K1G200-AD37-02 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 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. Translation of the original operating instructions CONTENTS 1. SAFETY REGULATIONS AND INFORMATION 1 1.1 Hazard levels for warnings 1.2 Staff qualifications 1.3 Basic safety rules 1.4 Voltage 1.5 Safety and protective features 1.6 Electromagnetic radiation 1.7 Mechanical movement 1.8 Emissions 1.9 Hot surface 1.10 Transport 1.11 Storage 1 1 1 1 2 2 2 2 2 2 2 2. INTENDED USE 3 3. TECHNICAL DATA 4 3.1 Product drawing 3.2 Nominal data 3.3 Data according to ErP Directive 3.4 Technical description 3.5 Mounting data 3.6 Transport and storage conditions 3.7 Electromagnetic compatibility 4 5 5 5 5 5 6 4. CONNECTION AND STARTUP 6 4.1 Mechanical connection 4.2 Electrical connection 4.3 Connecting the cables 4.4 Connection diagram 4.5 Checking connections 4.6 Switching on the device 4.7 Switching off the device 6 6 6 7 8 8 8 5. MAINTENANCE, MALFUNCTIONS, POSSIBLE CAUSES AND REMEDIES 8 5.1 Cleaning 5.2 Safety inspection 5.3 Disposal 9 9 9 1.1 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 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 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 ; Check the device's electrical equipment at regular intervals; see Chapter 5.2 Safety inspection. ; Replace loose connections and defective cables immediately. 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 Item no. 50899-5-9970 · ENU · Change 89188 · Approved 2016-04-18 · Page 1 / 9 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 K1G200-AD37-02 Operating instructions → 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. Translation of the original operating instructions 1.7 Mechanical movement DANGER Rotating device Risk of injury to body parts coming into contact with the rotor or the impeller. 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. → 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. Item no. 50899-5-9970 · ENU · Change 89188 · Approved 2016-04-18 · Page 2 / 9 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 K1G200-AD37-02 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 ● Using the device in DC grids only. ● 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. Translation of the original operating instructions ● Item no. 50899-5-9970 · ENU · Change 89188 · Approved 2016-04-18 · Page 3 / 9 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 K1G200-AD37-02 Operating instructions 3. TECHNICAL DATA 3.1 Product drawing All dimensions in mm. Cable AWG20, 4x crimped splices Direction of air flow "V" Translation of the original operating instructions 1 2 Item no. 50899-5-9970 · ENU · Change 89188 · Approved 2016-04-18 · Page 4 / 9 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 K1G200-AD37-02 3.2 Nominal data 3.4 Technical description Motor M1G074-BF Nominal voltage / VDC Nominal voltage range / VDC 48 36 .. 57 Method of obtaining data Status Speed / min-1 Power consumption / W Current draw / A Max. back pressure / Pa Min. ambient temperature / °C Max. ambient temperature / °C fa Weight Fan size Rotor surface Impeller material Housing material Support bracket material Number of blades Airflow direction Direction of rotation Degree of protection Insulation class Moisture (F) / Environmental (H) protection class Installation position Cooling hole/opening Mode Motor bearing Technical features prelim. 4140 183 5.6 520 -25 70 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 01 Overall efficiency ηes / % 02 Measurement category 03 Efficiency category 04 Efficiency grade N 05 Variable speed drive 06 Year of manufacture Translation of the original operating instructions 07 Manufacturer 08 Type 09 Power consumption Pe / kW 09 Air flow qv / m³/h 09 Pressure increase total psf / Pa 10 Speed n / min-1 11 Specific ratio* 12 Recycling/disposal 13 Maintenance 14 Additional components * Actual Req. 2015 44.6 A Static 62.2 Yes 32.4 Motor protection 50 The year of manufacture is specified on the product's rating label. ebm-papst Mulfingen GmbH & Co. KG Amtsgericht (court of registration) Stuttgart · HRA 590344 D-74673 Mulfingen K1G200-AD37-02 0.21 700 430 with cable Conformity with standards Approval 1.7 kg 200 mm Painted black PA6 plastic, glass-fiber reinforced PA6 plastic, glass-fiber reinforced PA6 plastic, glass-fiber reinforced 7 "V" Clockwise, viewed toward rotor IP20; installation- and position-dependent "B" F0 Any On rotor side S1 Ball bearing - Tach output - Motor current limitation - Soft start - Control input 0-10 VDC / PWM Reverse polarity and locked-rotor protection Lateral EN 60950-1 EAC; UL 1004-1; CSA C22.2 No. 77 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. 3.5 Mounting data For screw clearance, see Chapter 3.1 Product drawing 4070 1.00 ; Secure the screws against unintentional loosening (e.g. use selflocking screws). Information on recycling and disposal is provided in the operating instructions. Information on installation, operation and maintenance is provided in the operating instructions. Components used to calculate the energy efficiency that are not apparent from the measurement category are detailed in the CE declaration. Strength class of screws 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. 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) Min. permitted ambient temp. for motor (transport/ storage) + 80 °C - 40 °C Item no. 50899-5-9970 · ENU · Change 89188 · Approved 2016-04-18 · Page 5 / 9 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 K1G200-AD37-02 3.7 Electromagnetic compatibility EMC immunity to interference EMC interference emission According to EN 61000-6-2 (industrial environment) According to EN 55022 (Class B) We recommend the use of 105 °C cables. Ensure that the minimum cable cross-section is at least AWG 26 / 0.13 mm². 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. 4. CONNECTION AND STARTUP 4.1 Mechanical connection CAUTION Risk of cutting and crushing when removing device from packaging → Carefully remove the device from the packaging by grasping hold of the frame. Never subject to any impact.# Wear safety shoes and cut-resistant safety gloves. 4.3 Connecting the cables The device has external leads. ● Connect the cables according to your application. When doing so, observe Chapter 4.4 Connection diagram. ; 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 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 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. Translation of the original operating instructions → When working on the fan, secure the system/machine in which the fan is installed so as to prevent it from being switched back on. NOTE 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. Operate the device with a safely isolated power supply. 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. Item no. 50899-5-9970 · ENU · Change 89188 · Approved 2016-04-18 · Page 6 / 9 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 K1G200-AD37-02 4.4 Connection diagram Drawing preliminary! Conn. 1 2 3 4 Designation Un +48 VDC 0-10 VDC Tach GND Color red yellow white blue Function/assignment Power supply 48 VDC, maximum ripple 3.5% Control input Re > 100k Tach output, 3 pulses per revolution, Isink max = 10 mA Reference ground Translation of the original operating instructions No. 1 1 1 1 Item no. 50899-5-9970 · ENU · Change 89188 · Approved 2016-04-18 · Page 7 / 9 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 K1G200-AD37-02 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 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. 4.7 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. 5. MAINTENANCE, MALFUNCTIONS, POSSIBLE CAUSES AND REMEDIES Do not perform any repairs on your device. Send the device to ebmpapst 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 Impeller not running smoothly 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. Motor not turning Translation of the original operating instructions ; Disconnect the device from the power supply. Motor/electronics overtemperature Possible cause Imbalance in rotating parts Possible remedy Clean the device; replace it if imbalance persists after cleaning. Make sure no weight clips are removed during cleaning. 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. 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 Reduce the ambient too high temperature. Reset by reducing control input to 0. Impermissible point of Correct the operating operation point. Let the device cool down. Item no. 50899-5-9970 · ENU · Change 89188 · Approved 2016-04-18 · Page 8 / 9 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 K1G200-AD37-02 Operating instructions In the event of further malfunctions, contact ebm-papst. 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. 5.1 Cleaning NOTE Damage to the device during cleaning Malfunction possible 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. → Do not clean the device using a water jet or high-pressure cleaner.# Do not use any acid, alkali or solventbasedcleaning agents.# Do not use any pointed or sharpedged objects for cleaning 5.3.3 Component disposal 5.2 Safety inspection Translation of the original operating instructions What to check Contact protection cover for intactness or damage Device for damage Fastening the cables Insulation of cables for damage Impeller for wear/deposits/ corrosion and damage Condensation drainage holes for clogging, where necessary How to check How often Visual inspection At least every 6 months Visual inspection At least every 6 months Visual inspection At least every 6 months Visual inspection At least every 6 months → Secure components before unfastening to stop them falling. What action? Repair or replacement of device Replace device Fasten Replace cables Visual inspection At least every 6 months Clean or replace impeller Visual inspection At least every 6 months Open holes 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 5.3 Disposal ● Power cables 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. ● 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. 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. Item no. 50899-5-9970 · ENU · Change 89188 · Approved 2016-04-18 · Page 9 / 9 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