ebmpapst G2E120-AR38-01 AC Blower Centrifugal Ball Bearing Instruction Manual

ebmpapst G2E120-AR38-01 AC Blower Centrifugal Ball Bearing

Product Information

• Product Name: G2E120-AR38-01

Operating Instructions:

1. Safety Regulations and Notes
2. Proper Use
3. Technical Data
4. Connection and Start-Up
5. Maintenance, Malfunctions, Possible Causes and Remedies

Product Usage Instructions

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.

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.

Staff Qualification
The device may only be transported, unpacked, installed, operated, maintained and otherwise used by 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.

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. 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.

2. Proper Use
   (No information is provided in the manual extract)

3. Technical Data
   (No information is provided in the manual extract)

4. Connection and Start-Up
   (No information is provided in the manual extract)

5. Maintenance, Malfunctions, Possible Causes and Remedies
   (No information is provided in the manual extract)

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.

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 that, if not avoided, will result in death or serious injury. Compliance with the measures is mandatory.

• WARNING
  Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. Exercise extreme caution while working.

• CAUTION
  Indicates a potentially hazardous situation that, 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.

Staff qualification

• The device may only be transported, unpacked, installed, operated, maintained, and otherwise used by 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.

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.

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.

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.

Safety and protective functions

DANGER

The protective device missing and the 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 that 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.

Mechanical movement

DANGER

Rotating device
Body parts that come into contact with the rotor and impeller can be injured.

• 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, jewelry, 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 jewelry while working on rotating parts.# Protect long hair with a cap.

Emission

WARNING
Depending on the installation and operating conditions, a sound pressure level greater than 70 dB(A) may arise. The 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.

Hot surface

CAUTION
The high temperature at the motor housing Danger of burn injuries

• Ensure that sufficient protection against accidental contact is provided.

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.

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.

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 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 for taking on safety-related functions.
• Operation with completely or partially disassembled or modified protective features.
• In addition, all application options are not listed under proper use.

TECHNICAL DATA

Product Drawing

All measures have the unit mm.

Nominal data

• ml = Max. load · me = Max. efficiency · fa = Running at free air
• cs = Customer specs · cu = Customer unit

Subject to alterations

Technical features

galvanized
Housing material| Die-cast aluminium
Direction of rotation| Clockwise, seen on rotor
Type of protection| IP 44; Depending on installation and position
Insulation class| “B”
Humidity (F)/ environmental protection class (H)| H0 – dry environment
Mounting position| Any
Condensate discharge holes| None
Operation mode| S1
Motor bearing| Ball bearing
Touch current acc. IEC 60990 (measuring network Fig. 4, TN system)| < 0.75 mA
Motor protection| Thermal overload protector (TOP) wired internally
Protection class| I (if protective earth is connected by the customer)
Product conforming to the standard| 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.

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.

Transport and storage conditions
Use the device in accordance with its protection type.

CONNECTION AND START-UP

Connecting the mechanical system

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.

Connecting the electrical system

DANGER
The electric voltage on the device Electric shock

• Always install 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.

CAUTION

Electrical voltage
The device is a built-in component and features no electrically isolating switch.

• 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 customer’s 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.

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 cross-section. 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 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.

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.

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.
• The heating of the motor due to the use of a frequency converter must be checked in the application by the customer.

Connection of the cables
External leads are brought out of the device.

• First, connect the “PE” (protective earth) connection.
• Connect the lines according to your application. When doing so, observe chapter 4.4 Connection screen.

Connection screen

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.

Switch on the 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 airflow paths of the fan for foreign objects and remove any that are found.
• Apply the nominal voltage to the voltage supply.

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.

MAINTENANCE, MALFUNCTIONS, POSSIBLE CAUSES AND REMEDIES

Do not perform any repairs on your device. Return the device to ebm-papst 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 the 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.

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.

Motor does not turn| Mechanical blockage| Switch off, de- energise, and remove mechanical blockage.
| Mains supply voltage faulty| Check mains supply voltage,

restore power

supply.

| Faulty connection| De-energise, correct connection, see connection diagram.
| Thermal overload protector responded| Allow motor to cool off, locate and rectify cause of error, if necessary cancel restart lock-out
| Unacceptable operating point| Check operating point
Overtemperature of motor| Ambient temperature too high| Lower ambient temperature if possible

If you have any other problems, contact ebm-papst.

Cleaning

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 solvent-basedcleaning agents.# Do not use any pointed or sharp-edged objects for cleaning

Safety test

What has to be tested?| How to test?| Frequency| Which measure?
---|---|---|---
Check the protective casing against accidental contact for damage and to ensure that it is intact| Visual inspection| At least every 6 months| Repair or replacement of the device
Check the device for damage to blades and housing| Visual inspection| At least every 6 months| Replacement of the device
Mounting the connection lines| Visual inspection| At least every 6 months| Fasten
Mounting of protective earth connection| Visual inspection| At least every 6 months| Fasten
Check the insulation of the wires for damage| Visual inspection| At least every 6 months| Replace wires

Disposal

• For ebm-papst, environmental protection and resource preservation are top-priority corporate goals.
• ebm-papst operates an environmental management system that 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 the ecological disposal of the product and its components.

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.

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.

• Secure components before unfastening them to stop them from falling.

Component disposal
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
• Aluminium
• Non-ferrous metal, e.g. motor windings
• Plastics, particularly with brominated flame retardants, in accordance with the 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
• 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.

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.

References

• ebm-papst – energy-saving fans and motors from the world market leader – engineering a better life
• ebm-papst – energy-saving fans and motors from the world market leader – engineering a better life

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