G2E120-AR38-01 Operating instructions ebm-papst Mulfingen GmbH & Co. KG Bachmuhle 2 D-74673 Mulfingen Phone +49 (0) 7938 81-0 Fax +49 (0) 7938 81-110 info1@de.ebmpapst.com 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 1.2 Staff qualification 1.3 Basic safety rules 1.4 Electrical voltage 1.5 Safety and protective functions 1.6 Mechanical movement 1.7 Emission 1.8 Hot surface 1.9 Transport 1.10 Storage 1 1 1 1 2 2 2 2 2 2 2. PROPER USE 3 3. TECHNICAL DATA 4 3.1 Product drawing 3.2 Nominal data 3.3 Technical features 3.4 Mounting data 3.5 Transport and storage conditions 4 5 5 5 5 4. CONNECTION AND START-UP 5 4.1 Connecting the mechanical system 4.2 Connecting the electrical system 4.3 Connection of the cables 4.4 Connection screen 4.5 Checking the connections 4.6 Switch on device 4.7 Switching off the device 5 5 6 7 8 8 8 5. MAINTENANCE, MALFUNCTIONS, POSSIBLE CAUSES AND REMEDIES 8 5.1 Cleaning 5.2 Safety test 5.3 Disposal 9 9 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 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 ; 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. 11108-5-9970 * ENG * Revision 72138 * Release 2012-08-17 * Page 1 / 9 ebm-papst Mulfingen GmbH & Co. KG * Bachmuhle 2 * D-74673 Mulfingen * Phone +49 (0) 7938 81-0 * Fax +49 (0) 7938 81-110 * info1@de.ebmpapst.com * www.ebmpapst.com G2E120-AR38-01 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 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 a protective device is found to be missing or ineffective. 1.6 Mechanical movement Translation of the original operating instructions 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 3.5 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, dangling items of clothing, jewellery and similar items can become entangled and be pulled into the device. Risk of injury. Do not wear any loose-fitting or dangling clothing or jewellery while working on rotating parts.# Protect long hair with a cap. Item no. 11108-5-9970 * ENG * Revision 72138 * Release 2012-08-17 * Page 2 / 9 ebm-papst Mulfingen GmbH & Co. KG * Bachmuhle 2 * D-74673 Mulfingen * Phone +49 (0) 7938 81-0 * Fax +49 (0) 7938 81-110 * info1@de.ebmpapst.com * www.ebmpapst.com G2E120-AR38-01 Operating instructions 2. PROPER 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. Proper use also includes: Conveying of air at an ambient air pressure of 800 mbar to 1050 mbar. Using the device within the permitted ambient temperature range; see chapter 3.5 Transport and storage conditions and chapter 3.2 Nominal data. Operating the device with all protective devices. Observance of 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 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. Translation of the original operating instructions Item no. 11108-5-9970 * ENG * Revision 72138 * Release 2012-08-17 * Page 3 / 9 ebm-papst Mulfingen GmbH & Co. KG * Bachmuhle 2 * D-74673 Mulfingen * Phone +49 (0) 7938 81-0 * Fax +49 (0) 7938 81-110 * info1@de.ebmpapst.com * www.ebmpapst.com G2E120-AR38-01 Operating instructions 3. TECHNICAL DATA 3.1 Product drawing All measures have the unit mm. Connection line PVC 4G 0.5mm, 4x brass lead tips crimped Pilot hole for self-tapping M4 thread Translation of the original operating instructions 1 2 Item no. 11108-5-9970 * ENG * Revision 72138 * Release 2012-08-17 * Page 4 / 9 ebm-papst Mulfingen GmbH & Co. KG * Bachmuhle 2 * D-74673 Mulfingen * Phone +49 (0) 7938 81-0 * Fax +49 (0) 7938 81-110 * info1@de.ebmpapst.com * www.ebmpapst.com Operating instructions G2E120-AR38-01 3.2 Nominal data 3.4 Mounting data For depth of screw, see chapter 3.1 Product drawing Motor M2E068-BF Phase Nominal voltage / VAC Frequency / Hz 1~ 230 50 1~ 230 60 Type of data definition Valid for approval / standard Speed / min-1 Power input / W Current draw / A Motor capacitor / F Capacitor voltage / VDB Min. back pressure / Pa Min. ambient temperature / C Max. ambient temperature / C fa CE fa CE You can obtain additional mounting data from the product drawing if necessary. 2500 83 0.37 2 450 0 -25 2600 110 0.5 2 450 0 -25 3.5 Transport and storage conditions 50 60 ml = Max. load * me = Max. efficiency * fa = Running at free air cs = Customer specs * cu = Customer unit ; Secure the mounting screws against accidentally coming loose (e.g. by using self-locking screws). Strength class for mounting screws 8.8 ; 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 4. CONNECTION AND START-UP Subject to alterations 4.1 Connecting the mechanical system 3.3 Technical features Mass Size Material of impeller Translation of the original operating instructions Housing material Direction of rotation Type of protection Insulation class Humidity (F)/ environmental protection class (H) Mounting position Condensate discharge holes Operation mode Motor bearing Touch current acc. IEC 60990 (measuring network Fig. 4, TN system) Motor protection Protection class Product conforming to standard 2 kg 120 mm Sheet steel, hot-galvanised; Sheet steel, galvanised Die-cast aluminium Clockwise, seen on rotor IP 44; Depending on installation and position "B" H0 - dry environment Any None S1 Ball bearing < 0.75 mA CAUTION Cutting and crushing hazard when removing blower from packaging Carefully remove the blower from its packaging by grasping hold of the housing. Never subject to impact.# 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. CAUTION Possibility of damage to the device Serious damage may result if the device slips during assembly. Keep the device fixed in position at the installation location until all attachment screws have been tightened. 4.2 Connecting the electrical system DANGER Electric voltage on the device Electric shock Always install a protective earth first. Thermal overload protector (TOP) wired internally I (if protective earth is connected by customer) EN 60335-1; CE 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. 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. CAUTION Electrical voltage The device is a built-in component and features no electrically isolating switch. Item no. 11108-5-9970 * ENG * Revision 72138 * Release 2012-08-17 * Page 5 / 9 ebm-papst Mulfingen GmbH & Co. KG * Bachmuhle 2 * D-74673 Mulfingen * Phone +49 (0) 7938 81-0 * Fax +49 (0) 7938 81-110 * info1@de.ebmpapst.com * www.ebmpapst.com G2E120-AR38-01 Operating instructions 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 Water penetration into leads or wires Water enters at the cable end on the customers side and can damage the device. 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 4.4 Connection screen. 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 105C cables. Ensure that the minimum cable cross-section is at least AWG26/0.13 mm. Earth wire contact resistance in accordance with EN 60335 Compliance with the impedance specifications in accordance with EN 60335 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. Translation of the original operating instructions 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 Please use a frequency converter only after consultation with ebm-papst. For operation with frequency converters, fit sinusoidal filters that work on all poles (phase-phase and phase-earth) between the frequency converter and the motor. During operation with frequency converters, an all-pole sine filter protects the motor against high-voltage transients that can destroy the winding insulation system, and against harmful bearing currents. Heating of the motor due to use of a frequency converter must be checked in the application by the customer. Item no. 11108-5-9970 * ENG * Revision 72138 * Release 2012-08-17 * Page 6 / 9 ebm-papst Mulfingen GmbH & Co. KG * Bachmuhle 2 * D-74673 Mulfingen * Phone +49 (0) 7938 81-0 * Fax +49 (0) 7938 81-110 * info1@de.ebmpapst.com * www.ebmpapst.com G2E120-AR38-01 Operating instructions 4.4 Connection screen blue brown black green/yellow Translation of the original operating instructions U1 Z U2 PE Item no. 11108-5-9970 * ENG * Revision 72138 * Release 2012-08-17 * Page 7 / 9 ebm-papst Mulfingen GmbH & Co. KG * Bachmuhle 2 * D-74673 Mulfingen * Phone +49 (0) 7938 81-0 * Fax +49 (0) 7938 81-110 * info1@de.ebmpapst.com * www.ebmpapst.com G2E120-AR38-01 Operating instructions 4.5 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. 4.6 Switch on device The device is not to be switched on until it has been installed properly and in accordance with its intended use, including the required protective devices and professional electrical connection. This also applies to 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 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 the nominal voltage to the voltage supply. 4.7 Switching off the device ; Disconnect the device from the supply voltage at the main switch for the supply line. Translation of the original operating instructions ; When disconnecting, be sure to disconnect the earth wire connection last. 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 Electrical load on the capacitor after device is switched off Electric shock, risk of injury Discharge the capacitors before working on 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. 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 Overtemperature of motor Unacceptable operating point Ambient temperature too high 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 Lower ambient temperature if possible Item no. 11108-5-9970 * ENG * Revision 72138 * Release 2012-08-17 * Page 8 / 9 ebm-papst Mulfingen GmbH & Co. KG * Bachmuhle 2 * D-74673 Mulfingen * Phone +49 (0) 7938 81-0 * Fax +49 (0) 7938 81-110 * info1@de.ebmpapst.com * www.ebmpapst.com Operating instructions G2E120-AR38-01 Insufficient cooling Improve cooling If you have any other problems, contact ebm-papst. 5.1 Cleaning 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. 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. NOTE Damage to the device during cleaning Malfunction possible Do not clean the device using a water jet or high-pressure cleaner.# Do not use any acid, alkali or solventbasedcleaning agents.# Do not use any pointed or sharpedged objects for cleaning 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 How to test? Frequency Visual inspection At least every 6 months Visual inspection At least every 6 months Which measure? Repair or replacement of the device Replacement of the device 5.3.3 Component disposal The products are mostly made of steel, copper, aluminium and plastic. Metallic materials are generally considered to be fully recyclable. Separate the components for recycling into the following categories: Steel and iron Aluminium 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. 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 5.3 Disposal Translation of the original operating instructions Secure components before unfastening to stop them falling. 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. 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 Power lines 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. 11108-5-9970 * ENG * Revision 72138 * Release 2012-08-17 * Page 9 / 9 ebm-papst Mulfingen GmbH & Co. KG * Bachmuhle 2 * D-74673 Mulfingen * Phone +49 (0) 7938 81-0 * Fax +49 (0) 7938 81-110 * info1@de.ebmpapst.com * www.ebmpapst.com