Ebmpapst K3G097-AK34-65 User manual

Operating instructions
K3G097-AK34-65
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 NOTES
11. SAFETY REGULATIONS AND NOTES
Please read these operating instructions carefully before starting to work
with the device. Observe the following warnings to prevent malfunctions
or physical damage to both property and people.
These operating instructions are to be regarded as part of this device.
If the device is sold or transferred, the operating instructions must
accompany it.
These operating instructions may be duplicated and forwarded for
information about potential dangers and their prevention.
1.1 Levels of hazard warnings
11.1 Levels of hazard warnings
These operating instructions use the following hazard levels to indicate
potentially hazardous situations and important safety regulations:
DANGER
Indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury. Compliance with
the measures is mandatory.
WARNING
Indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury. Exercise extreme
caution while working.
CAUTION
Indicates a potentially hazardous situation which, if not avoided,
may result in minor or moderate injury or damage of property.
NOTE
A potentially harmful situation can occur and, if not avoided, can
lead to property damage.
1.2 Staff qualification
11.2 Staff qualification
The device may only be transported, unpacked, installed, operated,
maintained and otherwise used by qualified, trained and authorised
technical staff.
Only authorised 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
Any safety hazards stemming from the device must be re-evaluated
once it is installed in the end device.
The local industrial safety regulations must always be observed when
working on the device.
Keep the workplace clean and tidy. Untidiness in the working area
increases the risk of injury.
Observe the following when working on the unit:
;Do not make any modifications, additions or conversions to the
device without the approval of ebm-papst.
1.4 Electrical voltage
11.4 Electrical voltage
;Check the electrical equipment of the device at regular intervals, refer
to chapter 5.2 Safety test.
;Replace loose connections and defective cables immediately.
WARNING
Terminals and connections have voltage even with a
unit that is shut off
Electric shock
→ Wait five minutes after disconnecting the voltage at all poles
before opening the device.
21.5 Safety and protective functions
21.6 Electromagnetic radiation
21.7 Mechanical movement
21.8 Emission
21.9 Hot surface
21.10 Transport
21.11 Storage
32. PROPER USE
43. TECHNICAL DATA
43.1 Product drawing
53.2 Nominal data
53.3 Data in accordance with ecodesign regulation EU 327/2011
53.4 Technical features
53.5 Mounting data
63.6 Transport and storage conditions
63.7 Electromagnetic compatibility
64. CONNECTION AND START-UP
64.1 Connecting the mechanical system
64.2 Connecting the electrical system
64.3 Connection via plug
74.4 Connection screen
84.5 Checking the connections
84.6 Switch on device
84.7 Switching off the device
85. MAINTENANCE, MALFUNCTIONS, POSSIBLE
CAUSES AND REMEDIES
95.1 Cleaning
95.2 Safety test
95.3 Disposal
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Operating instructions
K3G097-AK34-65
Translation of the original operating instructions
CAUTION
If control voltage is applied or a speed setpoint is stored,
the motor will restart automatically, e.g. after a mains
failure.
Risk of injury
→ Keep out of the device hazard zone.
→ When working on the device, switch off the mains power
and ensure that it cannot be switched back on.
→ Wait until the device stops.
→ After working on the device, remove any tools used or
other objects from the device.
The leakage current of the device is greater than 3.5 mA. A
permanent earth wire connection is required. The device can be
earthed using two earth wires with a respective outer conductor
cross-section or one earth wire with at least 10 mm².
1.5 Safety and protective functions
DANGER
Guard missing and guard not functioning
Without a guard there is a risk of serious injury, for instance
when reaching into the device during operation. Loose parts or
items of clothing could be drawn in.
→ The device is a built-in component. As the operator, you are
responsible for ensuring that the device is secured
adequately.# Operate the device only with a fixed protective
device and guard grille.
→ 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 unacceptable emission intensities occur when the fan is installed,
appropriate shielding measures have to be taken by the user.
NOTE
Electrical or electromagnetic interferences after
integrating the device in installations on the customer's
side.
→ Verify that the entire setup is EMC compliant.
1.7 Mechanical movement
DANGER
Rotating device
Body parts that come into contact with the rotor and impeller
can be injured.
→ 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, dangling items of clothing, jewellery and similar items
can become entangled and be pulled into the device. Risk of
injury.
→ Do not wear any loose-fitting or dangling clothing or jewellery
while working on rotating parts.
→ Protect long hair with a cap.
1.8 Emission
WARNING
Depending on the installation and operating conditions,
a sound pressure level greater than 70 dB(A) may arise.
Danger of noise-induced hearing loss
→ Take appropriate technical safety measures.
→ Protect operating personnel with appropriate safety
equipment, e.g. hearing protection.
→ Also observe the requirements of local agencies.
1.9 Hot surface
CAUTION
High temperature at the electronics housing
Risk of burns
→ Ensure sufficient contact protection.
1.10 Transport
WARNING
Transportation of fan
Injuries from tipping or slipping.
→ Wear safety shoes and cut-resistant safety gloves.
→ Only transport the fan in its original packaging.
→ Transport the fan lying flat, in other words with the motor
axis vertical.
→ Secure the fan(s) so that nothing can slip or tip, e.g. by
using a lashing strip.
1.11 Storage
;Store the device, partially or fully assembled, in the original
packaging in a clean, dry and weatherproof place free of vibrations.
;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 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.
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Operating instructions
K3G097-AK34-65
Translation of the original operating instructions
2. PROPER 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.
Proper use also includes:
●Use the device in DC power systems only.
●Conveying of air at an ambient air pressure of 800 mbar to 1050 mbar.
●Using the device in accordance with the permitted ambient
temperature, see chapter 3.6 Transport and storage conditions and
chapter 3.2 Nominal data.
●Operating the device with all protective features in place.
●Minding the operating instructions.
Improper use
Using the device in the following ways is particularly prohibited and
may cause hazards:
●Operating the device with an imbalance, e.g. caused by dirt deposits
or icing.
●Resonance mode, operation with heavy vibrations. These also
include vibrations that are transmitted from the customer system to the
fan.
●Operation in medical equipment with a life-sustaining or lifesaving
function.
●Moving solids content in flow medium.
●Painting the device
●Connections (e.g. screws) coming loose during operation.
●Moving air that contains abrasive particles.
●Moving highly corrosive air, e.g. salt spray mist. Exceptions are
devices that are intended for salt spray mist and protected accordingly.
●Moving air that contains dust pollution, e.g. suctioning off saw dust.
●Operating the device close to flammable materials or components.
●Operating the device in an explosive atmosphere.
●Using the device as a safety component or for taking on safety-
related functions.
●Operation with completely or partially disassembled or modified
protective features.
●In addition, all application options that are not listed under proper use.
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Operating instructions
K3G097-AK34-65
Translation of the original operating instructions
3. TECHNICAL DATA
3.1 Product drawing
All measures have the unit mm.
16-pole strip TE Junior Power Timer WE_9901118
1.1 + UB
1.2 GND
1.3 PWM/LIN, 100% speed
1.4 80% speed
1.5 60% speed
1.6 not used / no function
Accessory part: Connection line (460 mm) with mating connector, part no. 02001-4-1021 not included in scope of delivery
6-pole mating connector TE 929504-2, 4x plug contact TE 927771-1, 2x plug contact TE 927768-1
2Electronics cover blue (RAL 5015)
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Operating instructions
K3G097-AK34-65
Translation of the original operating instructions
3.2 Nominal data
Motor M3G074-CF
Nominal voltage / VDC 26
Nominal voltage
range / VDC
16 .. 32
Type of data definition fa
Speed (rpm) / min-1 3830
Power input / W 394
Current draw / A 15.2
Min. ambient
temperature / °C
-40
Max. ambient
temperature / °C
70
ml = Max. load · me = Max. efficiency · fa = Running at free air
cs = Customer specs · cu = Customer unit
Subject to alterations
3.3 Data in accordance with ecodesign regulation EU 327/
2011
Actual Request 2015
01 Overall efficiency ηes / % 45.5 33.9
02 Measurement category A
03 Efficiency category Static
04 Efficiency grade N 55.6 44
05 Variable speed drive Yes
06 Year of manufacture The year of manufacture is specified on the
rating plate on the product.
07 Manufacturer ebm-papst Mulfingen GmbH & Co. KG
County court Stuttgart · HRA 590344
D-74673 Mulfingen
08 Type K3G097-AK34-65
09 Power input Pe/ kW 0.25
09 Air flow qv/ m³/h 705
09 Pressure increase total psf /
Pa
526
10 Speed (rpm) n / min-1 4505
11 Specific ratio*1.01
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 definition with optimum efficiency. The ErP data is determined using a motor-impeller
combination in a standardised measurement configuration.
3.4 Technical features
Mass 2.1 kg
Size 97 mm
Motor size 74
Material of impeller Plastic, PA UL94 HB (black)
Housing material Plastic, PP (black)
Balance quality
according to DIN ISO
21940-11
G 6.3
Direction of rotation Clockwise, seen on rotor
Type of protection Motor IP24 KM
Insulation class "B"
Humidity (F) /
environmental
protection class (H)
H1
Mounting position Any
Condensation
drainage holes
None, open rotor
Cooling bore / aperture Rotor-side
Operation mode S1
Motor bearing Ball bearing
Life expectancies 40,000 h (typical)
Technical features - Start at 85 °C (2 min.) permitted
-Load dump (58 V)
- Motor current limit
- Soft start
- Control input 0-10 VDC / PWM
- Overvoltage detection
- Over-temperature protected electronics
- Line undervoltage detection
Electrical connection Plug; Standby current less than 500 µA
Motor protection Passive reverse polarity and locked-
rotor protection
Approval EAC; E1
Remark Not approved at maximum back
pressure for continuous operation at
85°C; type approval number - 036432
For cyclic speed loads, note that the rotating parts of the device
are designed for maximum one million load cycles. If you have
specific questions, contact ebm-papst for support.
;Use the device in accordance with its protection type.
Notes on surface quality
The surfaces of the products conform to the generally applicable industrial
standard. The surface quality may vary during the production period.
Strength, dimensional stability and dimensional accuracy are not affected
by this.
The colour pigments of the paints used react perceptibly to UV light over
the course of time. This does not however have any influence on the
technical properties of the products. To prevent the formation of patches
and fading, the product is to be protected against UV radiation. Changes
in colour are not a reason for complaint and are not covered by the
warranty.
3.5 Mounting data
Any further mounting data required can be taken from the product
drawing or Section chapter 4.1 Connecting the mechanical system.
Strength class for
mounting screws
8.8
For depth of screw, see chapter 3.1 Product drawing
;Secure the mounting screws against accidentally coming loose (e.g.
by using self-locking screws).
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Operating instructions
K3G097-AK34-65
Translation of the original operating instructions
3.6 Transport and storage conditions
Max. permissible
ambient motor temp.
(transp./ storage)
+85 °C
Min. permissible
ambient motor temp.
(transp./storage)
-40 °C
3.7 Electromagnetic compatibility
EMC directives according to ECE R10 Rev. 3
4. CONNECTION AND START-UP
4.1 Connecting the mechanical system
CAUTION
Cutting and crushing hazard when removing device
from packaging
→ Carefully remove the device from its packaging, only
touching the housing. Strictly avoid shocks.
→ Wear safety shoes and cut-resistant safety gloves.
NOTE
Damage to device from vibration
Bearing damage, reduced service life
→ Forces or impermissibly high vibration levels must not be
transmitted to the fan from system components.
→ If the fan is connected to air ducts, it should isolated from
vibrations, for example using compensators or similar
elements.
→ Fasten the fan to the substructure without distorting it.
;The fan may not be handled in the area around the inlet nozzle during
transport and installation.
There is a risk of damage to the impeller.
;Check the device for transport damage. Damaged devices must no
longer be installed.
;Install the undamaged device according to your application.
CAUTION
Possibility of damage to the device
Serious damage may result if the device slips during assembly.
→ Keep the device fixed in position at the installation location
until all attachment screws have been tightened.
●The fan must not be strained on fastening.
4.2 Connecting the electrical system
CAUTION
Electrical voltage
The fan is a built-in component and features no electrically
isolating switch.
→ Only connect the fan to circuits that can be switched off with
an all-pole separating switch.
→ When working on the fan, you must switch off the
installation/machine in which the fan is installed and secure it
from being switched on again.
NOTE
Water penetration into leads or wires
Water enters at the cable end on the customers side and can
damage the device.
→ Make sure that the cable end is connected in a dry
environment.
4.2.1 Prerequisites
;Check that the data on the type plate match the connection data.
;Before connecting the device, ensure that the supply voltage matches
the operating voltage of the device.
;Only use cables designed for current according to the type plate.
For determining the cross-section, follow the basic principles in
accordance with EN 61800-5-1. The protective earth must have a
cross-section equal to or greater than the outer conductor cross-
section.
We recommend the use of 105°C cables. Ensure that the minimum
cable cross-section is at least
AWG26/0.13 mm².
Operate the device with a safely isolated power pack.
4.3 Connection via plug
4.3.1 Establish supply connections
;Check the PIN assignment of your connector.
;Connect the panel connector and mating connector.
;Ensure that the connector is locked in correctly.
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Operating instructions
K3G097-AK34-65
Translation of the original operating instructions
4.4 Connection screen
No. Conn. Designation Function / assignment
1.1 +UB Power supply
1.2 GND Power supply GND, reference earth
1.3 100%, PWM/LIN 100% speed, control input 0-10 V analogue voltage or PWM
1.4 80% 80% speed
1.5 60% 60% speed
1.6 NC Not used / no function
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Operating instructions
K3G097-AK34-65
Translation of the original operating instructions
4.5 Checking the connections
;Make sure that the power is off (all phases).
;Secure it from being switched on again.
;Check that the mating connector is correctly locked into the panel
connector.
;Check that the mating connector is correctly crimped to the
connection line.
4.6 Switch on device
The device is not to be switched on until it has been installed properly
and in accordance with its intended use, including the required protective
devices and professional electrical connection. This also applies to
devices which have already been equipped with plugs and terminals or
similar connectors by the customer.
WARNING
Hot motor housing
Fire hazard
→ Ensure that no combustible or flammable materials are
located close to the fan.
;Inspect the device for visible external damage and the proper function
of the protective features before switching it on.
;Check the air flow paths of the fan for foreign objects and remove any
that are found.
;Apply the nominal voltage to the voltage supply.
;Start the device by changing the input signal.
NOTE
Damage to device by vibrations
Bearing damage, reduced service life
→ The fan must operate free of vibrations throughout its speed
control range.
→ Strong vibrations can result from improper handling,
imbalance resulting from damage during transport, or
component-induced or structural resonances.
→ When putting the fan into service, determine the speed
ranges with excessive vibration levels and also any
resonance frequencies that may be present.
→ When regulating the speed, pass through resonance
ranges as quickly as possible or find another remedy.
→ Operation at excessive vibration levels can lead to
premature failure.
4.7 Switching off the device
Switching off the device during operation:
;Switch off the device via the control input.
;Do not switch the motor (e.g. in cyclic operation) on and off via power
supply.
Switching off the device for maintenance work:
;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 supply voltage.
5. MAINTENANCE, MALFUNCTIONS, POSSIBLE
CAUSES AND REMEDIES
Do not perform any repairs on your device. Return the device to ebm-
papst for repair or replacement.
WARNING
Terminals and connections have voltage even with a
unit that is shut off
Electric shock
→ Wait five minutes after disconnecting the voltage at all poles
before opening the device.
CAUTION
If control voltage is applied or a speed setpoint is stored,
the motor will restart automatically, e.g. after a mains
failure.
Risk of injury
→ Keep out of the device hazard zone.
→ When working on the device, switch off the mains power
and ensure that it cannot be switched back on.
→ Wait until the device stops.
→ After working on the device, remove any tools used or
other objects from the device.
If the device remains out of use for some time, e.g. when in
storage, we recommend switching the device on for at least
two hours to allow any condensate to evaporate and to move
the bearings.
Malfunction/error Possible cause Possible remedy
Impeller running
roughly
Imbalance in rotating
parts
Clean the device; if
imbalance is still
evident after cleaning,
replace the device.
If you have
attached any weight
clips during cleaning,
make sure to remove
them afterwards.
Motor does not turn Mechanical blockage Switch off, de-
energise, and
remove mechanical
blockage.
Mains supply voltage
faulty
Check mains supply
voltage,
restore power
supply,
apply control signal.
Faulty connection De-energise, correct
connection, see
connection diagram.
Overtemperature of
electronics/motor
Insufficient cooling Improve cooling. Let
the device cool down.
To reset the error
message, switch off
the mains supply
voltage for a min. of
25 s and switch it on
again.
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Operating instructions
K3G097-AK34-65
Translation of the original operating instructions
Ambient temperature
too high
Reduce the ambient
temperature.
Reset by reducing
control input to 0.
Unacceptable
operating point
Correct the operating
point. Let the device
cool down.
If you have any other problems, contact ebm-papst.
5.1 Cleaning
To ensure a long service life, the fans have to be regularly checked for
proper operation and degree of soiling. The frequency of the checks is to
be adapted to the occurrence of soiling.
;Dirt deposits on the motor housing could lead to overheating of the
motor.
;Dirt on the impeller can cause vibration which would shorten the
service life of the fan.
;Severe vibration could destroy the fan.
;In such cases immediately switch off and clean the fan.
;The preferred method of cleaning is dry cleaning, e.g. using
compressed air.
;Use is never to be made of corrosive cleaning agents!
;Completely remove any cleaning agents used.
;Immediately switch off and replace the device if severe corrosion is
apparent at load-bearing or rotating parts.
;Repairs to load-bearing or rotating parts are not permissible!
;Operate the fan for 2 hours at maximum speed to permit the
evaporation of any water which may have ingressed.
;If cleaning does not eliminate vibration, the fan may have to be re-
balanced. In such cases please contact ebm-papst.
;The fan is provided with maintenance-free ball bearings. The lifetime
lubrication of the ball bearings is designed for a service life of 40,000
hours.
;Please contact ebm-papst if bearing replacement is required after this
period.
;Adapt the maintenance intervals to the dust pollution occurring.
5.2 Safety test
What has to
be tested?
How to test? Frequency Which
measure?
Check the
protective
casing against
accidental
contact for
damage and to
ensure that it is
intact
Visual inspection At least every
6 months
Repair or
replacement of
the device
Check the
device for
damage to
blades and
housing
Visual inspection At least every
6 months
Replacement of
the device
Mounting the
connection lines
Visual inspection At least every
6 months
Fasten
Check the
insulation of the
wires for damage
Visual inspection At least every
6 months
Replace wires
Impeller for
wear/deposits/
corrosion and
damage
Visual inspection At least every
6 months
Clean impeller
or replace device
Abnormal
bearing noise
acoustic At least every
6 months
Replace device
5.3 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.
5.3.1 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.
5.3.2 Disassembly
Disassembly of the product must be performed or supervised by
qualified personnel with the appropriate technical knowledge.
The product is to be disassembled into suitable components for disposal
employing standard procedures for motors.
WARNING
Heavy parts of the product may drop off. Some of the
product components are heavy. These components
could drop off during disassembly.
This can result in fatal or serious injury and material damage.
→ Secure components before unfastening to stop them falling.
5.3.3 Component disposal
The products are mostly made of steel, copper, aluminium and plastic.
Metallic materials are generally considered to be fully recyclable.
Separate the components for recycling into the following categories:
●Steel and iron
●Aluminium
●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.
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Operating instructions
K3G097-AK34-65
Translation of the original operating instructions
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 lines
●Cables for internal wiring
●Electrolytic capacitors
Dispose of electronic components employing the proper procedures for
electronic scrap.
→ Please contact ebm-papst for any other questions on disposal.
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