0.4 0.25

108 108

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VDC-3-49.15

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Assembly instructions

3.3 Technical description

Note: The performance data, dimensions and functions listed in these

assembly instructions apply for the corresponding standard designs of the
VDC-3-49.15 drive in 24 or 48 V with analogue set value input.
For deviating performance data, dimensions and/or functions, refer to the
corresponding product specifications and/or drawings of the corresponding
design variants.

3.4 Transport and storage conditions

Storage conditions EN 61800-1:1998

Climatic conditions EN 60721-3-1:1998
Ambient temperature

Climatic conditions EN 60721-3-1:1998
Relative humidity

Max. storage elevation m above sea

Transport conditions EN 61800-1:1998

Climatic conditions EN 60721-3-2:1998
Ambient temperature

Climatic conditions EN 60721-3-2:1998
Relative humidity at +40 °C

Class

°C

Class

%

level

Class

°C

Class

%

1K4

-25 to +55

1K3

5 to 95

3000

2K3

-25 to +70

2K3

95

4 CONNECTION DESCRIPTION

4.1 Pin configuration

4.2 Specification of the interface

Digital control inputs "A" (grey-pink) and "B" (violet) - digital input
signals

Via the control signals at inputs "A" and "B", the various operating states can
be selected according to the logic below.

Input level - TTL level

Low level V < 0.8

High level V > 2.0

Protection against
reverse polarity and
voltage

For cable break - Logic level "0"

Internal resistance kΩ 22

Applied logic level -

/B

V ≤ 30

=0/B=0 = Power stage disabled
A=1/B=0 = Direction of rotation* cw
A=0/B=1 = Direction of rotation* ccw
A=1/B=1 = Brake

* View onto the motor shaft from the
front

Designation Colour Description

Gnd Blue (AWG 16) Supply ground

UB Brown (AWG 16) Logic supply voltage

UZK Black (AWG 16) Supply voltage

A grey-pink Digital control input

B violet Digital control input

C black Hardware enable

D yellow Drive status: ready (yes/no)

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E red Actual speed output, Channel A

F+ red-blue

IST grey Actual speed output, Channel B

S1 Pink set value input

S2 brown Adjustable current limit

Data A white RS485 (Data +)

Data B green RS485 (Data -)

Not assigned (optional for variant with
frequency set value)

GND

Fig.3 Internal input wiring of inputs A and B

Digital control input "C" (black) - hardware enable

The control input "C" is used for targeted switching on/off of the power stage
of the drive, independent of the supply voltage. In addition, this input is used
for switching on again (acknowledgement) after a fault shut-off (fault status
at digital output "D"). Switch-on/acknowledgement takes place with a change
of the signal level from 0 to 1.

Input level - TTL level

Low level V < 0.8

High level V > 2.0

Protection against
reverse polarity and
voltage

For cable break - Power stage "OFF"

Internal resistance kΩ 8

Applied logic level -

V ≤ 22

0 = Power stage switched off
1 = Power stage switched on

Gnd Blue Logic Ground

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VDC-3-49.15

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Assembly instructions

Digital output signal "D" (yellow) – drive status

If certain errors and associated safety shut-offs of the drive occur, a low
signal (open collector) is output at output "D" as a fault-signal.

For a more detailed description of the corresponding protection functions,
refer to Chapter 5. The drive can only restart until after digital input "C" is
acknowledged (change of the signal level from 0 to 1).

NOTE
Output D is not short-circuit proof and has no reverse
polarity protection.

If the output is overloaded or incorrectly poled, this will damage
the output wiring.
Signals can no longer be evaluated.

Æ Observe the information for max. voltage and current.

Design - Open collector

Max. external voltage U

Collector current IC mA 1 < IC < 10

Saturation voltage U

Logic -

Digital output signals "E" (Channel A, red) and "IST" (Channel B, grey)
for information about speed and direction of rotation

Each of the two open collector outputs can be read out separately as actual
speed value information. A rectangular signal is present at both outputs, and
can be evaluated either as a frequency or as a number of pulses (e.g.
number of rising edges per revolution). By default, the frequency is defined
such that 6 pulses (signal periods) per revolution are output.
This results in the following relationship:

Signal frequency * 10 = speed in rpm.

For design variants that deviate from this, the information in the product
specification must be taken into account.

When evaluating both outputs, a 2-channel encoder replacement signal is
obtained; as a result, both the double speed information and the direction of
rotation can be identified via the assignment of the leading channel.

NOTE
Outputs E and IST are not short-circuit proof and have no
reverse polarity protection.

If the output is overloaded or incorrectly poled, this will damage
the output wiring.

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Signals can no longer be evaluated.

Æ Observe the information for max. voltage and current.

V ≤ 36

ext. max

V 0.4

CEsat

0 = Fault, drive inactive
1 = No fault, drive active

Design - Open collector

Max. external voltage U

Collector current IC mA 1 < IC < 10

Saturation voltage U

Max. output frequency kHz 1

Duty cycle ±2% % 50
Phase offset

to Channel B

±25 % ° 90
(IST)
Output of speed information at "E"
or "IST"
Encoder replacement signal,
Channel A/B information

Direction of rotation assignment

Fig.4 Schematic diagram of open collector output for E and IST

Fig.5 Rectangular signals at the outputs E and IST

V 36

ext. max

V 0.4

CEsat

Pulses per

revolution

Pulses per

revolution

12

Channel A leading

before Channel B =

cw

Channel B leading

before Channel A =

ccw

6

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VDC-3-49.15

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Analogue set value input "S1" (Pink)

Via this input, using a set value in the range from 0-10 VDC, any speed set
value in the range from 0 to n
voltage = 0 VDC), the motor remains at a standstill and attempts to control
the motor at maximum torque (holding torque) when there is an attempt to
move the drive. In the standard designs, n
different design variants, refer to the respective product specifications for the
value for n

max

.

NOTE
For drives in the design with input "S1" (analogue set
value), the frequency set value input is not defined.

Æ Do not connect input "F+".

Operating voltage range V 0 to 10

For cable break - Level "0"

Internal resistance kΩ 30

Set value range -

Signal resolution bit 10
Protection against reverse

polarity and voltage

. can be specified in rpm. Blank (set value

max

. is defined as 4000 rpm. For

max

50 mV to 9.9 V correspond to

. in rpm

0 to n

max

V ≤ 30

Analogue set value input "S2" (brown)

Via this input, with a set value in the range of 0-5 VDC, the current limit can
be specified in the range from 0 (no torque, motor does not move, rotor runs
freely) to 100 % (maximum torque). Therefore, input "S2" must be connected
in order to operate the drive. The current limit configured via input "S2" works
equally for driving and for braking.

Operating voltage range V 0 to 5

For cable break - Level "0"

Internal resistance kΩ 30

Set value input range -

0 to 5 V correspond to 0 to 100 %

(max. torque)
Signal resolution bit 9
Protection against reverse

polarity and voltage

V ≤ 30

S2

S1

GND

Fig.6 Internal input wiring of set value input S1

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Fig.7 Characteristics of set value input S1 for speed setting via analogue

voltage

GND

Fig.8 Internal input wiring of set value input S2

Fig.9 Characteristics of set value input S2 for torque specification via

analogue voltage

Frequency set value input "F+" (red-blue)

This input is available for drive versions with frequency set value only and is
used to specify a speed set value using a defined frequency signal. For
detailed information in this regard, refer to the product specification.

NOTE
For drives in the design with frequency set value input, the
input "S1" (analogue set value) is not defined.

Æ Do not connect input "S1".

RS-485 interface "Data A" and "Data B" (white / green)

NOTE
The RS-485 interface is not available in the basic variants.

The interface is used for adapting drive parameters or software
variants at the factory.

Æ Do not connect the RS 485 interface.

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ebm-papst St. Georgen GmbH & Co. KG · Hermann-Papst-Straße 1 · 78112 St. Georgen · Phone: [phone] · Fax: [phone] · www.ebmpapst.com · [e-mail]

VDC-3-49.15

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Assembly instructions

4.3 Requirements for the power supply of the drive system

The VARIODRIVE Compact VDC-3-49.15 is designed such that it can be
operated with separate power supplies for the power and logic. This allows,
for example, the power supply to be shut off while the logic power supply for
the motor sensors can remain active.

Power supply

24 V version 48 V

version

Operating voltage range UZK V 18 to 30 18 to 55

Max. intermediate circuit
voltage ripple
Reverse polarity protection UZK - No No

Max. supply current IZK

ssignment power supply - Blue (AWG 16) - "Gnd"

Logic power supply

24 V version 48 V version

uxiliary voltage supply

range

Auxiliary voltage supply UB -

Max. auxiliary current IB mA < 175 < 175

ssignment of logic

power supply

Note: When using one voltage source, U

bridge is important as otherwise the logic or power supply will be missing
and the drive will not run.

CAUTION
When using two independent voltage sources without a
low-resistance ground connection, potential shifts and
associated compensation currents may result.

Danger of malfunctions or damage to the internal motor
electronics.

Æ If two separate voltage sources are used for U

make a low-resistance connection between the ground of
both voltage sources.

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NOTE
Feeding back of power when braking or if in controlled
brake or cycle operation.

A reverse voltage of up to 36 V (for 24 V version) or up to 63 V
(48 V version) can occur. Danger for the power supply.

Æ When selecting the power supply, ensure corresponding

feedback protection.

UZK V ≤ 1 ≤ 1

<10 <10

Black (AWG 16) - "U

V > 9.5 to < 75 > 9.5 to < 75

U

B

Short-circuit

proof and

protected from

polarity reversal

Blue - "Gnd"

­Brown (AWG 16) - "U

and UZK must be bridged. The

B

Short-circuit

proof and

protected from

polarity reversal

"

B

and UZK,

B

ZK"

5 FUNCTIONAL DESCRIPTION

The VDC-3-49.15 drive system is an electronically commutated external
rotor motor with integrated operating and control electronics. Commutation
takes place in sinus commutation based on a field-oriented control (FOC).

The drive system works as a speed controller with speed limiter and ramp
function as well as with a current controller (torque controller) with torque
limitation.

5.1 Speed set value input function

Note: Specify the speed set value to operate the motor.

According to the illustration in Chapter 4.2 (analogue set value input "S1"),
this input can be used to specify a set value that corresponds to a speed in
the range from 0 rpm to n
listed in the specification and the listed control accuracy, the drive attempts
to adjust the speed to the specified set value, even when there are load
fluctuations. The same function is also available for the drives in the version
with set value input as a frequency signal. Here, a defined frequency signal
corresponding to the product specification must be applied at input "F+".

5.2 Torque set value input function

Note: Specify the torque set value to operate the motor.

According to the illustration in Chapter 4.2 (analogue set value input "S2"),
this input can be used to specify a set value via this input that corresponds to
a torque in the range from 0 to 100 % (peak torque, see "I
limitation"). Within the specified tolerance range, the maximum attainable
torque of the drive can be configured. In this way, movement operations can
be limited to a maximum permitted torque if necessary.
In conjunction with a corresponding speed set value, this function enables
torque-controlled winding or coil processes to be implemented, for example.

5.3 Actual value output/encoder signal function

For external monitoring of the actual speed of the drive, the two outputs "E"
and "IST" are available. Each of the two outputs, which are switched as open
collector, deliver a frequency signal with 6 pulses per revolution, for which
the following relationship applies:

Signal frequency * 10 = speed in rpm.

Via the electrical phase offset of 90° of both signals to each other, when
evaluating both channels, an encoder replacement signal with rotation
direction information and 12 pulses per revolution are obtained. For special
designs, a higher number of pulses can also be implemented with a limited
speed range and limited maximum speed. For detailed information in this
regard, refer to the respective product specification.

. Within the power and speed range of the motor

max

2

t peak current

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VDC-3-49.15

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5.4 Overvoltage/undervoltage protection function

The protection function takes effect at the limit values listed in the
specification (relative to the terminal voltage U

If one of the switching thresholds is reached, the output stage is switched off
to protect the system and the drive starts freewheeling.

If the drive exceeds the limits for short periods (< 250 ms, occurrence of any
fault peaks in the power supply), it resumes running if the voltage range
returns to a permitted level within this time.

If the limits are exceeded for a longer period (>= 250 ms - interpreted as a
fault in the system), the output stage is shut off and an fault-signal is output
at status output "D".

By acknowledging the enable input "C" (change of signal level 0 to 1), status
output "D" is reset and the drive is again ready for operation.

5.5 Overtemperature protection function

An NTC on the printed circuit board (close to the power stage) protects the
drive from gradual overheating.

If the NTC reaches a temperature of approx. 110 °C, the output stage is shut
off. The status output "D" outputs an fault-signal that remains pending until it
is acknowledged successfully.

After enable input "C" is "acknowledged" with a rising switching edge, the
drive can be switched back on.

If the motor switches off due to overtemperature, for thermal protection of the
drive, successful acknowledgement is not possible until the NTC
temperature falls back below 100 °C.

5.6 I2t peak current limitation function

The I2t peak current limitation function enables an increase of the torque to
the respective specified peak torque. A so called threshold current is used to
determine the amplitude at which the squaring of the portions of the current
that lie above the threshold value begins.

In the initial state, the threshold current is close to the maximum permitted
winding current, so that depending on the environmental and operating
conditions, it is well possible for the motor to be operated at peak torque for
a number of minutes. If the internal temperature threshold value is reached,
the threshold value of the current is lowered and squaring of the portions of
the current in excess of the threshold value begins. With loading of the I
memory, the available winding current is then lowered successively; as a
result, the drive is increasingly limited in order to prevent an overload.

5.7 Acceleration and braking ramp function

The maximum possible dynamic behaviour of the drive is defined via an
internally defined parameter value that affects acceleration and braking in

inal installation

the same way. The slope of the ramp, specified as a max. possible change
of speed per unit of time, is thus limited to the following values:

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24 V drive version: max. 16 rpm/ms
48 V drive version: max. 25 rpm/ms

Ex. for the 24 V drive version:

For an external set value jump from 0 to 1600 rpm, the internal set speed of
the motor increases from 0 to 1600 rpm via a corresponding ramp function
within 100 ms.
Usually, this limitation is noticeable only when the motor without load. In this
case, it serves to optimise the control and transient response to the target
speed.

).

ZK

5.8 Safe braking operation

Activating the braking function via control inputs "A/B" or via a negative set
value jump activates a controlled braking operation.

The energy released during braking is fed back and the intermediate circuit
voltage increases. To protect the drive, when the max. reverse voltage is
reached, the braking operation is interrupted and the power stage is disabled
for a short period (freewheeling).

As soon as the voltage falls back below a threshold value defined by a
hysteresis, the braking function is automatically re-enabled, braking energy
is fed back and the intermediate circuit voltage increases again.

This process repeats itself at short intervals until the motor has reached the
new set value speed or has come to a standstill.

5.9 "Zero speed" function

The "Hold zero speed" function can be activated either by specifying a
corresponding speed set value or corresponding signal on the two digital
inputs "A / B".

If an attempt is made to move the motor shaft in this state, the deviation from
the control-set-value is recognized and integrated over the time. The drive
responds with a counterholding torque which increases to the peak torque
depending on the displacement.

NOTE
The "Zero speed" function does not guarantee that a set
position will be maintained exactly.

Æ Ensure that any slight movement does not have any

harmful consequences.

NOTE

s a result of disturbances, even when the motor is
without load, the rotor can turn a few degrees out of the
original position over time in "Zero speed" operating state

Exactly maintaining a set position can not be guaranteed.

Æ Ensure that any slight movement does not have any

harmful consequences.

.

5.10 Optional functions

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According to prior agreement, additional and/or customer-specific functions
can be implemented.

Examples of possible options here include:

• Adaptation of speed control ranges

• Adaptation of application-specific control parameters

• Adaptation of resolution for actual value or encoder signal (possible

depending on speed)

• Speed set value input via PWM signal

• RS-485 as programming and communication interface

For design details of such specific adaptations, refer to the corresponding
product specification.

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VDC-3-49.15

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Assembly instructions

6 CONNECTION AND START-UP

6.1 Connecting the mechanical system

Fig.10: Connecting the mechanical system

CAUTION
Motor is heavy.

The motor can fall down and cause crushing injuries.

Æ Wear safety shoes.

Dimensions and specifications from the product drawing (refer to
Chapter 3.1)

⇒ Adapt the mounting plate [3] to the centring diameter of the motor, pitch

circle and size of the mounting holes.

⇒ Drill the holes into the mounting plate [3].
⇒ Determine the suitable screw length [4]:

Minimum screw length [4] = minimum depth of screw (6.5 mm) +
material thickness of the mounting plate [3].

Maximum screw length [4] = maximum depth of screw (9.5 mm) +
material thickness of the mounting plate [3].

⇒ Screw the self threading screws [5] through the mounting plate [3] into

the motor flange [2].
Use self threading screws according to DIN 7500.

⇒ Tighten the screws [5] equally and tightly, maximum screw-in torque 3

+/- 0.2

Nm.

NOTE
Danger of damage to the bearing system.
When mounting mechanical elements on the motor shaft,
the maximum permitted static axial load of the bearing

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system can be exceeded.

Danger of increased running noises, reduced life expectancy of
the drive.

Æ Observe the maximum permitted static axial load of

300 N.

CAUTION
Danger of being drawn in by rotating shaft.

The rotating shaft can draw in body parts.

Æ Ensure adequate protection against accidental contact

when installed.

CAUTION
The motor gets hot during operation.

Danger of burn injuries from hot surface.

Æ Ensure that sufficient protection against accidental

contact is provided.

Æ Let the motor cool down before touching it.

6.2 Connecting the electrical system

The extensive electrical interface of the motor offers a wide variety of options
for operating the motor and evaluating the signals provided via the interface.

The information from Chapter 4 must be observed.

⇒ Connect the drive system as outlined in Chapter 4.1.
⇒ Before switching on the voltage, ensure that the supply voltage is within

the permitted range (refer to Chapter 3.2 Terminal configuration)

The following illustration shows an overview of the possible terminal
configurations of the motor. For additional information about the individual
inputs and outputs, refer to Chapter 4 of these assembly instructions.

The minimum terminal configuration includes the terminals that have to be
connected at minimum in order to operate the drive.

The optional terminals provide additional options that can be used,
depending on the requirement, as status information, for evaluating the
actual speed or for the separate feed of the logic power supply.
These terminals are not necessary for basic operation.

The last 3 terminals are intended for design variants or for factory-internal
programming and must not be connected on the application side.

Fig.11 Terminal configuration

Note: The unconnected strands must be shortened and/or routed such that

no electrical contact between the wire ends can occur.

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ebm-papst St. Georgen GmbH & Co. KG · Hermann-Papst-Straße 1 · 78112 St. Georgen · Phone: [phone] · Fax: [phone] · www.ebmpapst.com · [e-mail]

VDC-3-49.15

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Assembly instructions

6.3 Switching on and operating the drive

CAUTION
The motor gets hot during operation.

Danger of burn injuries from hot surface.

Æ Protect the surface of the motor from being touched.
Æ Let the motor cool down before touching it.

For the sequence when switching on the drive, observe any requirements or
basic conditions from the respective application.

The following sequence is one possible example, which can be used
depending on the situation or has to be adapted according to the
requirements from the application. The limit values described in Chapter 4
must be observed.

⇒ Switch on the power supply for power and logic.
⇒ Apply the digital signals for inputs A / B.
⇒ Adjust the set value input for the current limit (in the simplest case, +5

VDC for max. possible torque).

⇒ Switch on the high level at the enable input "C" to make the drive ready

for operation.

⇒ Switch on/adjust the analogue set value for the speed (motor starts)

until the desired operating point is reached.

NOTE
If the drive is plugged in or unplugged with the voltage
turned on, high voltage peaks can occur.

The integrated electronics can be damaged (drive is not "hot­plug compatible").

Æ Only plug in/unplug the drive system when the supply

voltage is switched on/off.

6.4 Integrated protective functions

The integrated protective functions ensure that the drive shuts off
automatically under certain operating conditions or in case of certain faults.
For a more detailed description, refer to Chapter 5.

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VDC-3-49.15

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Assembly instructions

7 MAINTENANCE, MALFUNCTIONS, POSSIBLE CAUSES AND REMEDIES

⇒ Do not perform any repairs on your drive system.
⇒ Return the drive system to ebm-papst for repair or exchange.

7.1 Troubleshooting

When switching on

Malfunction / error Possible cause Possible remedy

Missing set value signals at inputs S1 and S2 Specify desired set value

Motor does not start, the power
supply is switched on and within the
specified range

The motor does not turn, the power
supply and control signals are
connected.

Motor accelerates briefly, then
switches off and runs down, fault
signal "D" is set.

In operation

Malfunction / error Possible cause Possible remedy

Motor makes "clacking noises" when
braking function is activated or there
is a negative set value jump

When operated for longer periods,

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the motor torque output declines

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When operated for longer periods,
the motor stops turning

Missing digital signal at one of the inputs
(A / B)

Missing signal level change (change from
0 to 1) at input "C" to set the motor to ready
state.

Load/required start-up torque are too high. Reduce load or check motor dimensioning.

Mechanical blockage Switch off drive, remove mechanical blockage in the powertrain and

Faulty connection Check that pin configuration and control signals are correct, see

Drive defective Replace drive

High load or high acceleration with power
supply that is not designed to bear this.
Power supply reaches performance limit,
voltage drops sharply and drive detects
undervoltage.

Braking function:
Motor goes into brake operation, the fed­back energy causes a voltage increase in the
intermediate circuit; when the max. reverse
voltage is reached, controlled brake
operation begins in order to protect the
system (refer to Chapter 5.8).

Thermal overload: Motor is operated too long
at high load/at elevated ambient
temperature. Motor heating causes lowering
of the winding current by the I
limitation

Thermal overload: Motor is operated too long
at high load/at elevated ambient
temperature. Motor heating finally causes a
shutoff via the integrated temperature
monitoring.

2

t peak current

Connect at least one of the two inputs for the desired operating
mode/direction of rotation

Switch on signal level at Input C again (change from 0 to 1)

attempt to restart

Chapter 4 and Chapter 6

If possible, reduce load or acceleration.
In the other case, check the dimensioning of the power supply and
use a more powerful power supply.

Use set value ramps instead of set value
reaction is needed, the fed-back energy can be removed more
quickly via an additional brake chopper in the intermediate circuit.

Check load point, ambient conditions and possibilities for heat
dissipation.
Reduce load, lower ambient temperature or provide better heat
dissipation.

Check load point, ambient conditions and possibilities for heat
dissipation.
Reduce load, lower ambient temperature or provide better heat
dissipation.
The drive cannot be switched on again until the NTC temperature
falls back to <100 °C.

umps. If a fast brake

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VDC-3-49.15

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Assembly instructions

7.2 Restarting after a fault

After a fault or safety shut-off occurs, an fault-signal is transmitted at output
"D" and the power stage is switched off. The drive cannot be switched on
again until the enable input "C" (switching with a rising switching edge) is
acknowledged.

NOTE

If a fault remains even after you carry out the remedies
described here, please contact ebm-papst.

7.3 Cleaning

NOTE
Possible damage of the drive system during cleaning

Danger of malfunctions.

Æ Do not clean the drive system using a water jet or high-

pressure washer.

Æ Do not use any cleaners containing acids, bases or

solvents.

7.4 Safety inspection

Carry out the following visual inspection before each time you start up the
drive system.

• Visual inspection for damage

• Visual inspection for adequate mechanical fastening

• Visual inspection for correctly routed connection lines and

insulation.

7.5 Service and support

If you have any questions or problems, the following contact options are
available to you to provide support and consulting:

• The contact persons of the respective subsidiaries.

• Your responsible domestic regional contacts.

• The responsible contacts for support in inside sales.

Contact address:

ebm-papst St. Georgen GmbH & Co. KG
Hermann-Papst-Str. 1
D-78112 St. Georgen, Germany
Phone: +49 7724 / 81 - 0
Fax: +49 7724 / 81 - 1309
E-mail: [e-mail]

7.5.1 Approval and marking

ebm-papst St. Georgen GmbH & Co. KG does not mark the drive systems
described in these assembly instructions with the "CE" mark and does not
issue an EC Declaration of Conformity. This decision is based on
consideration of the relevant EC Directives.

Low voltage directive 2006/95/EC and EMC directive 2004/108/EC:

The drive systems described in these assembly instructions do not fall within
the scope of application of these two guidelines.

Machinery Directive 2006/42/EC

According to the definition of the term in Art. 2, lit. g), a drive system is an
"partly completed machinery" and thus does not receive a CE mark, but falls
under the process for incomplete machines according to Art. 13.

Assembly instructions (which is this document) to Annex IV and a
Declaration of Incorporation (refer to Chapter 8 of the assembly instructions)
to Annex II, Part1, Section B is available.

The specific technical documents to Art. 13, Sect. (1), lit. a) have been
created in-house and are archived for the government agencies of the
individual countries.

The products described in the assembly instructions fulfil the valid directives
for RoHS-compliant products. Other toxic substances are not used in any
unacceptable quantity or concentration. By request, we can create a material
overview list for different specific requirements.

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Article No.: 194 0005 008 · Version: V1.0 · dated 08.11.2011 · Page 13 of 14
ebm-papst St. Georgen GmbH & Co. KG · Hermann-Papst-Straße 1 · 78112 St. Georgen · Phone: [phone] · Fax: [phone] · www.ebmpapst.com · [e-mail]

VDC-3-49.15

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8 DECLARATION OF INCORPORATION

Article 1, Par. 1, lit. g); Article 2, Par. g); Annex II, No. 1, Par. B

The manufacturer:

Assembly instructions

Declaration of Incorporation

For the incorporation of an incomplete machine acc. to

of the Machinery Directive 2006/42/EC

Name:

ddress: Hermann-Papst-Straße 1

declares for the partly completed machinery specified below

z that it is not an independently functioning machine as defined by Article 2 g) of the Machinery Directive specified below and, for this reason, does not conform

in all parts to the Basic safety and health protection requirements (Annex I).

z the application and compliance with the following

harmonised European Standards or other standards and/or technical requirements etc.

Source Date of issue Reference to Directive

EN ISO 14121-1 2007-09

EN 61800-5-1 2007-09

EN 61800-3 2004-12 Adjustable speed electrical power drive systems - Part 3: EMC requirements and specific test methods

ebm-papst St. Georgen GmbH & Co. KG

D-78112 St. Georgen i. Schwarzwald, Germany

VDC-3-49.15 motor series

Machinery Directive 2006/42/EC
Adjustable speed electrical power drive systems - Part 5-1:

Safety requirements. Electrical, thermal and energy requirements

z that the product(s) covered by this Declaration must not be put into service until the machinery into which this incomplete machine is to be incorporated or of

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which it is a component has been found and declared to be in conformity with the protection requirements of the Machinery Directive.

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z that the specific Technical Documents in accordance with Annex VII B have been created and are available in their entirety.
z that by request, the specific documents can be transmitted to the government authorities via data medium, electronically or on paper.

The protective rights remain with the manufacturer specified above.

St.Georgen, Germany / 2010-09-01

Place/Date p.p. Martin Csermak, Development Manager

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ebm-papst St. Georgen GmbH & Co. KG · Hermann-Papst-Straße 1 · 78112 St. Georgen · Phone: [phone] · Fax: [phone] · www.ebmpapst.com · [e-mail]