ebm-paps W3G910-KU25-03 User manual

Operating instructions
W3G910-KU25-03
Translation of the original operating instructions
ebm-papst Mulfingen GmbH & Co. KG
Bachmühle 2
D-74673 Mulfingen
Phone [phone]
Fax [phone]
[email protected]
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 6.3 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
31.11 Storage
32. INTENDED USE
43. TECHNICAL DATA
43.1 Product drawing
53.2 Nominal data
53.3 Data according to Commission Regulation (EU) 327/2011
53.4 Technical description
63.5 Mounting data
63.6 Transport and storage conditions
63.7 Electromagnetic compatibility
64. CONNECTION AND STARTUP
64.1 Mechanical connection
74.2 Electrical connection
84.3 Connection in terminal box
94.4 Factory settings
104.5 Connection diagram
114.6 Configuration options
124.7 Equivalent circuit diagrams
134.8 Checking connections
134.9 Switching on the device
134.10 Switching off the device
135. INTEGRATED PROTECTIVE FEATURES
136. MAINTENANCE, MALFUNCTIONS, POSSIBLE
CAUSES AND REMEDIES
146.1 Warning/status codes
156.2 Cleaning
156.3 Safety inspection
156.4 Disposal
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Operating instructions
W3G910-KU25-03
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
Guard missing and guard not functioning
Without a guard, hands may become caught up in the device
during operation for example, resulting in serious injury. Loose
parts or items of clothing could be drawn in.
→ The device is a built-in component. As the owner, you are
responsible for ensuring that the device is adequately
safeguarded.# Operate the device only with a fixed
protective device and guard grill.
→ Stop the device immediately if a protective device is
found to be missing or ineffective.
WARNING
Damage to guard grill, parts flying out
The guard grill is not suitable for heavy loads. Parts lying on the
guard grill or falling through the guard grill may be thrown out by
the fan when in operation.
→ Never step on the guard grill or subject the guard grill to load.
→ Do not place any objects on the guard grill.
→ There must be sufficient space around the fan to be able
to get past the fan.
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.
DANGER
Ejected parts
Missing protective devices may cause balancing weights or
broken fan blades to be ejected and cause injuries.
→ Take appropriate safety measures.
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
WARNING
Transporting the fan
Injuries from tipping or slipping
→ Wear safety shoes and cut-resistant safety gloves.
→ The fan is only to be transported in its original packaging.
→ The fan is to be transported lying flat, i.e. the motor axis
must be vertical.
→ Secure the fan(s) e.g. with a lashing strip to stop
anything slipping or tipping.
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Operating instructions
W3G910-KU25-03
Translation of the original operating instructions
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 3.6 Transport and storage conditions.
;Make sure that all cable glands are fitted with dummy plugs.
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
●The device is only to be used in power systems with grounded
neutral (TN/TT power systems), in power systems with phase
conductor grounding, or in IT power systems.
●The device is to be used in networks with network quality
characteristics as per EN 50160.
●Using the device only in stationary systems.
●Performing all maintenance work.
●Conveying air at an ambient air pressure between 800 mbar and
1050 mbar.
●Using the device within the permitted ambient temperature range; see
Chapter 3.6 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.
●Opening the terminal box 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
W3G910-KU25-03
Translation of the original operating instructions
3. TECHNICAL DATA
3.1 Product drawing
All dimensions in mm.
1Airflow direction "V"
2Cable diameter min. 4 mm, max. 10 mm, tightening torque 4 ± 0.6 Nm
(The tightening torque is designed for PVC cables. If the cable materials are different, the tightening torque may have to be adjusted)
3Tightening torque 1.5 ± 0.2 Nm
4Attachment holes for FlowGrid (91000-2-2957 not included in scope of delivery)
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Operating instructions
W3G910-KU25-03
Translation of the original operating instructions
3.2 Nominal data
Motor M3G150-IF
Phase 3~
Nominal voltage / VAC 400
Nominal voltage
range / VAC
380 .. 480
Frequency / Hz 50/60
Method of obtaining
data
ml
Speed (rpm) / min-1 980
Power consumption / W 2550
Current draw / A 3.9
Max. back pressure / Pa 220
Min. ambient
temperature / °C
-40
Max. ambient
temperature / °C
60
ml = Max. load · me = Max. efficiency · fa = Free air
cs = Customer specification · ce = Customer equipment
Subject to change
Occasional start-up at temperatures between -40 °C and -25 °C is
permitted. For continuous operation at ambient temperatures below -25
°C (such as refrigeration applications), a fan design with special low-
temperature bearings must be used.
3.3 Data according to Commission Regulation (EU) 327/
2011
Actual Req. 2015
01 Overall efficiency ηes / % 53.2 36.1
02 Measurement category A
03 Efficiency category Static
04 Efficiency grade N 57.1 40
05 Variable speed drive Yes
06 Year of manufacture The year of manufacture is specified on the
product's rating label.
07 Manufacturer ebm-papst Mulfingen GmbH & Co. KG
Amtsgericht (court of registration) Stuttgart ·
HRA 590344
D-74673 Mulfingen
08 Type W3G910-KU25-03
09 Power consumption Ped / kW 2.38
09 Air flow qv/ m³/h 23685
09 Pressure increase total pfs /
Pa
182
10 Speed (rpm) n / min-1 980
11 Specific ratio*1.00
12 Recycling/disposal Information on recycling and disposal is
provided in the operating instructions.
13 Maintenance Information on installation, operation and
maintenance is provided in the operating
instructions.
14 Additional components Components used to calculate the energy
efficiency that are not apparent from the
measurement category are detailed in the
CE declaration.
*Specific ratio = 1 + pfs / 100 000 Pa
Data obtained at optimum efficiency level. The efficiency values displayed for achieving
conformity with the Ecodesign Regulation EU 327/2011 has been reached with defined air
duct components (e.g. inlet rings). The dimensions must be requested from ebm-papst. If
other air conduction geometries are used on the installation side, the ebm-papst evaluation
loses its validity/the conformity must be confirmed again. The product does not fall within
the scope of Regulation (EU) 2019/1781 due to the exception specified in Article 2 (2a)
(motors completely integrated into a product).
3.4 Technical description
Weight 48 kg
Size 910 mm
Motor size 150
Rotor surface Painted black
Electronics housing
material
Die-cast aluminum, painted gray
Impeller material PP plastic
Fan housing material Sheet steel, galvanized and coated with
black plastic (RAL 9005)
Guard grille material Steel, coated with black plastic (RAL
9005)
Number of blades 5
Blade pitch 0°
Airflow direction V
Direction of rotation Clockwise, viewed toward rotor
Degree of protection IP55
Insulation class "F"
Moisture (F) /
Environmental (H)
protection class
H2
Ambient temperature
note
Occasional start-up at temperatures
between -40°C and -25°C is permitted.
For continuous operation at ambient
temperatures below -25°C (such as
refrigeration applications), use must be
made of a fan design with special low-
temperature bearings.
Installation position Shaft horizontal or rotor on bottom; rotor
on top on request
Condensation
drainage holes
On rotor side
Mode S1
Motor bearing Ball bearing
Technical features - Operation and alarm display with LED
- External 15-50 VDC input
(parameterization)
- Alarm relay
- Integrated PI controller
- Configurable inputs/outputs (I/O)
- MODBUS V6.3
- Motor current limitation
- RS-485 MODBUS-RTU
- Soft start
- Voltage output 3.3-24 VDC, Pmax =
800 mW
- Control interface with SELV potential
safely disconnected from the mains
- Thermal overload protection for
electronics/motor
- Line undervoltage / phase failure
detection
Touch current
according to IEC
60990 (measuring
circuit Fig. 4, TN
system)
<= 3.5 mA
Electrical hookup Terminal box
Motor protection Reverse polarity and locked-rotor
protection
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Operating instructions
W3G910-KU25-03
Translation of the original operating instructions
Protection class
assignment
I; If a protective earth is connected by
the customer
This component for installation may
have several local protection classes.
This information relates to this
component’s basic design.
The final protection class is based on
the component’s intended installation and
connection.
Conformity with
standards
EN 61800-5-1; CE
Approval CSA C22.2 No. 77 + CAN/CSA-
E60730-1; UL 1004-7 + 60730-1; EAC
Comment Maximum permissible operating altitude
4000 m above sea level according to
DIN 61800-5-1_2008_Sec. 4.3.6.4.1
overvoltage category II.
Up to 2000 m above sea level,
overvoltage category III applies.
;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. 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. UV radiation
in the frequency range and the intensity of natural solar radiation has no
effect on the technical properties of the products.
3.5 Mounting data
Any further mounting data required can be taken from the product
drawing or Section Chapter 4.1 Mechanical connection.
Strength class of
screws
8.8
;Secure the screws against unintentional loosening (e.g. use self-
locking screws).
3.6 Transport and storage conditions
Max. permitted
ambient temp. for
motor (transport/
storage)
+80 °C
Min. permitted
ambient temp. for
motor (transport/
storage)
-40 °C
3.7 Electromagnetic compatibility
EMC immunity to
interference
According to EN 61000-6-2 (industrial
environment)
EMC interference
emission
According to EN 61000-6-3 (household
environment), except EN 61000-3-2 for
professionally used equipment with a
total rated power greater than 1 kW
If several devices are connected in parallel on the supply side
so that the line current of the arrangement is in the range 16 - 75
A, this arrangement conforms to IEC 61000-3-12, provided that
the short-circuit power Ssc at the connection point of the
customer system to the public power grid is greater than or
equal to 250 times the rated output of the arrangement. It is the
responsibility of the installation engineer or operator/owner of the
device to ensure, if necessary after consultation with the
network operator, that this device is only connected to a
connection point with an Ssc value greater than or equal to 250
times the rated output of the arrangement.
4. CONNECTION AND STARTUP
4.1 Mechanical connection
CAUTION
Cutting and crushing hazard when removing device
from packaging
Blades can bend
→ Carefully remove the device from its packaging, by the fan
housing. Strictly avoid shocks.
→ Wear safety shoes and cut-resistant safety gloves.
CAUTION
Device weighs over 25 kg! Heavy load when unpacking
device.
Risk of physical injury, such as back injuries.
→ Use suitable hoisting equipment to remove the device from
its packaging.
CAUTION
The blades of the impeller could be damaged.
→ Carefully set down the fan on a soft surface. Make sure the
blades are not subjected to load.
→ Following installation, make sure the impeller moves
easily and that the blades of the impeller are not deformed or
bent and do not catch at any point.
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.
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Operating instructions
W3G910-KU25-03
Translation of the original operating instructions
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 61800-5-1
Compliance with the resistance specifications according to EN 61800-5-
1 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. The protective earth
terminal is located on the housing and provided with a protective earth
symbol and a hole.
4.2.2 Supply connection and fuses
Assignment of supply cable cross-sections and their required fuses (line
protection only, no equipment protection).
Nominal
voltage
Fuse Automatic
circuit
breaker
Cable
cross-
section
Cable
cross-
section
VDE UL VDE mm² *AWG
3/PE AC
380-480
VAC
16 A 15 A C16A 1.5 16
3/PE AC
380-480
VAC
20 A 20 A C20A 2.5 14
3/PE AC
380-480
VAC
25 A 25 A C25A 4.0 12
* AWG = American Wire Gauge
4.2.3 Reactive currents
Because of the EMC filter integrated for compliance with EMC
limits (interference emission and immunity to interference),
reactive currents can be measured in the supply line even
when the motor is at a standstill and the line voltage is switched
on.
●The values are typically in the range < 250 mA
●At the same time, the effective power in this operating state
(operational readiness) is typically < 5 W.
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Operating instructions
W3G910-KU25-03
Translation of the original operating instructions
4.2.4 Residual current circuit breaker (RCCB)
If the use of a residual current device (RCD) is required in your
installation, only AC/DC-sensitive residual current devices
(type B or B+) are permissible. As with variable frequency
drives, residual current devices cannot provide personal safety
while operating the device. When the device power supply is
switched on, pulsed charging currents from the capacitors in the
integrated EMC filter can lead to the instant tripping of residual
current devices. We recommend the use of residual current
circuit breakers (RCCB) with a trip threshold of 300 mA and
delayed tripping (super-resistant, characteristic K).
4.2.5 Leakage current
For asymmetrical power systems or if a phase fails, the
leakage current can increase to a multiple of the nominal value.
4.2.6 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 Connection in terminal box
4.3.1 Preparing cables for connection
Only strip the cable as far as necessary, ensuring that the cable gland is
sealed and there is no strain on the connections. For tightening torques,
see Chapter 3.1 Product drawing.
NOTE
Tightness and strain relief are dependent on the cable
used.
→ This must be checked by the user.
Fig. 1: Recommended stripped lengths (inside terminal box)
(1) supply line (2) control and relay line
4.3.2 Terminal connection data
Supply line
min. max.
Rigid cable cross-
section
0.2 mm² 4 mm²
Flexible cable cross-
section
0.2 mm² 4 mm²
AWG/kcmil cable
cross-section
24 12
Wire-end ferrules with
insulating collar,
in accordance with
DIN 46228-4 for
flexible cable
0.25 mm² 4 mm²
Wire-end ferrules
without insulating
collar,
in accordance with
DIN 46228-1 for
flexible cable
0.25 mm² 4 mm²
NOTE
The cable and cable cross-section must be selected taking into
account the max. starting current of the drive and the type of
cable routing (see Chapter 4.2.2 Supply connection and fuses)
Control and relay cables
min. max.
Rigid cable cross-
section
0.2 mm² 1.5 mm²
Flexible cable cross-
section
0.2 mm² 1.5 mm²
AWG/kcmil cable
cross-section
24 16
Wire-end ferrules with
insulating collar,
in accordance with
DIN 46228-4 for
flexible cable
0.14 mm² 0.75 mm²
Wire-end ferrules
without insulating
collar,
in accordance with
DIN 46228-1 for
flexible cable
0.25 mm² 1.5 mm²
NOTE
Crimping and pressing forms of the wire-end ferrules
For flexible control and relay cables, from a cable cross-section
of 1.0 mm², a trapezoid crimp is required to ensure correct
installation on the connector.
Fig. 2: Trapezoid crimp
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Operating instructions
W3G910-KU25-03
Translation of the original operating instructions
4.3.3 Connect cables to terminals
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.
;Open the terminal box.
;Remove the cap from the cable gland.
;Only remove caps where cables are fed in.
Fig. 3: Installing the connectors in the terminal box. The connectors
must engage properly.
;Depending on the cable diameter, the seals included in the terminal
box must be inserted into the cable gland if necessary.
;Route the cable(s) (not included in the scope of delivery) into the
terminal box.
;Ensure separate routing of the supply cable(s) and the cables for
status contact and control interface. Depending on the requirements for
the end device, the physical separation of these cables in the terminal
box may be mandatory. Use the partitions inside the terminal box as
an aid to routing for this purpose.
;First connect the protective earth "PE". Tightening torque 3.5 ±0.4 Nm
;Connect the cables to the corresponding terminals. Use a
screwdriver to do so. When connecting, make sure the wires do not
splay out. Insert the strands until they meet with resistance.
Fig. 4: Connection of cables at terminals
;There must not be any tensile stress between the terminal and the
cable gland. The cable must be provided with strain relief.
;The cable glands must be tight.
;Fit the terminal box cover, making sure that the sealing surfaces are
clean.
;Screw in the four screws (for tightening torque, see Chapter 3.1
Product drawing).
4.3.4 Cable routing
Water must be prevented from reaching the cable gland along the cable.
NOTE
Damage caused by moisture penetration.
Moisture can penetrate into the terminal box if water is
constantly present at the cable glands.
→ To prevent the constant accumulation of water at the cable
glands, the cable should be routed in a U-shaped loop
wherever possible.
→ If this is not possible, a drip edge can be produced by
fitting a cable tie directly in front of the cable gland for example.
Fans installed lying flat
Make sure the cable is routed in a U-shaped loop.
Fans installed upright
When routing the cable, make sure that the cable glands are located at
the bottom. The cables must always be routed downward.
4.4 Factory settings
Factory settings made for the device by ebm-papst.
Mode parameter set 1 PWM control
Mode parameter set 2 PWM control
Fan/device address 01
Max. PWM / % 100
Min. PWM / % 5
Save set value to
EEPROM
Yes
Set value requirement Analog (linear)
Direction of action
parameter set 1
Positive (heating)
Direction of action
parameter set 2
Positive (heating)
Item no. 55565-5-9970 · ENU · Change 247619 · Approved 2021-11-25 · Page 9 / 16
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Operating instructions
W3G910-KU25-03
Translation of the original operating instructions
4.5 Connection diagram
No. Conn. Designation Function/assignment
CON1 L1, L2, L3 Power supply, phase, see nameplate for voltage range
PE PE Protective earth
CON2 RSA RS485 interface for MODBUS, RSA; SELV
CON2 RSB RS485 interface for MODBUS, RSB; SELV
CON2 GND Reference ground for control interface, SELV
CON2 IO1 Function parameterizable (see “Optional interface functions” table)
Factory setting:
Digital input - high active, function: Disable input, SELV
- inactive: Pin open or applied voltage < 1.5 VDC
- active: applied voltage 3.5-50 VDC
Reset function: Triggering of error reset on change of state from "enabled" to "disabled"
CON2 IO2 Function parameterizable (see “Optional interface functions” table)
Factory setting:
Analog input 0-10 V / PWM, Ri=100 kΩ, function: Set value
Characteristic curve parameterizable (see input characteristic curve P1-IN), SELV
CON2 IO3 Function parameterizable (see “Optional interface functions” table)
Factory setting:
Analog output 0-10 V, max. 5 mA, function: Fan modulation level
Characteristic curve parameterizable (see output characteristic curve P3-OUT), SELV
CON2 Vout Voltage output 3.3-24 VDC ±5%, Pmax=800 mW, voltage parameterizable
Factory setting: 10 VDC
short-circuit-proof, supply for external devices, SELV
alternatively: 15-50 VDC input for parameterization via MODBUS without line voltage
CON2 COM Status relay, floating status contact, common connection, contact rating 250 VAC / 2 A (AC1) / min. 10 mA,
reinforced insulation on supply side and on control interface side
CON2 NC Status relay, floating status contact, break for failure
LED green: status = good, ready for operation
orange: status = warning
red: status = failure
P1-IN Input characteristic curve
P3-OUT Output characteristic curve
Item no. 55565-5-9970 · ENU · Change 247619 · Approved 2021-11-25 · Page 10 / 16
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Operating instructions
W3G910-KU25-03
Translation of the original operating instructions
4.6 Configuration options
For further information and additional functions see EC Control Software, Fan-Set-App, or MODBUS Parameter Specification V6.3
D101 [...]
D147 [...]
D104 [...]
D12E [...]
D
148 [...]
D16C [...]
D16A [...]
(selected directly
v
ia IO mode)
(
selected directly
v
ia IO mode)
D
130 [0]
D130 [1]
D130 [2]
D130 [5]
D00C [1]
D130 [4]
switch: direction of rotation: cw / ccw
source: set value
source: sensor value
switch: parameter set: #1 / #2
switch: control function: heating (pos.) /
cooling (neg.)
signal: system modulation level %
signal: remote control output 0-10V
pulse input for auto-adressing
pulse output for auto-adressing
switch: set value source
switch: fan enable / disable
signal: tach out
signal: diagnostics out
signal: fan modulation level %
signal: actual speed
configurable IO
functions: normal /
inverse
switch: direction of rotation: cw / ccw
source: set value
source: sensor value
switch: parameter set: #1 / #2
switch: control function: heating (pos.) /
cooling (neg.)
signal: system modulation level %
signal: remote control output 0-10V
pulse input for auto-adressing
pulse output for auto-adressing
switch: set value source
switch: fan enable / disable
signal: tach out
signal: diagnostics out
signal: fan modulation level %
signal: actual speed
CON2 configurable IO mode electrical specification
MODBUS Register for IO
mode configuration
Din1 (active high): digital input
not active: pin open or applied voltage < 1,5VDC
active: applied voltage 3,5-50VDC, SELV
D158 [0]
○ ○ ○ ○ ○ ○
○
Ain1 0-10V/PWM: analog input Ri = 100K, characteristic curve parameterizable, f
PWM
= 1k..10KHz, SELV D158 [2]
○ ○
○
Tach out (open collector output) Umax = 50VDC, Imax = 20mA, SELV D158 [5]
○
○
Diagnostics out (open collector output) Umax = 50VDC, Imax = 20mA, SELV D158 [6]
○
○
Din2 (active high): digital input
not active: pin open or applied voltage < 1,5VDC
active: applied voltage 3,5-50VDC, SELV
D159 [0]
○ ○ ○ ○ ○
Ain2 0-10V/PWM: analog input D159 [2]
Ri = 100K, characteristic curve parameterizable, f
PWM
= 1k..10KHz, SELV
○
Ain2 4-20mA: analog input Ri = 125R, characteristic curve parameterizable, SELV D159 [3]
○
Din3 (active high): digital input
not active: pin open or applied voltage < 1,5VDC
active: applied voltage 3,5-50VDC, SELV
D15A [0]
○
Din3 (active low): digital input
not active: pin open or applied voltage 3,5-50VDC
active: applied voltage < 1,5VDC, SELV
D15A [1]
○PWMin3: digital input,idle level high
PWM = 40Hz - 10kHz, characteristics parameterizable
active: pin open or applied voltage 3,5-50VDC
not active: applied voltage < 1,5VDC, SELV
D15A [7]
○
Aout3 0-10V: analog output function parameterizable, max. 5mA, max output frequency300Hz, SELV D15A [4]
○○○○ ○
○
Tacho out (pulses), analog output 0-10V max. 5mA, max output frequency 300Hz, SELV D15A [5]
○
○
Diagnostics out (pulses) 0-10V max. 5mA, max output frequency 300Hz, SELV D15A [6]
○
RSA RSB
RS485 bus connection, MODBUS RTU, specification V6.3, SELV
○
○ ○ ○ ○ ○
Vout
voltage output
voltage parameterizable 3,3...24VDC +/- 5%, Pmax=800mW, short-circuit-proof,
supply for external devices, SELV
15...50VDC
switch: direction of rotation: cw / ccw
source: set value
source: sensor value
switch: parameter set: #1 / #2
switch: control function: heating (pos.) /
cooling (neg.)
signal: system modulation level %
signal: remote control output 0-10V
pulse input for auto-adressing
pulse output for auto-adressing
IO1 IO2
○ ○
switch: set value source
switch: fan enable / disable
signal: tach out
signal: diagnostics out
signal: fan modulation level %
signal: actual speed
IO3
○ ○ ○ ○○
○configurable option
INPUT
OUTPUT
alternatively: Input auxillary power supply for
parameterization via RS485/MODBUS RTU without line
voltage
D16E [...]
○PWMin3: digital input,idle level low
40Hz - 10kHz, c haracteristics parameterizable
a
ctive: applied voltage 3,5-50VDC
not active: pin open or applied voltage < 1,5VDC, SELV
D15A [8]
○
Item no. 55565-5-9970 · ENU · Change 247619 · Approved 2021-11-25 · Page 11 / 16
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Operating instructions
W3G910-KU25-03
Translation of the original operating instructions
4.7 Equivalent circuit diagrams
Item no. 55565-5-9970 · ENU · Change 247619 · Approved 2021-11-25 · Page 12 / 16
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Operating instructions
W3G910-KU25-03
Translation of the original operating instructions
4.8 Checking connections
;Ensure isolation from supply (all phases).
;Make sure a restart is impossible
;Check the cables for proper fit.
;Screw the terminal box cover back on again. Terminal box tightening
torque, see Chapter 3.1 Product drawing.
;Route the cables in the terminal box so that the terminal box cover
closes without resistance.
;Use all screw plugs. Insert the screws by hand to avoid damage to
the threads.
;Make sure the terminal box is completely closed and sealed and that
all screws and cable glands have been properly tightened.
4.9 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.
4.10 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.
Line undervoltage (line voltage
outside of permitted nominal
voltage range)
;If the line voltage returns to
permitted values, the motor
restarts automatically.
Phase failure A phase of the supply voltage
fails for at least 5 s.
;When all phases are correctly
supplied again, the motor
automatically restarts after 10-40
s.
6. MAINTENANCE, MALFUNCTIONS, POSSIBLE
CAUSES AND REMEDIES
Do not perform any repairs on your device. Send the device to ebm-
papst 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 three hours
once a month to move the bearings and allow any condensate
that may have ingressed to evaporate.
Malfunction/fault Possible cause Possible remedy
Item no. 55565-5-9970 · ENU · Change 247619 · Approved 2021-11-25 · Page 13 / 16
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Operating instructions
W3G910-KU25-03
Translation of the original operating instructions
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.
Attention! The error
message resets
automatically.
Device restarts
automatically without
warning.
Faulty connection Isolate from supply,
correct connection;
see connection
diagram.
Broken motor winding Replace device
Inadequate cooling Improve cooling.
Allow the device to
cool down.
Ambient temperature
too high
Reduce the ambient
temperature. Allow
the device to cool
down.
Impermissible
operating point (e.g.
back pressure too
high)
Correct the operating
point. Allow the
device to cool down.
In the event of further malfunctions, contact ebm-papst.
6.1 Warning/status codes
The LED on the electronics housing shows the motor status with various
colors and flash codes. The flash codes have a frequency of 2 Hz.
Each flash code is followed by a pause lasting 3 seconds. The following
colors are used: Green: no warning or fault. Orange: There is a warning.
No user intervention is required for warnings. Red: There is at least one
error. See the following table. If there are multiple simultaneous errors,
their associated flash codes are displayed in succession. If there are
simultaneous warnings and errors, only the errors are displayed.
6.1.1 Warning codes
Number of pulses Motor status - LED
orange
Message at status
relay
1 Current limitation in
action
2 Line impedance too
high (DC-link voltage
unstable)
3 Power limiter in action
4 Output stage
temperature high
5 Motor temperature high
6 Temperature inside
electronics high
7 DC-link voltage low
8 Braking mode: set in
case of external drive
in opposite direction
at high speed for
lengthy period
Yes
9 Calibration of rotor
position sensor in
progress
10 Actual speed is lower
than run monitoring
speed limit
Yes
11 Open circuit at analog
input or PWM input
for the set value
Yes
13 DC-link voltage high
15 Line voltage high
16 Shake-loose function
activated
6.1.2 Status codes
Manual reset by "Switch off line voltage - wait briefly - switch line
voltage back on" or, if provided,
via the "Fan enable/disable" input
Number of
pulses
Motor status -
LED red
Possible cause Possible
remedy
1 Phase failure or
line undervoltage
Missing phase
Poor power
supply quality
Check line
voltage
3 Output stage
overheating
Electronics
housing
contaminated
Provide better
cooling.
Manual reset
required
4 Communication
error between
master
controller and
slave controller
External
supply applied
via Vout for
setting
parameters.
Internal error
Switch off line
voltage
- wait -
switch back on
6 Motor
overheating
Ambient
temperature too
high
Impermissible
operating point
Reduce
ambient
temperature
Correct
operating point.
Manual reset
required
7 Hall sensor error Internal error Switch off line
voltage
- wait -
switch back on
8 Motor blocked Mechanical
blockage
Switch off
- check safe
isolation from
supply -
check
freedom of
movement of
rotor
Item no. 55565-5-9970 · ENU · Change 247619 · Approved 2021-11-25 · Page 14 / 16
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Operating instructions
W3G910-KU25-03
Translation of the original operating instructions
9 Speed limit
exceeded
- -
11 Rotor position
sensor
calibration error
Observe
ebm-papst
replacement
instructions
Rotor position
sensor
calibration
necessary.
Notify ebm-
papst
13 DC-link
undervoltage
Line voltage not
OK
Check the line
voltage applied.
6.2 Cleaning
To ensure a long service life, check the fans regularly for proper
operation and soiling. The frequency of checking is to be adapted
accordingly depending on the degree of soiling.
DANGER
Risk of injury from rotating fan.
→ Only clean when not in motion. Do not disconnect the fan
from the power supply, just switch it off via the control input.
This will prevent start-up of the fan.
;Dirt deposits on the motor housing can cause overheating of the motor.
;Soiling of the impeller can cause vibration that will shorten the service
life of the fan.
;Severe vibration can destroy the fan.
;In such cases, switch off the fan immediately and clean it.
;The preferred method of cleaning is dry cleaning, e.g. using
compressed air.
;Do not use aggressive cleaning agents!
NOTE
Damage to the device during cleaning
Malfunction possible
→ Do not clean the device using a high-pressure cleaner.# Do
not use acid, alkali or solvent-based cleaning agents.
→ Do not use any pointed or sharp-edged objects for
cleaning.
;Completely remove any cleaning agents used.
;If severe corrosion is visible on load-bearing or rotating parts, switch
off the device immediately and replace it.
;Repair of load-bearing or rotating parts is not permitted!
;Operate the fan for 2 hours at maximum speed so that any water that
has ingressed can evaporate.
;If cleaning does not eliminate vibrations, the fan may need to be
rebalanced. To have it rebalanced, contact ebm-papst.
;The fan is equipped with maintenance-free ball bearings. The lifetime
lubrication of the ball bearings is designed for a service life of 40,000
hours.
;If bearing replacement is necessary after that period, contact ebm-
papst.
;Adapt the maintenance intervals to the actual level of dust exposure.
6.3 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
Insulation of
cables for
damage
Visual inspection At least every
6 months
Replace cables
Tightness of
cable gland
Visual inspection At least every
6 months
Retighten,
replace if
damaged
Condensation
drainage holes
for clogging,
where necessary
Visual inspection At least every
6 months
Open holes
Welds for crack
formation
Visual inspection At least every
6 months
Replace device
Abnormal
bearing noise
acoustic At least every
6 months
Replace device
6.4 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.
6.4.1 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.
Item no. 55565-5-9970 · ENU · Change 247619 · Approved 2021-11-25 · Page 15 / 16
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Operating instructions
W3G910-KU25-03
Translation of the original operating instructions
6.4.2 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.
6.4.3 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.
;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.
Item no. 55565-5-9970 · ENU · Change 247619 · Approved 2021-11-25 · Page 16 / 16
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