Ebmpapst G3G190-RP03-04 User manual

Operating instructions
G3G190-RP03-04
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 6.2 Safety inspection.
;Replace loose connections and defective cables immediately.
DANGER
Electrically charged device
Risk of electric shock
→ When working on an electrically charged device, stand on a
rubber mat.
21.5 Safety and protective features
21.6 Electromagnetic radiation
21.7 Mechanical movement
21.8 Emissions
21.9 Hot surface
21.10 Transport
21.11 Storage
32. INTENDED USE
43. TECHNICAL DATA
43.1 Product drawing
53.2 Nominal data
53.3 Technical description
53.4 Mounting data
53.5 Transport and storage conditions
53.6 Electromagnetic compatibility
64. CONNECTION AND STARTUP
64.1 Mechanical connection
64.2 Electrical connection
74.3 Connecting the cables
84.4 Connection diagram
94.5 Checking connections
94.6 Switching on the device
94.7 Switching off the device
95. INTEGRATED PROTECTIVE FEATURES
96. MAINTENANCE, MALFUNCTIONS, POSSIBLE
CAUSES AND REMEDIES
106.1 Cleaning
106.2 Safety inspection
106.3 Disposal
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Operating instructions
G3G190-RP03-04
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.
DANGER
Voltage!
Risk of electric shock
→ The electronics cover and, if available, the motor and
connection-side connectors and cables in the connector area
may be live in the event of a fault. They must not be able to
be touched after they have been installed for their intended
purpose.
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.
1.6 Electromagnetic radiation
Interference from electromagnetic radiation is possible, e.g. in conjunction
with open- and closed-loop control devices.
If impermissible radiation levels occur following installation, appropriate
shielding measures have to be taken by the user.
NOTE
Electrical or electromagnetic interference after installing
the device in customer equipment.
→ Verify that the entire setup is EMC-compliant.
1.7 Mechanical movement
DANGER
Rotating device
Risk of injury to body parts coming into contact with the rotor or
the impeller.
→ Secure the device against accidental contact.
→ Before working on the system/machine, wait until all
parts have come to a standstill.
WARNING
Rotating device
Long hair and dangling items of clothing, jewelry and the like
can become entangled and be pulled into the device. Injuries
can result.
→ Do not wear any loose-fitting or dangling clothing or jewelry
while working on rotating parts.
→ Protect long hair with a cap.
1.8 Emissions
WARNING
Depending on the installation and operating conditions,
the sound pressure level may exceed 70 dB(A).
Risk of noise-induced hearing loss
→ Take appropriate technical safety measures.
→ Protect operating personnel with appropriate safety
equipment such as hearing protection.
→ Also observe the requirements of local agencies.
1.9 Hot surface
CAUTION
High temperature on electronics housing
Risk of burns
→ Ensure sufficient protection against accidental contact.
1.10 Transport
NOTE
Transporting the device
→ Transport the device in its original packaging only.
1.11 Storage
;Store the device, partially or fully assembled, in a dry place,
protected against the weather and free from vibration, in the original
packaging in a clean environment.
;Protect the device against environmental effects and dirt until final
installation.
;We recommend storing the device for no longer than one year in
order to guarantee trouble-free operation and the longest possible
service life.
;Even devices explicitly intended for outdoor use are to be stored as
described prior to commissioning.
;Maintain the storage temperature, see
Chapter 3.5 Transport and storage conditions.
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Operating instructions
G3G190-RP03-04
Translation of the original operating instructions
2. INTENDED USE
The device is exclusively designed as a built-in device for conveying
air according to its technical data.
Any other usage above and beyond this does not conform with the
intended purpose and constitutes misuse of the device.
Customer equipment must be capable of withstanding the mechanical
and thermal stresses that can arise from this product. This applies for the
entire service life of the equipment in which this product is installed.
Intended use also includes
●Use of the device in stationary systems only.
●Performance of 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 3.5 Transport and storage conditions and
Chapter 3.2 Nominal data.
●Operating the device with all protective devices.
●Following the operating instructions.
Improper use
In particular, operating the device in the following ways is prohibited and
could be hazardous:
●Operating the device in an unbalanced state, e.g. due to dirt deposits
or ice formation.
●Resonant operation, operation with severe vibration. This also
includes vibration transmitted to the fan from the customer installation.
●Operation in medical equipment with a life-sustaining or life-support
function.
●Conveying solids in the flow medium.
●Painting the device
●Connections (e.g. screws) coming loose during operation.
●Conveying air that contains abrasive particles.
●Conveying highly corrosive air, e.g. salt spray. Exception: devices
designed for salt spray and correspondingly protected.
●Conveying air with high dust content, e.g. suctioning off sawdust.
●Operating the device close to flammable materials or components.
●Operating the device in an explosive atmosphere.
●Using the device as a safety component or to perform safety-related
functions.
●Operation with completely or partially disassembled or manipulated
protective devices.
●In addition, all applications not listed among the intended uses.
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Operating instructions
G3G190-RP03-04
Translation of the original operating instructions
3. TECHNICAL DATA
3.1 Product drawing
All dimensions in mm.
1Cable PVC AWG22
3x splice
2Cable PVC AWG20
3x splice
3Tapping hole prepared for self-tapping screw for fastening plastics (Remform) dia. 4 mm, clearance for screw max. 15 mm. The torque is
to be determined on the basis of the screw.
45x sheet metal nut for thread EN ISO 1478-ST4.8 (max. screw length 16 mm plus thickness of mounting material)
5Screw-on domes are only permissible for Flowgrid!
6Connecting sleeve not suitable for installation with pipe clamps
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Operating instructions
G3G190-RP03-04
Translation of the original operating instructions
3.2 Nominal data
Motor M3G055-BI
Phase 1~
Nominal voltage / VAC 230
Nominal voltage
range / VAC
200 .. 240
Frequency / Hz 50/60
Method of obtaining
data
ml
Speed (rpm) / min-1 3050
Power consumption / W 72
Current draw / A 0.7
Min. ambient
temperature / °C
-25
Max. ambient
temperature / °C
60
ml = Max. load · me = Max. efficiency · fa = Free air
cs = Customer specification · ce = Customer equipment
Subject to change
3.3 Technical description
Weight 1.95 kg
Size 190 mm
Motor size 55
Rotor surface Thick-film passivated
Impeller material PP plastic
Housing material PP plastic
Number of blades 7
Direction of rotation Clockwise, viewed toward rotor
Degree of protection Motor IP54, electronics IP20
Insulation class "B"
Moisture (F) /
Environmental (H)
protection class
H0+
Installation position Any
Condensation
drainage holes
None, open rotor
Mode S1
Motor bearing Ball bearing
Technical features - Power limiter
- Motor current limitation
- RS-485 MODBUS-RTU
- Soft start
- Control interface with SELV potential
safely disconnected from the mains
- Overvoltage detection
- Thermal overload protection for
electronics/motor
- Line undervoltage detection
Touch current
according to IEC
60990 (measuring
circuit Fig. 4, TN
system)
<= 3.5 mA
Motor protection Electronic motor protection
with cable Variable
Protection class I (with customer connection of protective
earth)
Conformity with
standards
EN 60335-1; UKCA; CE
;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.
3.4 Mounting data
Further mounting data can be taken from the product drawing or Chapter
4.1 Mechanical connection as required.
Strength class of
screws
8.8
For screw clearance, see Chapter 3.1 Product drawing
;Secure the screws against unintentional loosening (e.g. use self-
locking screws).
3.5 Transport and storage conditions
Max. permitted
ambient temp. for
motor (transport/
storage)
+ 80 °C
Min. permitted
ambient temp. for
motor (transport/
storage)
- 40 °C
3.6 Electromagnetic compatibility
EMC immunity to
interference
According to EN 61000-6-2 (industrial
environment)
EMC circuit feedback According to EN 61000-3-2/3
EMC interference
emission
According to EN 61000-6-3 (household
environment)
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Operating instructions
G3G190-RP03-04
Translation of the original operating instructions
4. CONNECTION AND STARTUP
4.1 Mechanical connection
CAUTION
Cutting and crushing hazard when removing blower
from packaging
→ Carefully remove the blower from its packaging, touching
only the housing. Strictly avoid shocks.
→ Wear safety shoes and cut-resistant safety gloves.
NOTE
Damage to the device from vibration
Bearing damage, shorter service life
→ The fan must not be subjected to force or excessive vibration
from sections of the installation.
→ If the fan is connected to air ducts, the connection should
be isolated from vibration, e.g. using compensators or similar
elements.
→ Ensure stress-free attachment of the fan to the
substructure.
;Check the device for transport damage. Damaged devices are not to
be installed.
;Install the undamaged device in accordance with your application.
4.1.1 Installing the fan
Attach the fan to the contact surfaces intended for this purpose. The air
must be able to circulate freely in the area of the electronics (1), adequate
ventilation must be ensured. The electronics (1) must not be covered up.
Fig. 1: Installed fan
DANGER
Voltage!
Risk of electric shock
→ The electronics cover and, if available, the motor and
connection-side connectors and cables in the connector area
may be live in the event of a fault. They must not be able to
be touched after they have been installed for their intended
purpose.
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 device is a built-in component and has no disconnecting
switch.
→ Only connect the device to circuits that can be switched off
with an all-pole disconnection switch.
→ When working on the device, secure the system/
machine in which the device is installed so as to prevent it
from being switched back on.
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.
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Operating instructions
G3G190-RP03-04
Translation of the original operating instructions
4.2.1 Requirements
;Check whether the information on the nameplate matches the
connection data.
;Before connecting the device, make sure the power supply matches
the device voltage.
;Only use cables designed for the current level indicated on the
nameplate.
For determining the cross-section, note the sizing criteria according
to EN 61800-5-1. The protective earth must have a cross-section
equal to or greater than that of the phase conductor.
We recommend the use of 105 °C cables. Ensure that the minimum
cable cross-section is at least
AWG 26 / 0.13 mm².
Protective earth contact resistance according to EN 60335
Compliance with the resistance specifications according to EN 60335 for
the protective earth connection circuit must be verified in the end
application. Depending on the installation situation, it may be necessary
to connect an additional protective earth conductor by way of the extra
protective earth terminal provided on the device.
4.2.2 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 < 50 mA
●At the same time, the effective power in this operating state
(operational readiness) is typically < 2 W.
4.2.3 Residual current circuit breaker (RCCB)
If the use of a residual current device (RCD) is required in your
installation, only pulse-current sensitive and/or AC/DC-
sensitive residual current devices (type F or B) are
permissible. As with variable frequency drives, residual current
devices cannot provide personal safety while the device is
being operated. When the device power supply is switched on,
pulsed charging currents from the capacitors in the integrated
EMC filter can lead to the residual current devices tripping
instantly. We recommend the use of residual current circuit
breakers (RCCB) with a trip threshold of 300 mA and delayed
tripping (super-resistant, characteristic K).
4.2.4 Locked-rotor protection
Due to the locked-rotor protection, the starting current (LRA) is
equal to or less than the nominal current (FLA).
4.3 Connecting the cables
The device has external leads.
;First connect the "PE" (protective earth).
●Connect the cables according to your application. When doing so,
observe Chapter 4.4 Connection diagram.
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Operating instructions
G3G190-RP03-04
Translation of the original operating instructions
4.4 Connection diagram
Drawing preliminary!
No. Conn. Designation Color Function/assignment
CON10 1 L black Power supply, phase, see nameplate for voltage range
CON11 1 N blue Power supply, neutral conductor, see nameplate for voltage range
CON12 1 PE green/
yellow
Protective earth
CON130 3 RSB brown RS485 interface for MODBUS, RSB; SELV
CON130 2 RSA white RS485 interface for MODBUS, RSA; SELV
CON130 1 GND blue Reference ground for control interface, SELV
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Operating instructions
G3G190-RP03-04
Translation of the original operating instructions
4.5 Checking connections
;Ensure isolation from supply (all phases).
;Make sure a restart is impossible
;Check the cables for proper fit.
4.6 Switching on the device
The device may only be switched on if it has been installed properly and
in accordance with its intended use, including the required safety
mechanisms and professional electrical hookup. This also applies for
devices which have already been equipped with plugs and terminals or
similar connectors by the customer.
WARNING
Hot motor housing
Risk of fire
→ Ensure that no combustible or flammable materials are
located close to the blower.
;Before switching on, check the device for visible external damage
and make sure the protective devices are functional.
;Check the fan's air flow paths for foreign matter and remove any
foreign matter found.
;Apply the nominal supply voltage.
;Start the device by changing the input signal.
NOTE
Damage to the device from vibration
Bearing damage, shorter service life
→ Low-vibration operation of the fan must be ensured over the
entire speed control range.
→ Severe vibration can arise for instance from inexpert
handling, transportation damage and resultant imbalance or
be caused by component or structural resonance.
→ Speed ranges with excessively high vibration levels and
possibly resonant frequencies must be determined in the
course of fan commissioning.
→ Either run through the resonant range as quickly as
possible with speed control or find another remedy.
→ Operation with excessively high vibration levels can
lead to premature failure.
4.7 Switching off the device
;Disconnect the device from the power supply at the supply line's
main switch.
;When disconnecting, be sure to disconnect the ground connection last.
5. INTEGRATED PROTECTIVE FEATURES
The integrated protective functions cause the motor to switch off
automatically in the event of the faults described in the table.
Fault Safety feature description/
function
Rotor position detection error An automatic restart follows.
Blocked rotor ;After the blockage is
removed, the motor restarts
automatically.
6. MAINTENANCE, MALFUNCTIONS, POSSIBLE
CAUSES AND REMEDIES
Do not perform any repairs on your device. Send the device to 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.
If the device is out of use for some time, e.g. when in storage,
we recommend switching it on for at least two hours to allow
any condensation to evaporate and to move the bearings.
Malfunction/fault Possible cause Possible remedy
Impeller not
running smoothly
Imbalance in rotating
parts
Clean the device;
replace it if imbalance
persists after cleaning.
Make sure no
weight clips are
removed during
cleaning.
Motor not turning Mechanical blockage Switch off, isolate
from supply and
remove mechanical
blockage.
Line voltage faulty Check line voltage,
restore power
supply, apply control
signal.
Faulty connection Isolate from supply,
correct connection;
see connection
diagram.
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Operating instructions
G3G190-RP03-04
Translation of the original operating instructions
Motor/electronics
overtemperature
Deficient cooling Improve cooling. Let
the device cool down.
To reset the error
message, switch off
the line voltage for at
least 25 s and then
switch it on again.
Ambient temperature
too high
Reduce the ambient
temperature. Let the
device cool down.
Impermissible point of
operation
Correct the operating
point. Let the device
cool down.
In the event of further malfunctions, contact ebm-papst.
6.1 Cleaning
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!
;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.
6.2 Safety inspection
NOTE
High-voltage test
The integrated EMC filter has Y capacitors. The tripping current
is exceeded when AC testing voltage is applied.
→ Test the device with DC voltage when you perform the
legally required high-voltage test. The voltage to be used
corresponds to the peak value of the AC voltage required by
the standard.
What to check How to check How often What action?
Contact
protection
cover for
intactness or
damage
Visual inspection At least every
6 months
Repair or
replacement of
device
Device for
damage to
blades and
housing
Visual inspection At least every
6 months
Replacement of
device
Fastening the
cables
Visual inspection At least every
6 months
Fasten
Fastening the
protective earth
terminal
Visual inspection At least every
6 months
Fasten
Insulation of
cables for
damage
Visual inspection At least every
6 months
Replace cables
Abnormal
bearing noise
acoustic At least every
6 months
Replace device
6.3 Disposal
For ebm-papst, environmental protection and resource preservation are
top priority corporate goals.
ebm-papst operates an environmental management system which is
certified in accordance with ISO 14001 and rigorously implemented
around the world on the basis of German standards.
Right from the development stage, ecological design, technical safety
and health protection are fixed criteria.
The following section contains recommendations for ecological disposal
of the product and its components.
6.3.1 Country-specific legal requirements
NOTE
Country-specific legal requirements
Always observe the applicable country-specific legal
regulations with regard to the disposal of products or waste
occurring in the various phases of the life cycle. The
corresponding disposal standards are also to be heeded.
6.3.2 Disassembly
Disassembly of the product must be performed or supervised by
qualified personnel with the appropriate technical knowledge.
The product is to be disassembled into suitable components for disposal
employing standard procedures for motors.
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Operating instructions
G3G190-RP03-04
Translation of the original operating instructions
WARNING
Heavy parts of the product may drop off. Some of the
product components are heavy. These components
could drop off during disassembly.
This can result in fatal or serious injury and material damage.
→ Secure components before unfastening to stop them falling.
6.3.3 Component disposal
The products are mostly made of steel, copper, aluminum and plastic.
Metallic materials are generally considered to be fully recyclable.
Separate the components for recycling into the following categories:
●Steel and iron
●Aluminum
●Non-ferrous metal, e.g. motor windings
●Plastics, particularly with brominated flame retardants, in accordance
with marking
●Insulating materials
●Cables and wires
●Electronic scrap, e.g. circuit boards
Only ferrite magnets and not rare earth magnets are used in external
rotor motors from ebm-papst Mulfingen GmbH & Co. KG.
;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. 56205-5-9970 · ENU · Change 260698 · Approved 2022-07-01 · Page 11 / 11
ebm-papst Mulfingen GmbH & Co. KG · Bachmühle 2 · D-74673 Mulfingen · Phone [phone] · Fax [phone] · [email protected] · www.ebmpapst.com