R2E160-BG34-05 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 Mechanical movement 2 1.7 Emission 2 1.8 Hot surface 2 1.9 Transport 2 1.10 Storage 2 1.11 Disposal 2 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 4. CONNECTION AND START-UP 6 4.1 Connecting the mechanical system 6 4.2 Connecting the electrical system 6 4.3 Connection of the cables 6 4.4 Connection of the Hall IC 6 4.5 Connection screen 7 4.6 Checking the connections 8 4.7 Switch on device 8 4.8 Switching off the device 8 5. MAINTENANCE, MALFUNCTIONS, POSSIBLE CAUSES AND REMEDIES 8 5.1 Cleaning 9 5.2 Safety test 9 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 Only specialised electrical personnel may install the device, perform the test run and work on the electrical system. Only trained and authorised specialist personnel are permitted to transport, unpack, assemble, operate or maintain the device, or to use it in any other manner. 1.3 Basic safety rules 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: ; 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 5.2 Safety test. ; Replace loose connections and defective cables immediately. DANGER Electrical load on the device Risk of electric shock → Stand on a rubber mat if you are working on an electrically charged device. 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. 11882-5-9970 · Revision 75470 · Release 2012-09-07 · 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 R2E160-BG34-05 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 The motor restarts automatically when operating voltage is applied, 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. 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 by reaching into the running device with your hands. 1.8 Hot surface CAUTION High temperature at the motor housing Danger of burn injuries → Ensure that sufficient protection against accidental contact is provided. 1.9 Transport NOTE Transport of device → Transport the device in its original packaging only. → Secure the device so that it does not slip, e.g. by using a clamping strap. 1.10 Storage ; Store the device, partially or fully assembled, in a dry and weatherproof manner in the original packing in a clean environment. ; Protect the device from environmental impacts and dirt until the final installation. → 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. ; We recommend storing the device for a maximum up to one year to guarantee proper operation and longest possible service life. → The device is a built-in component. You, the owner/ operator, are responsible for providing adequate protection for the device. ; Maintain the storage temperature, see chapter 3.5 Transport and storage conditions. → Shut down the device immediately if you detect a missing or ineffective protective feature. 1.6 Mechanical movement ; Even devices explicitly suited for outdoor use are to be stored as described prior to being commissioned. 1.11 Disposal When disposing of the device, please comply with all relevant requirements and regulations applicable in your country. DANGER Rotating device Body parts that come into contact with the rotor and impeller can be injured. → Secure the device against accidental contact. Translation of the original operating instructions → Before working on the system/machine, wait until all parts have come to a standstill. 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. 1.7 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. Item no. 11882-5-9970 · Revision 75470 · Release 2012-09-07 · 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 R2E160-BG34-05 Operating instructions 2. PROPER USE The device is exclusively designed as a built-in device for moving air 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. Proper use also includes: ● Use the device only for moving exhaust air from exhaust gas blowers for wood-based fuels. ● Using the device in accordance with the permitted ambient temperature, see chapter 3.5 Transport and storage conditions and chapter 3.2 Nominal data. ● Only using the device in stationary systems. ● Commissioning the built-in component only after installation in the customer unit. ● 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. ● Moving highly corrosive air, e.g. salt spray mist. Exceptions are devices that are intended for salt spray mist and protected accordingly. ● Operation with external vibrations. ● Operating the device in an explosive atmosphere. ● 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. ● Using the device as a safety component or for taking on safetyrelated functions. ● In addition, all application options that are not listed under proper use. Translation of the original operating instructions ● Item no. 11882-5-9970 · Revision 75470 · Release 2012-09-07 · 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 R2E160-BG34-05 Operating instructions 3. TECHNICAL DATA 3.1 Product drawing All measures have the unit mm. Connection line silicone 4G 0.5 mm², 4 x brass lead tips crimped Connection line Raychem AWG24, 3x brass lead tips crimped Translation of the original operating instructions 1 2 Item no. 11882-5-9970 · Revision 75470 · Release 2012-09-07 · 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 R2E160-BG34-05 3.2 Nominal data Motor M2E068-DF Phase Nominal voltage / VAC Frequency / Hz 1~ 230 50 Type of data definition Valid for approval / standard Speed / min-1 Power input / W Current draw / A Motor capacitor / µF Capacitor voltage / VDB Capacitor standard Min. back pressure / Pa Max. ambient temperature / °C ml CE 2800 57 0.26 1.5 450 P0 (CE) 150 80 ml = max. load · me = max. efficiency · fa = running at free air cs = customer specs · cu = customer unit Subject to alterations 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 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 3.3 Technical features Mass Size Surface of rotor Material of impeller Number of blades Motor suspension Translation of the original operating instructions Direction of rotation Type of protection Insulation class Humidity class Mounting position Condensate discharge holes Operation mode Motor bearing Touch current acc. IEC 60990 (measuring network Fig. 4, TN system) Motor protection Cable exit Protection class Product conforming to standard 4.4 kg 160 mm Partially cast in aluminium Sheet steel 6 Motor anti-vibration mounted on one side via mounting plate Counter-clockwise, seen on rotor IP 44; Depending on installation and position "F" F0 Any None S1 Ball bearing < 0.75 mA Thermal overload protector (TOP) wired internally Variable I (if protective earth is connected by customer) EN 60335-1; CE Item no. 11882-5-9970 · Revision 75470 · Release 2012-09-07 · 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 R2E160-BG34-05 Operating instructions 4. CONNECTION AND START-UP 4.1 Connecting the mechanical system CAUTION Cutting and crushing hazard when removing the fan from the packaging → Carefully hold the impeller to remove the device from its packaging. 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 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. cable cross-section is at least AWG26/0.13 mm². 4.2.2 Voltage control With open loop speed control using transformers or electronic voltage regulators (e.g. phase angle control), excessive current may occur. In addition, noises can occur with phase angle control depending on the mounting situation. 4.2.3 Frequency inverter Fit sinusoidal filters that work on all poles (live-live and liveearth) between the frequency inverter and the motor for operation with frequency inverters. Depending on how the device is installed, noises may occur. 4.3 Connection of the cables External leads are brought out of device. ; First connect the "PE" (protective earth) connection. ; Connect the lines according to your application. When doing so, observe chapter 4.5 Connection screen. 4.4 Connection of the Hall IC External leads are brought out of device. ; Connect the lines according to your application. When doing so, observe chapter 4.5 Connection screen. 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. Translation of the original operating instructions → 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. Connect the device only to circuits that can be switched off using an all-pole disconnecting switch. 4.2.1 Prerequisites ; Check whether the data on the type plate agree with the connection data and the data of the operating capacitor. ; 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 Item no. 11882-5-9970 · Revision 75470 · Release 2012-09-07 · 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 R2E160-BG34-05 Operating instructions 4.5 Connection screen Fan connection diagram Blue brown black green/yellow Hall IC circuit Hall IC Red (+5V) White (out) Black (0V) Translation of the original operating instructions 1 U1 Z U2 PE 2 2.1 2.2 2.3 2.4 Item no. 11882-5-9970 · Revision 75470 · Release 2012-09-07 · 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 R2E160-BG34-05 Operating instructions 4.6 Checking the connections ; Make sure that the power is off (all phases). ; Secure it from being switched on again. ; Check the correct fit of the connection lines. 4.7 Switch on device WARNING Hot motor housing Fire hazard → Ensure that no combustible or flammable materials are located close to the fan. 5. 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. ; Inspect the device for visible external damage and the proper function of the protective features before switching it on. CAUTION Electrical load on the capacitor after device is switched off Electric shock, risk of injury ; Check the air flow paths of the fan for foreign objects and remove any that are found. → Discharge the capacitors before working on the device. ; Apply the nominal voltage to the voltage supply. 4.8 Switching off the device ; Disconnect the device from the supply voltage at the main switch for the supply line. ; When disconnecting, be sure to disconnect the earth wire connection last. CAUTION The motor restarts automatically when operating voltage is applied, 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. Translation of the original operating instructions 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 Impeller running roughly Possible cause Imbalance in rotating parts Motor does not turn Mechanical blockage Mains supply voltage faulty Faulty connection Thermal overload protector responded 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. Check mains supply voltage, restore power supply. De-energise, correct connection, see connection diagram. Allow motor to cool off, locate and rectify cause of error, if necessary cancel restart lock-out Item no. 11882-5-9970 · Revision 75470 · Release 2012-09-07 · 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 Operating instructions R2E160-BG34-05 Overtemperature of motor Unacceptable operating point Ambient temperature too high Insufficient cooling Check operating point Lower ambient temperature if possible Improve cooling If you have any other problems, contact ebm-papst. 5.1 Cleaning NOTE Damage to the device during cleaning. Malfunction possible → Do not clean the device using a water jet or high-pressure washer. → Do not use any cleaners containing acids, bases or solvents. → Do not use any pointed or sharp-edged objects to clean. Translation of the original operating instructions 5.2 Safety test What has to be tested? Check the protective casing against accidental contact for damage and to ensure that it is intact Device for damage Mounting the connection lines Mounting of protective earth connection Check the insulation of the wires for damage Weld seams for crack formation Check the ball bearings to ensure they are quiet, can move easily and are free of play How to test? Frequency Visual inspection At least every 6 months Which measure? Repair or replacement of the device Visual inspection At least every 6 months Visual inspection At least every 6 months Visual inspection At least every 6 months Replace device Visual inspection At least every 6 months Replace wires Visual inspection At least every 6 months Replace device Manual check by turning the rotor in shut-off state Replace device in case of noise, difficulty of movement or clearance of the bearings At least every 6 months Fasten Fasten Item no. 11882-5-9970 · Revision 75470 · Release 2012-09-07 · 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