ebm-papst R3G630-FA38-03 - User Manual

Operating instructions
R3G630-FA38-03
Translation of the original 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
info1@de.ebmpapst.com
www.ebmpapst.com
CONTENTS
1. SAFETY REGULATIONS AND INFORMATION
11. 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.
1.1 Hazard levels for warnings
11.1 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
11.2 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
11.3 Basic safety rules
The safety hazards associated with the device must be assessed again
following installation in the final product.
The locally applicable industrial safety regulations are always to be
observed when working on the device.
Keep the workplace clean and tidy. Untidiness in the work area
increases the risk of accidents.
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
11.4 Voltage
; Check the device's electrical equipment at regular intervals; see
Chapter 6.4 Safety inspection.
; Replace loose connections and defective cables immediately.
DANGER
Electrically charged device
Risk of electric shock
→ When working on an electrically charged device, stand on a
rubber mat.
21.5 Safety and protective features
21.6 Electromagnetic radiation
21.7 Mechanical movement
21.8 Emissions
21.9 Hot surface
21.10 Transport
21.11 Storage
32. INTENDED USE
43. TECHNICAL DATA
43.1 Product drawing
63.2 Nominal data
63.3 Data according to Commission Regulation (EU) 327/2011
63.4 Technical description
73.5 Mounting data
73.6 Transport and storage conditions
73.7 Electromagnetic compatibility
74. CONNECTION AND STARTUP
74.1 Mechanical connection
74.2 Electrical connection
94.3 Connection in terminal box
94.4 Factory settings
104.5 Connection diagram
114.6 Configuration options
124.7 Equivalent circuit diagrams
134.8 Checking connections
134.9 Switching on the device
134.10 Switching off the device
135. INTEGRATED PROTECTIVE FEATURES
146. MAINTENANCE, MALFUNCTIONS, POSSIBLE
CAUSES AND REMEDIES
146.1 Warning/status codes
156.2 Vibration testing
156.3 Cleaning
166.4 Safety inspection
166.5 Disposal
Item no. 56483-5-9970 · ENU · Change 211126 · Approved 2020-08-28 · Page 1 / 16
ebm-papst Mulfingen GmbH & Co. KG · Bachmühle 2 · D-74673 Mulfingen · Phone +49 (0) 7938 81-0 · Fax +49 (0) 7938 81-110 · info1@de.ebmpapst.com · www.ebmpapst.com

Summary

Safety Regulations and Information

Hazard Levels for Warnings

Explains hazard level symbols (DANGER, WARNING, CAUTION, NOTE) and their meanings.

Staff Qualifications

Specifies requirements for personnel handling the device.

Basic Safety Rules

General safety guidelines and workplace cleanliness.

Voltage

Mentions voltage considerations.

Safety and Protective Features

Discusses the importance of guards and protective devices.

Electromagnetic Radiation

Addresses potential interference and shielding measures.

Mechanical Movement

Warns about hazards related to rotating parts.

Emissions

Notes potential noise levels and hearing protection.

Hot Surface

Warns about burn risks from hot surfaces.

Transport

Provides guidance on safe handling and transport.

Storage

Details proper storage conditions to maintain device integrity.

Intended Use

Improper Use

Lists prohibited operations that could be hazardous.

Technical Data

Product Drawing

Shows dimensional drawings and reference points for the device.

Nominal Data

Presents key specifications and ratings of the device.

Data According to Commission Regulation (EU) 327;2011

Provides energy efficiency data as per EU regulation.

Technical Description

Details the technical specifications and features of the device.

Mounting Data

Specifies requirements for secure mounting.

Transport and Storage Conditions

Outlines conditions for safe transport and storage.

Electromagnetic Compatibility

Details EMC immunity and emission standards.

Connection and Startup

Mechanical Connection

Provides instructions for physically connecting the device.

Electrical Connection

Details the process and safety precautions for electrical hookup.

Supply Connection and Fuses

Specifies fuse assignments and cable cross-sections.

Reactive Currents

Explains reactive currents due to EMC filter.

Residual Current Circuit Breaker (RCCB)

Recommends specific RCCB types for safety.

Leakage Current

Discusses potential increase in leakage current.

Locked-Rotor Protection

Details protection against locked rotor conditions.

Connection in Terminal Box

Guides on preparing and connecting cables within the terminal box.

Cable Routing

Provides instructions for routing cables to prevent moisture ingress.

Factory Settings

Lists the default configuration settings for the device.

Connection Diagram

Illustrates the wiring of terminals and connections.

Configuration Options

Details various parameter and input/output configuration options.

Equivalent Circuit Diagrams

Shows electrical schematics for various inputs and outputs.

Checking Connections

Provides steps to verify secure and proper connections.

Switching on the Device

Instructions for safe startup and initial operation.

Switching off the Device

Procedures for safely turning off the device.

Integrated Protective Features

Faults and Safety Features

Describes integrated protective functions and their responses to faults.

Maintenance, Malfunctions, Possible Causes and Remedies

Ambient Temperature Too High; Impermissible Operating Point

Addresses issues related to temperature and operating conditions.

Warning;Status Codes

Explains LED indicators and their corresponding error codes.

Status Codes

Details LED status codes for various fault conditions.

Vibration Testing

Provides guidelines for checking mechanical vibration.

Cleaning

Instructions for cleaning the device to ensure longevity.

Safety Inspection

High-Voltage Test

Guidance on performing high-voltage tests with DC voltage.

Inspection Schedule

Lists items to check, how to check, frequency, and action.

Disposal

Country-Specific Legal Requirements

Highlights country-specific regulations for product disposal.

Component Disposal

Provides guidelines for separating and recycling device components.

Overview

1. Function Description
2. Important Technical Specifications
3. Usage Features
4. Maintenance Features

This document describes the R3G630-FA38-03 fan, a built-in device designed for conveying air. It is intended for use in stationary systems within specific environmental and electrical parameters, and adherence to all safety regulations and operating instructions is crucial for proper function and longevity.

Function Description

The R3G630-FA38-03 is an axial fan, specifically a M3G150-FF motor-impeller combination, designed for air conveyance. It operates on a 3-phase AC power supply with a nominal voltage range of 380-480 VAC and a frequency of 50/60 Hz. The fan features a die-cast aluminum electronics housing and a PP plastic impeller with 6 blades, rotating clockwise when viewed toward the rotor. It incorporates an integrated PI controller, motor current limitation, soft start, and thermal overload protection for both electronics and motor. The device also includes line undervoltage and phase failure detection.

The fan's control interface offers configurable inputs/outputs (I/O) and supports MODBUS V6.0 via an RS-485 MODBUS-RTU interface, allowing for external parameterization. It can be controlled via analog input (0-10V/PWM) for speed set value, and provides a voltage output (3.3-24 VDC) for external devices. Status and alarm indications are provided by an LED and an alarm relay. The device is designed for continuous operation within specified ambient temperature ranges, with occasional start-up permitted at lower temperatures.

Important Technical Specifications

• Motor Type: M3G150-FF
• Phase: 3~
• Nominal Voltage Range: 380-480 VAC
• Frequency: 50/60 Hz
• Speed: 1270 rpm
• Power Consumption: 2650 W
• Current Draw: 4.1 A
• Weight: 24.3 kg
• Size: 630 mm
• Impeller Material: PP plastic
• Number of Blades: 6
• Direction of Rotation: Clockwise (viewed toward rotor)
• Degree of Protection: IP55
• Insulation Class: "F"
• Moisture/Environmental Protection Class: H1
• Min. Ambient Temperature: -40 °C (occasional start-up), -25 °C (continuous operation with special low-temperature bearings)
• Max. Ambient Temperature: 40 °C
• Motor Bearing: Ball bearing
• Overall Efficiency (ηes): 71.6% (Actual), 55.9% (Req. 2015)
• Efficiency Category: Static
• Efficiency Grade N: 77.7 (Actual), 62 (Req. 2015)
• Variable Speed Drive: Yes
• Power Consumption Ped: 2.6 kW
• Air Flow qv: 11380 m³/h
• Pressure Increase Total psf: 559 Pa
• Specific Ratio: 1.01
• Touch Current (according to IEC 60990): ≤ 3.5 mA
• Electrical Hookup: Terminal box
• Protection Class: I (with customer connection of protective earth)
• Conformity with Standards: EN 61800-5-1; CE, UL 1004-7 + 60730-1; EAC; CSA C22.2 No. 77 + CAN/CSA-E60730-1
• Recommended Cable Cross-Sections (380-480 VAC):
  • 16 A fuse: 1.5 mm² (AWG 16)
  • 20 A fuse: 2.5 mm² (AWG 14)
  • 25 A fuse: 4.0 mm² (AWG 12)
• Mounting Screw Strength Class: 8.8
• Tightening Torque (Cable Gland): 4 ± 0.6 Nm
• Tightening Torque (Terminal Box Screws): 1.5 ± 0.2 Nm

Usage Features

The R3G630-FA38-03 is designed for use in power systems with grounded neutral (TN/TT), phase conductor grounding, or IT power systems, adhering to EN 50160 network quality characteristics. It must be used in stationary systems and is not suitable for conveying solids, abrasive particles, highly corrosive air (unless specifically protected), or air with high dust content. Operation near flammable materials or in explosive atmospheres is prohibited.

The device is a built-in component and requires proper safeguarding with a fixed protective device and guard grill. It is crucial to ensure that the device is not subjected to force or excessive vibration from the installation. If connected to air ducts, vibration isolation (e.g., compensators) is recommended. The electrical connection requires careful attention to cable selection, routing, and grounding, with specific recommendations for residual current circuit breakers (RCCB) of type B or B+ with a trip threshold of 300 mA and delayed tripping.

The fan offers configurable operational modes, including PWM control, and allows for setting parameters via MODBUS. The factory settings include PWM control, fan/device address 01, max PWM 100%, min PWM 5%, and positive direction of action. The device features integrated protective functions that automatically switch off the motor in case of rotor position detection error, blocked rotor, line undervoltage, or phase failure, with automatic restart capabilities once the fault is cleared.

Maintenance Features

Regular maintenance is essential for ensuring a long service life and trouble-free operation. This includes:

• Safety Inspection (every 6 months):
  • Visual inspection of contact protection cover for intactness or damage.
  • Visual inspection of the device for damage to blades and housing.
  • Visual inspection of cable fastenings.
  • Visual inspection of cable insulation for damage.
  • Visual inspection of impeller for wear, deposits, corrosion, and damage.
  • Visual inspection of cable gland tightness.
  • Visual inspection of condensation drainage holes for clogging.
  • Acoustic check for abnormal bearing noise.
  • Vibration test (using a vibration tester, start-up or deceleration measurement).
• Cleaning:
  • Fans should be checked regularly for proper operation and soiling. The cleaning frequency should be adapted to the degree of soiling.
  • Cleaning must only be performed when the device is not in motion, and the power supply must be switched off via the control input to prevent accidental start-up.
  • Dry cleaning, such as using compressed air, is the preferred method.
  • Aggressive cleaning agents, high-pressure cleaners, acids, alkalis, solvents, or pointed/sharp-edged objects must not be used.
  • After cleaning, operate the fan for 2 hours at maximum speed to evaporate any ingressed water.
  • If cleaning does not eliminate vibrations, rebalancing of the fan may be necessary.
• Storage:
  • Store the device in a dry, weather-protected, vibration-free, clean environment in its original packaging.
  • Recommended storage duration is no longer than one year for optimal operation and service life.
  • Maintain storage temperature within -40 °C to +80 °C.
  • Ensure all cable glands are fitted with dummy plugs.
• Operation during extended non-use:
  • If the device is not operated for a lengthy period (e.g., 4 months in a dry environment or 1 month in a damp environment), it should be started up and operated at full speed for at least one hour (dry) or three hours (damp) to move the bearings and evaporate any condensate.

The device is equipped with maintenance-free ball bearings designed for a service life of 40,000 hours. If bearing replacement is necessary after this period, contact ebm-papst. Modifications, additions, or conversions to the device without ebm-papst's approval are prohibited. Loose connections and defective cables must be replaced immediately. Disposal of the product and its components must follow country-specific legal requirements and standard procedures for electronic scrap, steel, copper, aluminum, and plastic.

ebm-papst R3G630-FA38-03 Specifications