W4D500-GM03-10 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 Data according to ErP directive 5 3.4 Technical features 5 3.5 Mounting data 5 3.6 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 in terminal box 7 4.4 Connection screen 8 4.5 Open additional screwed cable glands 9 4.6 Checking the connections 9 4.7 Switch on device 9 4.8 Switching off the device 9 ; Check the electrical equipment of the device at regular intervals, refer to chapter 5.2 Safety test. 5. MAINTENANCE, MALFUNCTIONS, POSSIBLE CAUSES AND REMEDIES 10 ; Replace loose connections and defective cables immediately. 5.1 Cleaning 10 5.2 Safety test 10 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 qualified, trained and authorised technical staff. Only authorised specialists are permitted to install the device, to carry out a test run and to perform work on the electrical installation. 1.3 Basic safety rules 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 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. 10764-5-9970 · Revision 83223 · Release 2014-05-16 · Page 1 / 10 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 W4D500-GM03-10 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. → Insert the brought-out thermal overload protector into the control circuit so that the cooled off motor does not switch on independently after a fault. 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. Translation of the original operating instructions 1.6 Mechanical movement DANGER Rotating device Body parts that come into contact with the rotor and impeller can be injured. 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. 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. ; 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. ; Maintain the storage temperature, see chapter 3.6 Transport and storage conditions. ; Please make sure that all screwed cable glands are fitted with dummy plugs. → Secure the device against accidental contact. 1.11 Disposal → Before working on the system/machine, wait until all parts have come to a standstill. When disposing of the device, please comply with all relevant requirements and regulations applicable in your country. 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. Item no. 10764-5-9970 · Revision 83223 · Release 2014-05-16 · Page 2 / 10 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 W4D500-GM03-10 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 in power systems with earthed neutral (TN/TT power systems) only. ● Only using the device in stationary systems. ● Carrying out all maintenance. ● Moving air with a density of 1.2 kg/m³. ● Using the device in accordance with the permitted ambient temperature, see chapter 3.6 Transport and storage conditions and chapter 3.2 Nominal data. ● Operating the device with all protective features in place. ● Minding the operating instructions. Improper use 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. ● Operation in medical equipment with a life-sustaining or lifesaving function. ● Operation with external vibrations. ● Moving solids content in flow medium. ● Painting the device ● Connections (e.g. screws) coming loose during operation. ● Opening the terminal box during operation. ● Moving air that contains abrasive particles. ● Moving highly corrosive air, e.g. salt spray mist. Exceptions are devices that are intended for salt spray mist and protected accordingly. ● Moving air that contains dust pollution, e.g. suctioning off saw dust. ● Operating the device close to flammable materials or components. ● Operating the device in an explosive atmosphere. ● Using the device as a safety component or for taking on safetyrelated functions. ● Operation with completely or partially disassembled or modified protective features. ● In addition, all application options that are not listed under proper use. Item no. 10764-5-9970 · Revision 83223 · Release 2014-05-16 · Page 3 / 10 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 W4D500-GM03-10 Operating instructions 3. TECHNICAL DATA 3.1 Product drawing All measures have the unit mm. Direction of air flow "V" Tightening torque 1.5±0.2 Nm Cable diameter: min. 6 mm, max. 12 mm, tightening torque: 2±0.3 Nm Translation of the original operating instructions 1 2 3 Item no. 10764-5-9970 · Revision 83223 · Release 2014-05-16 · Page 4 / 10 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 W4D500-GM03-10 3.2 Nominal data Motor M4D110-GF Phase Nominal voltage / VAC Connection Frequency / Hz 3~ 400 Δ 50 3~ 400 Y 50 3~ 400 Δ 60 3~ 460 Δ 60 Type of data definition Valid for approval / standard Speed / min-1 Power input / W Current draw / A Max. back pressure / Pa Min. ambient temperature / °C Max. ambient temperature / °C Starting current / A Maximum safe operating speed / min-1 ml CE ml CE ml CE ml CE 1390 720 1.41 140 -40 1180 550 0.9 100 -40 1590 1020 1.7 130 -40 1640 1060 1.64 138 -40 65 65 50 60 6.5 2.2 5.9 6.8 1920 1920 1920 1920 @ 55 °C @ 55 °C @ 55 °C @ 55 °C ml = Max. load · me = Max. efficiency · fa = Running at free air cs = Customer specs · cu = Customer unit 3.3 Data according to ErP directive * Product conforming to standard Approval Via terminal box Thermal overload protector (TOP) brought out Axial I (if protective earth is connected by customer) EN 61800-5-1; CE CCC; EAC; UL 1004-1; CSA C22.2 Nr.100 ; Secure the mounting screws against accidentally coming loose (e.g. by using self-locking screws). Strength class for mounting screws Specific ratio = 1 + pfs / 100 000 Pa Actual Translation of the original operating instructions Cable exit Protection class S1 Ball bearing <= 3.5 mA 3.5 Mounting data A Static No 1.00 Overall efficiency ηes / % Efficiency grade N Power input Pe / kW Air flow qv / m³/h Pressure increase total psf / Pa Speed n / min-1 Condensate discharge holes Operation mode Motor bearing Touch current acc. IEC 60990 (measuring network Fig. 4, TN system) Electrical leads Motor protection IP 54 "F" F4-1 Shaft horizontal or rotor on bottom; rotor on top on request Rotor-side 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. Subject to alterations Installation category Efficiency category Variable speed drive Specific ratio* Type of protection Insulation class Humidity class Mounting position 33.4 40.6 0.73 5860 151 1385 Request 2013 28.8 36 Request 2015 32.8 40 Data definition with optimum efficiency. The ErP data is determined using a motor-impeller combination in a standardised measurement configuration. 8.8 You can obtain additional mounting data from the product drawing if necessary. 3.6 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 3.4 Technical features Mass Size Surface of rotor Material of terminal box Material of blades Material of wall ring Material of guard grille Number of blades Direction of air flow Direction of rotation 16.2 kg 500 mm Coated in black PC / ABS plastic Press-fitted sheet steel blank, sprayed with PP plastic Sheet steel, pre-galvanised and coated in black plastic (RAL 9005) Steel, coated in black plastic (RAL9005) 5 "V" Counter-clockwise, seen on rotor Item no. 10764-5-9970 · Revision 83223 · Release 2014-05-16 · Page 5 / 10 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 W4D500-GM03-10 Operating instructions 4. CONNECTION AND START-UP 4.1 Connecting the mechanical system CAUTION Cutting and crushing hazard when removing the device from the packaging Blades can be bent → Carefully remove the device from its packaging, only touching the wall ring. Make sure to avoid any shock. → Wear safety shoes and cut-resistant safety gloves. CAUTION Heavy load when taking out the device Bodily harm, e.g. back injuries, are possible. → Two people should remove the device out of its packaging together. ; Check the device for transport damage. Damaged devices must no longer be installed. ; Do not make any modifications, additions or renovations to the device. Replacing the terminal box is not permitted. ; 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. Translation of the original operating instructions → Route cables such that they cannot be touched by any rotating parts. 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. CAUTION Electrical voltage The fan is a built-in component and features no electrically isolating switch. → Only connect the fan to circuits that can be switched off with an all-pole separating switch. → When working on the fan, you must switch off the installation/machine in which the fan is installed and secure it from being switched on again. NOTE Water penetration into leads or wires Water enters at the cable end on the customers side and can damage the device. → Make sure that the cable end is connected in a dry environment. 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. ; 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. Earth wire contact resistance to EN 61800-5-1 Compliance with the impedance specifications to EN 61800-5-1 for the protective earth circuit must be verified in the end application. Depending on the installation situation, it may be necessary to install an additional protective earthing conductor via the additional protective earth connection point available on the device. The protective earth connection point is located on the housing and has a protective earth symbol and a bore hole. 4.2.2 Residual current operated device Only pulse-current sensitive and/or universal RCD protective devices (Type A or B) are permitted. Like frequency inverters, RCD protective devices cannot provide personal safety while operating the device. 4.2.3 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. 4.2.4 Frequency inverter Please use a frequency converter only after consultation with ebm-papst. When a frequency converter is used for speed adjustment, the maximum safe operating speed (see 3.2 Nominal data) may not be exceeded. 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. Heating of the motor due to use of a frequency converter must be checked in the application by the customer. Item no. 10764-5-9970 · Revision 83223 · Release 2014-05-16 · Page 6 / 10 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 W4D500-GM03-10 Operating instructions 4.3 Connection in terminal box 4.3.1 Preparing connection lines for the connection Strip the cable just enough so that the screwed cable gland is tight and the terminals are relieved of strain. Tightening torque, see chapter 3.1 Product drawing. Fig. 3: Cable routing for fans installed upright. 4.3.2 Connecting cables with terminals ; Remove the cap from the screwed cable gland. Remove the cap only in those places where cables are inserted. ; Insert the line(s) (not included in the standard scope of delivery) into the terminal box. ; First connect the "PE" (protective earth) connection. ; Connect the lines to the corresponding terminals. ; Connect the thermal overload protector (TOP). Use a screwdriver to do so. During the connection work, ensure that no cables splice off. The terminal strip is equipped with a penetration prevention device. ; Insert the strands until they meet resistance. ; Seal the terminal box. 4.3.3 Cable routing No water may penetrate along the cable in the direction of the cable gland. Fans installed lying flat Translation of the original operating instructions Make sure that the cable is routed in the form of a loop (water trap). 4.3.4 Motor protection CAUTION Voltage The device is a built-in component with no isolating switch. → Connect the device to a suitable tripping device. → Only connect the device to circuits which can be deenergised with an all-pole disconnection switch. → When working on the device, the system/machine in which the device is installed must be secured so as to prevent it from being switched back on. NOTE Lack of motor protection Without motor protection, the motor can overheat and suffer damage. → Connect up the thermal overload protector installed in the coil. The motors are equipped with thermal overload protectors to protect the devices. Check to make sure that the thermal overload protector is correctly connected before each operation. Failure to connect up the thermal overload protector correctly will invalidate your warranty claim. Fig. 2: Fan installed lying flat, cable routed as a water trap. Fans installed in upright position When routing the cable, ensure that the screwed cable glands are arranged at the bottom. The cables must always be routed downwards. Item no. 10764-5-9970 · Revision 83223 · Release 2014-05-16 · Page 7 / 10 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 W4D500-GM03-10 Operating instructions 4.4 Connection screen Delta connection Star connection = V1 = blue = U1 = black = W1 = brown yellow green white 2 x grey green/yellow Translation of the original operating instructions Δ Y L1 L2 L3 W2 U2 V2 TOP PE Item no. 10764-5-9970 · Revision 83223 · Release 2014-05-16 · Page 8 / 10 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 W4D500-GM03-10 Operating instructions 4.5 Open additional screwed cable glands 4.8 Switching off the device You have the ability to break a second cable gland opening through on the terminal box. ; Disconnect the device from the supply voltage at the main switch for the supply line. WARNING In event of a fault, the screwed cable gland is under electrical voltage Electric shock ; When disconnecting, be sure to disconnect the earth wire connection last. → Do not use metal cable glands for plastic terminal boxes. ; Screw the cable gland into the pre-cut thread using a screwdriver. When doing so, note the tightening torques, see chapter 3.1 Product drawing. ; Remove the plastic tab that falls off when the wire is pressed through into the terminal box. Fig. 4: Screwed cable gland opening 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. ; Screw the terminal box cover closed again. Terminal box tightening torque, see chapter 3.1 Product drawing. ; Make sure that the terminal box is correctly closed and sealed and that all screws and screwed cable glands are properly tightened. 4.7 Switch on device Translation of the original operating instructions 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. WARNING Hot motor housing Fire hazard → Ensure that no combustible or flammable materials are located close to the fan. ; Inspect the device for visible external damage and the proper function of the protective features before switching it on. ; Check the air flow paths of the fan for foreign objects and remove any that are found. ; Apply the nominal voltage to the voltage supply. Item no. 10764-5-9970 · Revision 83223 · Release 2014-05-16 · Page 9 / 10 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 W4D500-GM03-10 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. 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. → Insert the brought-out thermal overload protector into the control circuit so that the cooled off motor does not switch on independently after a fault. 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. Translation of the original operating instructions Malfunction/error Impeller running roughly Motor does not turn Possible cause Imbalance in rotating parts Mechanical blockage Mains supply voltage faulty Faulty connection Thermal overload protector responded Unacceptable operating point 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 Check operating point Overtemperature of motor Ambient temperature too high Insufficient cooling 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. 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 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 Tightness of screwed cable gland Condensate discharge holes for clogging, as necessary Weld seams for crack formation 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 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 Visual inspection At least every 6 months Retighten, replace if damaged Open bore holes Visual inspection At least every 6 months Visual inspection At least every 6 months Fasten Replace device Item no. 10764-5-9970 · Revision 83223 · Release 2014-05-16 · Page 10 / 10 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