G1G144-AF49-70 Operating instructions ebm-papst Mulfingen GmbH & Co. KG Bachmühle 2 D-74673 Mulfingen Phone +49 (0) 7938 81-0 Fax +49 (0) 7938 81-110 [email protected] www.ebmpapst.com 1. 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. Translation of the original operating instructions CONTENTS 1. SAFETY REGULATIONS AND NOTES 1 1.1 Levels of hazard warnings 1 1.2 Staff qualification 1 1.3 Basic safety rules 1 1.4 Electrical voltage 1 1.5 Safety and protective functions 2 1.6 Electromagnetic radiation 2 1.7 Mechanical movement 2 1.8 Deflagration 2 1.9 Emission 2 1.10 Hot surface 2 1.11 Transport 2 1.12 Storage 3 1.13 Disposal 3 2. PROPER USE 3 3. TECHNICAL DATA 4 3.1 Product drawing 4 3.2 Nominal data 5 3.3 Technical features 5 3.4 Mounting data 5 3.5 Transport and storage conditions 5 1.3 Basic safety rules 4. CONNECTION AND START-UP 6 4.1 Connecting the mechanical system 6 4.2 Connecting the electrical system 6 Any safety hazards stemming from the device must be re-evaluated once it is installed in the end device. Observe the following when working on the unit: 4.3 Connection via plug 7 4.4 Connection screen 8 4.5 Checking the connections 9 4.6 Switch on device 9 4.7 Switching off the device 9 5. INTEGRATED PROTECTIVE FUNCTIONS 9 6. MAINTENANCE, MALFUNCTIONS, POSSIBLE CAUSES AND REMEDIES 10 DANGER Electrical load on the device Risk of electric shock 6.1 Cleaning 10 6.2 Safety test 10 → Stand on a rubber mat if you are working on an electrically charged device. 1.1 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 The device may only be transported, unpacked, installed, operated, maintained and otherwise used by 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. ; Do not make any modifications, additions or conversions to the device without the approval of ebm-papst. 1.4 Electrical voltage ; Check the electrical equipment of the device at regular intervals, refer to chapter 6.2 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. Item no. 51288-5-9970 · Revision 79946 · Release 2013-12-02 · Page 1 / 11 ebm-papst Mulfingen GmbH & Co. KG · Bachmühle 2 · D-74673 Mulfingen · Phone +49 (0) 7938 81-0 · Fax +49 (0) 7938 81-110 · [email protected] · www.ebmpapst.com G1G144-AF49-70 Operating instructions CAUTION In the event of failure, there is electric voltage at the rotor and impeller The rotor and impeller are base insulated. → Do not touch the rotor and impeller once they are installed. CAUTION If control voltage is applied or a speed setpoint is stored, the motor automatically restarts, e.g. after a power failure. Danger of injury → Keep out of the danger zone of the device. → When working on the device, switch off the mains supply voltage and secure the latter from being switched on again. → Wait until the device stops. → After working on the device, remove any used tools or other objects from the device. 1.5 Safety and protective functions DANGER Missing safety device and non-functioning safety device If there is no safety device, you could be seriously injured, for example if you reach into the running device or your hands are sucked into it. → Operate the device only with a fixed and isolating safety protection and a fixed guard grille. The guard must withstand the kinetic energy of a fan blade detaching at maximum speed. → The device is a built-in component. You, the owner/ operator, are responsible for providing adequate protection for the device. → Shut down the device immediately if you detect a missing or ineffective protective feature. 1.6 Electromagnetic radiation Translation of the original operating instructions 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 Danger of injury from open blower Gas escapes. When the blower is open, you come into contact with rotating and electrically live parts. Escaping gas may also cause explosions. → Never open the blower. WARNING Rotating device Long hair, loose items of clothing and jewellery could become entangled and pulled into the device. You could be injured. → Do not wear any loose clothing or jewellery while working on rotating parts. → Protect long hair by wearing a cap. WARNING Flying parts Missing safety devices may cause fan blades to be ejected at high speeds, causing bodily harm. → Take appropriate safety measures. The safety devices must prevent contact with rotating parts and the printed circuit board. 1.8 Deflagration DANGER Gas escapes through leaky housing after deflagration Danger of injury → After a deflagration, check that the housing of the gas blower is tightly sealed. → Replace any gas blower with a leaky housing. DANGER Fire and deflagration hazard The gas blower is not approved according to Ex protection guidelines. Rotating parts can scrape against stationary parts. This may cause sparks and chips. The surface temperature may rise, resulting in a fire. → Check which hazards arise from installing, operating, servicing or disposing the gas blower in conjunction with your device. Prevent these hazards. Carry out all appropriate measures to this purpose. 1.9 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. 1.10 Hot surface CAUTION High temperature at the electronics enclosure Danger of burn injuries → Ensure that sufficient protection against accidental contact is provided. 1.11 Transport NOTE Transport of blower → Transport the blower in its original packaging only. → Secure the blower so that it does not slip, e.g. by using a clamping strap. Item no. 51288-5-9970 · Revision 79946 · Release 2013-12-02 · Page 2 / 11 ebm-papst Mulfingen GmbH & Co. KG · Bachmühle 2 · D-74673 Mulfingen · Phone +49 (0) 7938 81-0 · Fax +49 (0) 7938 81-110 · [email protected] · www.ebmpapst.com G1G144-AF49-70 Operating instructions 1.12 Storage 2. PROPER USE ; Store the device, partially or fully assembled, in a dry and weatherproof manner in the original packing in a clean environment. The device is exclusively designed as a built-in device for moving air and gases according to its technical data. Any other or secondary use is deemed improper and constitutes a misuse of the device. Installations on the customer's side must meet the mechanical, thermal and service life-related stresses that can occur. ; Protect the device from environmental impacts and dirt until the final installation. ; We recommend storing the device for a maximum up to one year to guarantee proper operation and longest possible service life. ; Even devices explicitly suited for outdoor use are to be stored as described prior to being commissioned. Proper use also includes: ● Moving air in gas burners. ; Maintain the storage temperature, see chapter 3.5 Transport and storage conditions. ● Moving air with a density ranging from 0.9 to 1.2 kg/m³. ● Minding the operating instructions. 1.13 Disposal ● Using the device in accordance with the permitted ambient temperature, see chapter 3.5 Transport and storage conditions and chapter . ● Only using the device in stationary systems. ● Installing the device into an overall system for moving air. ● Commissioning the built-in component only after installation in the customer unit. ● Operating the device with all protective features in place. When disposing of the device, please comply with all relevant requirements and regulations applicable in your country. Improper use Translation of the original operating instructions 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. ● Moving a medium that contains abrasive particles. ● Moving a highly corrosive medium. ● Moving a medium that contains dust pollution, e.g. suctioning off saw dust. ● Operating the gas blower in an environment that contains flammable gases or dust or combustible solids or fluids. ● Moving an air/gas mixture outside an overall system that fulfils the requirements described above. ● Using the blower as a safety component or for taking on safety-related functions. ● Operation in medical equipment with a life-sustaining or lifesaving function. ● Contact with materials that could damage blower parts, e.g. liquids during cleaning. ● Operation with completely or partially disassembled or modified protective features. ● Exposure to radiation which could damage blower parts, e.g. strong UV radiation. ● Operation with external vibrations. ● Operating the device in an explosive atmosphere. ● Operation with completely or partially disassembled or modified protective features. ● In addition, all application options that are not listed under proper use. Item no. 51288-5-9970 · Revision 79946 · Release 2013-12-02 · Page 3 / 11 ebm-papst Mulfingen GmbH & Co. KG · Bachmühle 2 · D-74673 Mulfingen · Phone +49 (0) 7938 81-0 · Fax +49 (0) 7938 81-110 · [email protected] · www.ebmpapst.com G1G144-AF49-70 Operating instructions 3. TECHNICAL DATA 3.1 Product drawing Translation of the original operating instructions All measures have the unit mm. 1 2 2.1 2.2 2.3 3 3.1 3.2 3.3 3.4 3.5 4 Housing side parts sealed with NBR round cord (pentane-resistant) 3-pole strip, mating connector: (not included in standard scope of delivery) tyco No. 350 766-1; female terminal: tyco No. 926 884-1 L N PE 5-pole strip; mating connector (not included in delivery) Molex No. 39-01-4050, female connector Molex No. 39-00-0059 (+) Speed monitoring Not assigned PWM input (-) GND Closed bleeder connection for pressure relief (drilled open if necessary) Item no. 51288-5-9970 · Revision 79946 · Release 2013-12-02 · Page 4 / 11 ebm-papst Mulfingen GmbH & Co. KG · Bachmühle 2 · D-74673 Mulfingen · Phone +49 (0) 7938 81-0 · Fax +49 (0) 7938 81-110 · [email protected] · www.ebmpapst.com Operating instructions G1G144-AF49-70 You can control the blower either via the 0-10 VDC input or the PWM input. Note: Inputs cannot be used simultaneously. 3.2 Nominal data 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. 3.4 Mounting data Motor M1G055-BD Phase Nominal voltage / VAC Frequency / Hz 1~ 230 50/60 Type of data definition Speed / min-1 Power input / W Current draw / A Min. ambient temperature / °C Max. ambient temperature / °C Min. temp. of flow medium / °C Max. temp. of flow medium / °C fa 4800 75 0.5 -25 70 -25 80 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). Strength class for mounting screws 8.8 You can obtain additional mounting data from the product drawing if necessary. 3.5 Transport and storage conditions ; Use the device in accordance with its protection type. Max. permissible ambient motor temp. (transp./ storage) Min. permissible ambient motor temp. (transp./storage) + 80 °C - 40 °C ml = Max. load · me = Max. efficiency · fa = Running at free air cs = Customer specs · cu = Customer unit Subject to alterations Translation of the original operating instructions 3.3 Technical features Mass Size Surface of rotor Material of protective cover Material of impeller Housing material Direction of rotation Type of protection Insulation class Mounting position Condensate discharge holes Operation mode Premix Motor bearing Technical features Touch current acc. IEC 60990 (measuring network Fig. 4, TN system) Motor protection Remark 1.9 kg 144 mm Thick layer passivated PP plastic PA plastic Die-cast aluminium Clockwise, seen on rotor IP 20 "B" Any None S1 Not suitable for pre-mixture. Ball bearing - Tach output - Motor current limit - Control input PWM <= 3.5 mA Reverse polarity and locked-rotor protection Complete unit must be tested for required approvals. Item no. 51288-5-9970 · Revision 79946 · Release 2013-12-02 · Page 5 / 11 ebm-papst Mulfingen GmbH & Co. KG · Bachmühle 2 · D-74673 Mulfingen · Phone +49 (0) 7938 81-0 · Fax +49 (0) 7938 81-110 · [email protected] · www.ebmpapst.com G1G144-AF49-70 Operating instructions 4. CONNECTION AND START-UP 4.1 Connecting the mechanical system DANGER Gas leaking from improperly sealed housing Risk of fatal injury → Prior to commissioning, check that the housing of the gas blower is pressure-tight. When doing so, close the intake and exhaust opening and the shaft opening. → In addition, check that rotating parts do not scrape against stationary parts. → Connect the device only to circuits that can be switched off using an all-pole disconnecting switch. → When working on the device, you must switch off the system/machine in which the device is installed and secure it from being switched on again. NOTE Interferences and failures are possible Maintain a distance to the power supply line when routing the control lines of the device. DANGER Leaks may occur. As a result of design necessities, the gas blower is not tightly sealed, e.g. at the shaft opening. This may cause leaks during operation. Deflagrations may also cause long-term damage or deformation of the housing, which can result in leaks. An air/ gas mixture may accumulate outside of the gas blower. The blower may explode. You could be severely injured. → Ensure a sufficiently large clearance. Recommendation: clearance > 10 cm (separate cable routing) → Check which hazards arise from installing, operating, servicing or disposing of the gas blower in conjunction with your device. Prevent these hazards. Carry out all appropriate measures to this purpose. → Make sure that the cable end is connected in a dry environment. CAUTION Cutting and crushing hazard when removing the blower from the packaging → Carefully remove the blower from its packaging, only touching the housing. Make sure to avoid any shock. → Wear safety shoes and cut-resistant safety gloves. ; Check the device for transport damage. Damaged devices must no longer be installed. ; Install the undamaged device according to your application. 4.2 Connecting the electrical system Translation of the original operating instructions CAUTION Electrical voltage The device is a built-in component and features no electrically isolating switch. DANGER Electric voltage on the device Electric shock → Always install a protective earth first. → Check the protective earth. DANGER Incorrect insulation Risk of fatal injury from electric shock → Use only cables that meet the specified installation requirements for voltage, current, insulation material, load etc. → Route cables such that they cannot be touched by any rotating parts. NOTE Water penetration into leads or wires Water enters at the cable end on the customers side and can damage the device. The control voltage circuit is not electrically isolated. Connect the device only to circuits that can be switched off using an allpole disconnecting switch. 4.2.1 Prerequisites ; Check whether the data on the type plate agree with 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 crosssection. We recommend the use of 105°C cables. Ensure that the minimum cable cross-section is at least AWG26/0.13 mm². 4.2.2 Idle current Because of the EMC filter integrated for compliance with EMC limits (interference emission and interference immunity), idle currents in the mains cable can be measured even when the motor is at a standstill and the mains voltage is switched on. 4.2.3 Locked-rotor protection Due to the locked-rotor protection, the start-up current (LRA) is equal to or less than the nominal current (FLA). DANGER Electrical load (>50 µC) between mains wire and protective earth connection after switching of the supply when switching multiple devices in parallel. Electric shock, risk of injury → Make sure that sufficient protection against accidental contact is provided. Before working on the electrical connection, the connections to the mains supply and PE must be shorted. Item no. 51288-5-9970 · Revision 79946 · Release 2013-12-02 · Page 6 / 11 ebm-papst Mulfingen GmbH & Co. KG · Bachmühle 2 · D-74673 Mulfingen · Phone +49 (0) 7938 81-0 · Fax +49 (0) 7938 81-110 · [email protected] · www.ebmpapst.com G1G144-AF49-70 Operating instructions 4.3 Connection via plug 4.3.1 Establish supply connections CAUTION Electrical voltage The device is a built-in component and features no electrically isolating switch. → Connect the device to a suitable trigger device. Connect the device only to circuits that can be switched off using an allpole disconnecting switch. → When working on the device, you must switch off the system/machine in which the device is installed and secure it from being switched on again. ; Check the PIN assignment of your connector. ; Connect the panel connector and mating connector. Translation of the original operating instructions ; Ensure that the connector is locked in correctly. Item no. 51288-5-9970 · Revision 79946 · Release 2013-12-02 · Page 7 / 11 ebm-papst Mulfingen GmbH & Co. KG · Bachmühle 2 · D-74673 Mulfingen · Phone +49 (0) 7938 81-0 · Fax +49 (0) 7938 81-110 · [email protected] · www.ebmpapst.com G1G144-AF49-70 Operating instructions Translation of the original operating instructions 4.4 Connection screen Item no. 51288-5-9970 · Revision 79946 · Release 2013-12-02 · Page 8 / 11 ebm-papst Mulfingen GmbH & Co. KG · Bachmühle 2 · D-74673 Mulfingen · Phone +49 (0) 7938 81-0 · Fax +49 (0) 7938 81-110 · [email protected] · www.ebmpapst.com G1G144-AF49-70 Operating instructions 4.5 Checking the connections 5. INTEGRATED PROTECTIVE FUNCTIONS ; Make sure that the power is off (all phases). ; Secure it from being switched on again. The integrated protective functions cause the motor to switch off automatically in case of faults described in the table. ; Check the correct fit of the connection lines. Malfunctions 4.6 Switch on 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 connection. This also applies for devices which have already been equipped with plugs and terminals or similar connectors by the customer. Rotor position detection error Locked rotor Description / Function of safety feature An automatic restart occurs. ; After the blockage is removed, the motor restarts automatically. WARNING Hot motor housing Fire hazard → Ensure that no combustible or flammable materials are located close to the blower. ; 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 0 VDC to the 0-10 V control input (if you are using the control input) ; Apply 0 % PWM to the PWM control input (if you are using the PWM control input) ; Apply the nominal voltage to the voltage supply. ; Start the device by changing the input signal. 4.7 Switching off the device Switching off the device during operation: ; Switch on 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 on the device via the control input. Translation of the original operating instructions ; Do not switch the motor (e.g. in cyclic operation) on and off via power supply. ; Disconnect the device from the supply voltage. ; When disconnecting, be sure to disconnect the earth wire connection last. Item no. 51288-5-9970 · Revision 79946 · Release 2013-12-02 · Page 9 / 11 ebm-papst Mulfingen GmbH & Co. KG · Bachmühle 2 · D-74673 Mulfingen · Phone +49 (0) 7938 81-0 · Fax +49 (0) 7938 81-110 · [email protected] · www.ebmpapst.com Operating instructions G1G144-AF49-70 Mains supply voltage faulty 6. MAINTENANCE, MALFUNCTIONS, POSSIBLE CAUSES AND REMEDIES Do not perform any repairs on your device. Return the device to ebmpapst 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. Faulty connection Overtemperature of electronics/motor Insufficient cooling CAUTION If the control signal of a blower that is connected to the power system is removed, the motor can restart automatically. Danger of injury → When working on the blower, switch off the mains supply voltage and secure it from being switched on again. Ambient temperature too high → Wait until the device stops. CAUTION Electrical load after device is switched off Electric shock in case of contact → Wait for five minutes after disconnecting the voltage at all poles before touching the unit. CAUTION If control voltage is applied or a speed setpoint is stored, the motor automatically restarts, e.g. after a power failure. Danger of injury Unacceptable operating point Deflagration Leakage of the handled air/gas mixture Check mains supply voltage, restore power supply, apply control signal. De-energise, correct connection, see connection diagram. 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. Reduce the ambient temperature. Reset by reducing control input to 0. Correct the operating point. Let the device cool down. Check for leaks; replace blower if not properly sealed If you have any other problems, contact ebm-papst. → Keep out of the danger zone of the device. → When working on the device, switch off the mains supply voltage and secure the latter from being switched on again. → Wait until the device stops. Translation of the original operating instructions → After working on the device, remove any used tools or other objects from the device. If the blower remains out of use for some time, e.g. when in storage, we recommend switching the blower on for at least 2 hours to allow any condensate to evaporate and to move the bearings. Malfunction/error Impeller running roughly Motor does not turn Possible cause Imbalance in rotating parts Mechanical blockage Possible remedy 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. Switch off, deenergise, and remove mechanical blockage. 6.1 Cleaning NOTE The device does not need to be cleaned. 6.2 Safety test NOTE High-voltage test The integrated EMC filter contains Y capacitors. Therefore, the trigger current is exceeded when AC testing voltage is applied. → Test the device with DC voltage when you carry out the high-voltage test required by law. The voltage to be used corresponds to the peak value of the AC voltage required by the standard. What has to be tested? Check the protective casing against accidental contact for damage and to ensure that it is intact How to test? Frequency Visual inspection At least every 6 months Which measure? Repair or replacement of the device Item no. 51288-5-9970 · Revision 79946 · Release 2013-12-02 · Page 10 / 11 ebm-papst Mulfingen GmbH & Co. KG · Bachmühle 2 · D-74673 Mulfingen · Phone +49 (0) 7938 81-0 · Fax +49 (0) 7938 81-110 · [email protected] · www.ebmpapst.com G1G144-AF49-70 Visual inspection At least every 6 months Replacement of the device Visual inspection At least every 6 months Visual inspection At least every 6 months Fasten Visual inspection At least every 6 months Replace wires Fasten Translation of the original operating instructions Check the device for damage to blades and housing Mounting the connection lines Mounting of protective earth connection Check the insulation of the wires for damage Operating instructions Item no. 51288-5-9970 · Revision 79946 · Release 2013-12-02 · Page 11 / 11 ebm-papst Mulfingen GmbH & Co. KG · Bachmühle 2 · D-74673 Mulfingen · Phone +49 (0) 7938 81-0 · Fax +49 (0) 7938 81-110 · [email protected] · www.ebmpapst.com