Ebmpapst W3G630-GD03-A1 User manual

Operating instructions
W3G630-GD03-A1
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.
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.
WARNING
Live terminals and connections even with device
switched off
Electric shock
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 Data according to ErP Directive
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
64.2 Electrical connection
74.3 Connecting the cables
74.4 Factory settings
94.5 Connection diagram
104.6 Checking connections
104.7 Switching on the device
104.8 Switching off the device
105. INTEGRATED PROTECTIVE FEATURES
106. MAINTENANCE, MALFUNCTIONS, POSSIBLE
CAUSES AND REMEDIES
116.1 Cleaning
116.2 Safety inspection
116.3 Disposal
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Operating instructions
W3G630-GD03-A1
Translation of the original operating instructions
→ 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 danger zone.
→ When working on the device, switch off the line voltage
and ensure that it cannot be switched back on.
→ After working on the device, remove any tools or other
objects from the device.
1.5 Safety and protective features
DANGER
Protective device missing and protective device not
functioning
Without a protective device there is a risk of serious injury, for
instance if the hands reach or are sucked into the device during
operation.
→ Operate the device only with a fixed protective device and
guard grille.# The fixed protective device must be able to
withstand the kinetic energy of a fan blade that becomes
detached at maximum speed. There must not be any gaps
which it is possible to reach into with the fingers, for example.
→ The device is a built-in component. As the operator, you
are responsible for ensuring that the device is secured
adequately.
→ Stop the device immediately if you notice a missing or
ineffective protective device.
1.6 Electromagnetic radiation
Interference from electromagnetic radiation is possible, e.g. in conjunction
with open- and closed-loop control devices.
If impermissible radiation levels occur following installation, appropriate
shielding measures have to be taken by the user.
NOTE
Electrical or electromagnetic interference after installing
the device in customer equipment.
→ Verify that the entire setup is EMC-compliant.
1.7 Mechanical movement
DANGER
Rotating device
Risk of injury to body parts coming into contact with the rotor or
the impeller.
→ Secure the device against accidental contact.
→ Before working on the system/machine, wait until all
parts have come to a standstill.
WARNING
Rotating device
Long hair and dangling items of clothing, jewelry and the like
can become entangled and be pulled into the device. Injuries
can result.
→ Do not wear any loose-fitting or dangling clothing or jewelry
while working on rotating parts.#Protect long hair with a cap.
1.8 Emissions
WARNING
Depending on the installation and operating conditions,
the sound pressure level may exceed 70 dB(A).
Risk of noise-induced hearing loss
→ Take appropriate technical safety measures.
→ Protect operating personnel with appropriate safety
equipment such as hearing protection.
→ Also observe the requirements of local agencies.
1.9 Hot surface
CAUTION
High temperature on electronics housing
Risk of burns
→ Ensure sufficient protection against accidental contact.
1.10 Transport
NOTE
Transporting the device
→ Transport the device in its original packaging only.
→ Secure the device so it cannot slip, e.g. by using a
lashing strip.
1.11 Storage
;Store the device, partially or fully assembled, in a dry and
weatherproof manner 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.
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Operating instructions
W3G630-GD03-A1
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
●conveying air at an ambient air pressure between 750 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.
●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
W3G630-GD03-A1
Translation of the original operating instructions
3. TECHNICAL DATA
3.1 Product drawing
All dimensions in mm.
1Direction of air flow "V"
2Cable PVC AWG18, 5x crimped ferrules
3Cable PVC AWG22, 3x crimped ferrules
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Operating instructions
W3G630-GD03-A1
Translation of the original operating instructions
3.2 Nominal data
Motor M3G084-GF
Phase 1~
Nominal voltage / VAC 230
Nominal voltage
range / VAC
200 .. 277
Frequency / Hz 50/60
Method of obtaining
data
ml
Speed / min-1 800
Power consumption / W 280
Current draw / A 1.2
Max. back pressure / Pa 75
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 Data according to ErP Directive
Actual Req. 2015
01 Overall efficiency ηes / % 42.3 29.8
02 Measurement category A
03 Efficiency category Static
04 Efficiency grade N 52.5 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 W3G630-GD03-A1
09 Power consumption Ped / kW 0.24
09 Air flow qv/ m³/h 6570
09 Pressure increase total psf /
Pa
52
10 Speed n / min-1 805
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 ErP data is determined using a motor-impeller
combination in a standardized measurement setup.
3.4 Technical description
Weight 19.6 kg
Fan size 630 mm
Rotor surface Painted black
Blade material Press-fitted sheet steel blank, sprayed
with PP plastic
Fan housing material Sheet steel, pre-galvanized and coated
with black plastic (RAL 9005)
Guard grille material Steel, coated with black plastic (RAL
9005)
Number of blades 5
Airflow direction "V"
Direction of rotation Counterclockwise, viewed toward rotor
Degree of protection IP54; installation- and position-dependent
Insulation class "B"
Moisture (F) /
Environmental (H)
protection class
F3-1
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 - Output 10 VDC, max. 10 mA
- Alarm relay
- Motor current limitation
- PFC, active
- Soft start
- Control input 0-10 VDC / PWM
- Control interface with SELV potential
safely disconnected from supply
- 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
Motor protection Thermal overload protector (TOP)
internally connected
with cable Variable
Protection class I (with customer connection of protective
earth)
Conformity with
standards
EN 61800-5-1
Approval EAC
With regard to cyclic speed loads, note that the rotating parts of
the device are designed for a maximum of one million load
cycles. If you have special questions, consult ebm-papst for
support.
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Operating instructions
W3G630-GD03-A1
Translation of the original operating instructions
3.5 Mounting data
For screw clearance, see Chapter 3.1 Product drawing
;Secure the screws against unintentional loosening (e.g. use self-
locking screws).
Strength class of
screws
8.8
Any further mounting data required can be taken from the product drawing.
3.6 Transport and storage conditions
;Use the device in accordance with its degree of protection.
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 circuit feedback According to EN 61000-3-2/3
EMC interference
emission
According to EN 55022 (Class B,
household environment)
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
Heavy load when unpacking device
Risk of physical injury, such as back injuries.
→ Two people should work together to remove the device from
its packaging.
;Check the device for transport damage. Damaged devices are not to
be installed.
;Install the undamaged device in accordance with your application.
CAUTION
Possible damage to the device
If the device slips during installation, serious damage can result.
→ Ensure that the device is securely positioned at its place of
installation until all fastening screws have been tightened.
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.
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Operating instructions
W3G630-GD03-A1
Translation of the original operating instructions
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 data on the nameplate match 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.
Ground conductor contact resistance according to EN 61800-5-1
Compliance with the impedance specifications according to EN 61800-5-
1 for the protective earth connection circuit must be verified in the end
application.
Depending on the circumstances of installation, it may be necessary to
connect an additional protective earth conductor to the extra protective
earth terminal on the device.
The protective earth terminal is on the housing and has a ground
conductor symbol and a bore hole.
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 less than 250 mA.
●At the same time, the effective power in this operating state
(operational readiness) is typically < 4 W.
4.2.3 Residual current circuit breaker (RCCB)
Only universal residual current devices (type B or B+) are
allowed. As with variable frequency drives, residual current
devices cannot provide personal safety while operating the
device.
When the device's power supply is switched on, pulsed
charging currents from the capacitors in the integrated EMC
filter can lead to the residual current devices tripping without
delay. We recommend the use of residual current circuit
breakers 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 4.5 Connection diagram.
4.3.1 Cable routing
Water must be prevented from reaching the cable exit along the cable.
Fans installed lying flat
Fig. 1: Fan installed lying flat, cable routed in a U-shaped loop.
Fans installed upright
Fig. 2: Cable routing for fans installed upright.
The cables must always be routed downward.
4.4 Factory settings
Factory settings made for the device by ebm-papst.
Mode PWM control
Group address 01
Fan/device address 01
Max. PWM / % 100
Min. PWM / % 0
Save set value to
EEPROM
No
Set value requirement Analog
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Operating instructions
W3G630-GD03-A1
Translation of the original operating instructions
Direction of action Positive (heating)
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Operating instructions
W3G630-GD03-A1
Translation of the original operating instructions
4.5 Connection diagram
Drawing preliminary!
No. Conn. Designation Color Function/assignment
1 1,2 PE green/
yellow
Protective earth
1 3 N blue Power supply, neutral conductor, 50/60 Hz
1 4 L black Power supply, phase, 50/60 Hz
1 5 COM white 1 Floating status contact, break for failure (2 A, max. 250 VAC, min. 10 mA)
1 6 NC white 2 Floating status contact, break for failure
2 8 0 - 10 V yellow Control input, set value 0-10 VDC, impedance 100 kOhm, SELV
2 11 10 VDC red Voltage output 10 VDC (±3%), max. 10 mA, power supply for external devices (e.g.
potentiometers), SELV
2 12 GND blue Reference ground for control interface, SELV
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Operating instructions
W3G630-GD03-A1
Translation of the original operating instructions
4.6 Checking connections
;Ensure isolation from supply (all phases).
;Make sure a restart is impossible
;Check the cables for proper fit.
4.7 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.
4.8 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.
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 danger zone.
→ When working on the device, switch off the line voltage
and ensure that it cannot be switched back on.
→ 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
W3G630-GD03-A1
Translation of the original operating instructions
Thermal overload
protector activated
Allow motor to cool
off, locate and rectify
cause of error,
release restart lockout
if necessary
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.
Reset by reducing
control input to 0.
Impermissible point of
operation
Correct the operating
point. Let the device
cool down.
In the event of further malfunctions, contact ebm-papst.
6.1 Cleaning
NOTE
Damage to the device during cleaning
Malfunction possible
→ Do not clean the device using a water jet or high-pressure
cleaner.# Do not use any acid, alkali or solvent-
basedcleaning agents.# Do not use any pointed or sharp-
edged objects for cleaning
6.2 Safety inspection
NOTE
High-voltage test
The integrated EMC filter has Y capacitors. The tripping current
is exceeded when AC testing voltage is applied.
→ Test the device with DC voltage when you perform the
legally required high-voltage test. The voltage to be used
corresponds to the peak value of the AC voltage required by
the standard.
What to check How to check How often What action?
Contact
protection
cover for
intactness or
damage
Visual inspection At least every
6 months
Repair or
replacement of
device
Device for
damage to
blades and
housing
Visual inspection At least every
6 months
Replacement of
device
Fastening the
cables
Visual inspection At least every
6 months
Fasten
Fastening the
protective earth
terminal
Visual inspection At least every
6 months
Fasten
Insulation of
cables for
damage
Visual inspection At least every
6 months
Replace cables
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
6.3 Disposal
For ebm-papst, environmental protection and resource preservation are
top priority corporate goals.
ebm-papst operates an environmental management system which is
certified in accordance with ISO 14001 and rigorously implemented
around the world on the basis of German standards.
Right from the development stage, ecological design, technical safety
and health protection are fixed criteria.
The following section contains recommendations for ecological disposal
of the product and its components.
6.3.1 Country-specific legal requirements
NOTE
Country-specific legal requirements
Always observe the applicable country-specific legal
regulations with regard to the disposal of products or waste
occurring in the various phases of the life cycle. The
corresponding disposal standards are also to be heeded.
6.3.2 Disassembly
Disassembly of the product must be performed or supervised by
qualified personnel with the appropriate technical knowledge.
The product is to be disassembled into suitable components for disposal
employing standard procedures for motors.
WARNING
Heavy parts of the product may drop off. Some of the
product components are heavy. These components
could drop off during disassembly.
This can result in fatal or serious injury and material damage.
→ Secure components before unfastening to stop them falling.
6.3.3 Component disposal
The products are mostly made of steel, copper, aluminum and plastic.
Metallic materials are generally considered to be fully recyclable.
Separate the components for recycling into the following categories:
●Steel and iron
●Aluminum
●Non-ferrous metal, e.g. motor windings
●Plastics, particularly with brominated flame retardants, in accordance
with marking
●Insulating materials
●Cables and wires
●Electronic scrap, e.g. circuit boards
Only ferrite magnets and not rare earth magnets are used in external
rotor motors from ebm-papst Mulfingen GmbH & Co. KG.
;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
Item no. 50431-5-9970 · ENU · Change 89187 · Approved 2016-04-15 · Page 11 / 12
ebm-papst Mulfingen GmbH & Co. KG · Bachmühle 2 · D-74673 Mulfingen · Phone [phone] · Fax [phone] · [email protected] · www.ebmpapst.com
[email protected]

Operating instructions
W3G630-GD03-A1
Translation of the original operating instructions
●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. 50431-5-9970 · ENU · Change 89187 · Approved 2016-04-15 · Page 12 / 12
ebm-papst Mulfingen GmbH & Co. KG · Bachmühle 2 · D-74673 Mulfingen · Phone [phone] · Fax [phone] · [email protected] · www.ebmpapst.com
[email protected]