Assembly instructions

Transcription

1 ebm-papst St. Georgen GmbH & Co. KG Hermann-Papst-Straße St. Georgen Phone: Fax: info2@de.ebmpapst.com 6.1 Connecting the mechanical system Connecting the electrical system Switching on and operating the drive Integrated protective functions 11 7 MAINTENANCE, MALFUNCTIONS, POSSIBLE CAUSES AND REMEDIES Troubleshooting Restarting after an error Cleaning Safety inspection Service and support 13 8 Declaration of Incorporation 14 3-phase external rotor motor in EC technology with integrated electronic operation and control. CONTENTS 1 Safety regulations and instructions Warnings Information symbols Type plate Staff qualification Basic safety rules Electrical voltage Electromagnetic radiation Mechanical movement Noise emissions Hot surface Transport/storage/unpacking Disposal 3 2 Use Proper use Reasonably foreseeable misuse 3 3 Technical data Product drawing Performance data Technical description Transport and storage conditions 5 4 Connection description Pin configuration Specification of the interface Requirements for the drive power supply 8 5 Functional description Speed set value input function Torque set value input function Actual value output/encoder signal function Overvoltage/undervoltage protection function Overtemperature protection function I 2 t peak current limitation function Acceleration and braking ramp function Safe braking operation "Zero speed" function Optional functions 9 1 SAFETY REGULATIONS AND INSTRUCTIONS Please read these assembly instructions carefully before starting to work with the drive system. Observe the following warnings to prevent malfunctions or physical damage to both property and people. These assembly instructions are to be regarded as part of this drive system. If the drive system is sold or transferred, the assembly instructions must accompany it. These assembly instructions may be duplicated and forwarded for information about potential dangers and their prevention. 1.1 Warnings Hazard levels of warnings These assembly 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. Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. A potentially harmful situation can occur and, if not avoided, can lead to property damage. 6 Connection and start-up 10 Article No.: Version: V1.0 dated Page 1 of 14

2 1.1.2 Pictograms These pictograms are used in these assembly instructions and on the motor if necessary. Warning of a general hazard. This warning sign appears in front of activities for which hazards can be caused by multiple reasons. Warning of hazardous electrical voltage This warning sign appears in front of activities that carry a risk of electric shock, possibly resulting in death. Warning of hot surface This warning sign appears in front of activities in which hazards from hot surfaces exist. Warning of property damage. This warning sign appears in front of activities for which a risk of property damage exists. 1.2 Information symbols For bulleted lists. Measures to avoid dangers. Instructs you to take action. 1.6 Electrical voltage Check the electrical equipment of the drive system on a regular basis. Remove loose connections and defective cables immediately. 1.7 Electromagnetic radiation Interference from electromagnetic radiation is possible, e.g. in conjunction with open and closed-loop control devices. If unacceptably high interference emission occurs when the device is installed, the user must take suitable measures. The product emits high-frequency EMC radiation. For the respective data, refer to the specification. Electrical or electromagnetic interferences after integrating the drive system in installations on the customer's side. When operating the drive system, interference may occur due to the high switching frequencies and the switching process. The electromagnetic compatibility of a machine depends on the type of installation and the care exercised during installation. Pay particular attention to design, filtering, shielding and earthing. Ensure the electromagnetic compatibility in the end device/installed condition. 1.3 Type plate The type plate is installed on the edge of the motor flange Design of type plate XX XXVDC WW/YY XXXX XXXX Fig.1 Design of type plate 5 1. Manufacturer 2. Product number 3. Serial number 4. Date code 5. Nominal voltage 1.4 Staff qualification 4 Only specialised electrical personnel may install the drive system, 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 drive system, or to use it in any other manner Mechanical movement WARNING Rotating shaft. Body parts that come into contact with the shaft can be injured. Secure the drive system against accidental contact. Before working on the installation/machine, wait until all parts have come to a standstill. WARNING Rotating shaft. Long hair, loose items of clothing and jewellery could become entangled and pulled into the drive system. Danger of severe injuries. Do not wear any loose clothing or jewellery while working on rotating parts. Protect long hair with a hood. 1.5 Basic safety rules The safety hazards originating from the drive system must be re-evaluated after installation in the end drive system. When working on the drive system, observe the following information: Do not make any modifications, additions or conversions to the drive system without the approval of ebm-papst. Article No.: Version: V1.0 dated Page 2 of 14

3 1.9 Noise emissions Sound pressure level, SPL Lp < 63 db(a) (measured at free-running speed and at a measuring distance of 250 mm). Reference value valid for product number Hot surface High temperature on the motor. Danger of burn injuries from hot surface. Ensure that sufficient protection against accidental contact is provided Transport/storage/unpacking Transport the motor in its original packaging only. Check the motor after receipt to ensure that it is complete and undamaged. Store the drive system in the original packaging, in a dry and clean place protected against weather conditions. Protect the drive system from environmental impacts and dirt until the final installation. We recommend storing the drive system for a maximum of one year. Observe the transport and storage conditions (refer to Chapter 3.4). Motor is heavy. The motor can fall down and cause crushing injuries. Wear safety shoes. 2 USE 2.1 Proper use The drive systems of the series are determined for installation in stationary end devices and machines in the industrial area and must be operated on electricity only when in installed condition! Therefore, it must not be put into service until the machinery into which this product is to be incorporated has been found and declared to be in conformity with the protection requirements of the Machinery Directive. This product is not intended for the end consumer. No provision is made for use in a residential environment without further testing and the use of correspondingly adapted EMC protective measures. 2.2 Reasonably foreseeable misuse In particular, the following uses of the drive system are prohibited and can lead to dangerous situations: Operating the drive system in the vicinity of flammable materials or components. Operating the drive system in an explosive atmosphere. Using the drive system as a safety system component or for the assumption of safety-related functions. In addition, all application options that are not listed under proper use Disposal When disposing of the drive system, comply with all relevant requirements and regulations applicable in your country. By request, a materials list can be created for various purposes. (Ex. RoHS, REACH, overview of insulation materials) Article No.: Version: V1.0 dated Page 3 of 14

4 3 TECHNICAL DATA 3.1 Product drawing Fig.2: Product drawing Reference example (product number: ) All measurements in mm 3.2 Performance data Designation Unit B00 D00 Nominal voltage (UN) VDC Permitted supply voltage range (UZK) VDC (XX to XX) 18 to to 55 Nominal speed (nn) rpm Nominal torque (MN) mnm Nominal current (IN) A Nominal output power (PN) W Free-running speed (nl) rpm Free-running current (IL) A Max. reverse voltage VDC Set value input VDC 0 to 10 0 to 10 Meximum speed rpm 0 to to 4000 Recomm. speed control range rpm 0 to to 4000 Locked-rotor protection thermal Locked-rotor protection pulsing No Protection from overload Yes Starting torque mnm Rotor moment of inertia (JR) kgm 2 x Thermal resistance (Rth) K/W - - Protection class IP 54* IP 54* Ambient temperature range (TU) C 0 to 40 0 to 40 Motor mass (m) kg * Sealing on the flange side (towards the ball bearing) must be ensured in installed condition. Article No.: Version: V1.0 dated Page 4 of 14

5 3.3 Technical description Note: The performance data, dimensions and functions listed in these assembly instructions apply for the corresponding standard designs of the drive in 24 or 48 V with analogue set value input. For deviating performance data, dimensions and/or functions, refer to the corresponding product specifications and/or drawings of the corresponding design variants. 3.4 Transport and storage conditions 4.2 Specification of the interface Digital control inputs "A" (grey-pink) and "B" (violet) - digital input signals Via the control signals at inputs "A" and "B", the various operating states can be selected according to the logic below. Input level - TTL level Low level V < 0.8 Storage conditions EN :1998 Climatic conditions EN :1998 Ambient temperature Climatic conditions EN :1998 Relative humidity Max. storage elevation Transport conditions EN :1998 Climatic conditions EN :1998 Ambient temperature Climatic conditions EN :1998 Relative humidity at +40 C 4 CONNECTION DESCRIPTION 4.1 Pin configuration Class C Class % m above sea level Class C Class % Designation Colour Description Gnd Blue (AWG 16) Supply ground 1K4-25 to +55 1K3 5 to K3-25 to +70 2K3 95 High level V > 2.0 Protection against reverse polarity and voltage V 30 For cable break - Logic level "0" Internal resistance kω 22 Applied logic level - A/B A=0/B=0 = Power stage disabled A=1/B=0 = Direction of rotation* cw A=0/B=1 = Direction of rotation* ccw A=1/B=1 = Brake * View onto the motor shaft from the front UB Brown (AWG 16) Logic supply voltage UZK Black (AWG 16) Supply voltage Fig.3 Internal input wiring of inputs A and B GND A grey-pink Digital control input B violet Digital control input C black Hardware enable D yellow Drive status: ready (yes/no) E red Actual speed output, Channel A F+ red-blue Not assigned (optional for variant with frequency set value) IST grey Actual speed output, Channel B S1 Pink set value input S2 brown Adjustable current limit Data A white RS485 (Data +) Data B green RS485 (Data -) Digital control input "C" (black) - hardware enable The control input "C" is used for targeted switching on/off of the power stage of the drive, independent of the supply voltage. In addition, this input is used for switching on again (acknowledgement) after a fault shut-off (fault status at digital output "D"). Switch-on/acknowledgement takes place with a change of the signal level from 0 to 1. Input level - TTL level Low level V < 0.8 High level V > 2.0 Protection against reverse polarity and voltage V 22 For cable break - Power stage "OFF" Internal resistance kω 8 Applied logic level - 0 = Power stage switched off 1 = Power stage switched on Gnd Blue Logic Ground Article No.: Version: V1.0 dated Page 5 of 14

6 Digital output signal "D" (yellow) drive status If certain errors and associated safety shut-offs of the drive occur, a low signal (open collector) is output at output "D" as a fault-signal. For a more detailed description of the corresponding protection functions, refer to Chapter 5. The drive can only restart until after digital input "C" is acknowledged (change of the signal level from 0 to 1). Output D is not short-circuit proof and has no reverse polarity protection. If the output is overloaded or incorrectly poled, this will damage the output wiring. Signals can no longer be evaluated. Observe the information for max. voltage and current. Design - Open collector Max. external voltage Uext. max V 36 Collector current IC ma 1 < IC < 10 Saturation voltage UCEsat V 0.4 Logic - 0 = Fault, drive inactive 1 = No fault, drive active Digital output signals "E" (Channel A, red) and "IST" (Channel B, grey) for information about speed and direction of rotation Each of the two open collector outputs can be read out separately as actual speed value information. A rectangular signal is present at both outputs, and can be evaluated either as a frequency or as a number of pulses (e.g. number of rising edges per revolution). By default, the frequency is defined such that 6 pulses (signal periods) per revolution are output. This results in the following relationship: Signal frequency * 10 = speed in rpm. For design variants that deviate from this, the information in the product specification must be taken into account. When evaluating both outputs, a 2-channel encoder replacement signal is obtained; as a result, both the double speed information and the direction of rotation can be identified via the assignment of the leading channel. Outputs E and IST are not short-circuit proof and have no reverse polarity protection. If the output is overloaded or incorrectly poled, this will damage the output wiring. Signals can no longer be evaluated. Observe the information for max. voltage and current. Design - Open collector Max. external voltage Uext. max V 36 Collector current IC ma 1 < IC < 10 Saturation voltage UCEsat V 0.4 Max. output frequency khz 1 Duty cycle ±2% % 50 Phase offset to Channel B (IST) ±25 % 90 Output of speed information at "E" Pulses per or "IST" revolution 6 Encoder replacement signal, Pulses per Channel A/B information revolution 12 Channel A leading before Channel B = Direction of rotation assignment cw Channel B leading before Channel A = ccw Fig.4 Schematic diagram of open collector output for E and IST Fig.5 Rectangular signals at the outputs E and IST Article No.: Version: V1.0 dated Page 6 of 14

7 Analogue set value input "S1" (Pink) Via this input, using a set value in the range from 0-10 VDC, any speed set value in the range from 0 to nmax. can be specified in rpm. Blank (set value voltage = 0 VDC), the motor remains at a standstill and attempts to control the motor at maximum torque (holding torque) when there is an attempt to move the drive. In the standard designs, nmax. is defined as 4000 rpm. For different design variants, refer to the respective product specifications for the value for nmax. For drives in the design with input "S1" (analogue set value), the frequency set value input is not defined. Do not connect input "F+". Operating voltage range V 0 to 10 For cable break - Level "0" Internal resistance kω 30 Set value range - 50 mv to 9.9 V correspond to 0 to nmax. in rpm Signal resolution bit 10 Protection against reverse polarity and voltage V 30 Analogue set value input "S2" (brown) Via this input, with a set value in the range of 0-5 VDC, the current limit can be specified in the range from 0 (no torque, motor does not move, rotor runs freely) to 100 % (maximum torque). Therefore, input "S2" must be connected in order to operate the drive. The current limit configured via input "S2" works equally for driving and for braking. Operating voltage range V 0 to 5 For cable break - Level "0" Internal resistance kω 30 Set value input range - 0 to 5 V correspond to 0 to 100 % (max. torque) Signal resolution bit 9 Protection against reverse polarity and voltage V 30 S2 S1 GND Fig.8 Internal input wiring of set value input S2 GND Fig.6 Internal input wiring of set value input S1 Fig.7 Characteristics of set value input S1 for speed setting via analogue voltage Fig.9 Characteristics of set value input S2 for torque specification via analogue voltage Frequency set value input "F+" (red-blue) This input is available for drive versions with frequency set value only and is used to specify a speed set value using a defined frequency signal. For detailed information in this regard, refer to the product specification. For drives in the design with frequency set value input, the input "S1" (analogue set value) is not defined. Do not connect input "S1". RS-485 interface "Data A" and "Data B" (white / green) The RS-485 interface is not available in the basic variants. The interface is used for adapting drive parameters or software variants at the factory. Do not connect the RS 485 interface. Article No.: Version: V1.0 dated Page 7 of 14

8 4.3 Requirements for the power supply of the drive system The VARIODRIVE Compact is designed such that it can be operated with separate power supplies for the power and logic. This allows, for example, the power supply to be shut off while the logic power supply for the motor sensors can remain active. Power supply 24 V version 48 V version Operating voltage range UZK V 18 to to 55 Max. intermediate circuit UZK V 1 1 voltage ripple Reverse polarity protection UZK - No No Max. supply current IZK A <10 <10 Assignment power supply - Blue (AWG 16) - "Gnd" Black (AWG 16) - "UZK" Logic power supply Auxiliary voltage supply range Auxiliary voltage supply UB - 24 V version 48 V version UB V > 9.5 to < 75 > 9.5 to < 75 Short-circuit proof and protected from polarity reversal Short-circuit proof and protected from polarity reversal Max. auxiliary current IB ma < 175 < 175 Assignment of logic power supply - Blue - "Gnd" Brown (AWG 16) - "UB" Note: When using one voltage source, UB and UZK must be bridged. The bridge is important as otherwise the logic or power supply will be missing and the drive will not run. When using two independent voltage sources without a low-resistance ground connection, potential shifts and associated compensation currents may result. Danger of malfunctions or damage to the internal motor electronics. If two separate voltage sources are used for UB and UZK, make a low-resistance connection between the ground of both voltage sources. Feeding back of power when braking or if in controlled brake or cycle operation. A reverse voltage of up to 36 V (for 24 V version) or up to 63 V (48 V version) can occur. Danger for the power supply. When selecting the power supply, ensure corresponding feedback protection. 5 FUNCTIONAL DESCRIPTION The drive system is an electronically commutated external rotor motor with integrated operating and control electronics. Commutation takes place in sinus commutation based on a field-oriented control (FOC). The drive system works as a speed controller with speed limiter and ramp function as well as with a current controller (torque controller) with torque limitation. 5.1 Speed set value input function Note: Specify the speed set value to operate the motor. According to the illustration in Chapter 4.2 (analogue set value input "S1"), this input can be used to specify a set value that corresponds to a speed in the range from 0 rpm to nmax. Within the power and speed range of the motor listed in the specification and the listed control accuracy, the drive attempts to adjust the speed to the specified set value, even when there are load fluctuations. The same function is also available for the drives in the version with set value input as a frequency signal. Here, a defined frequency signal corresponding to the product specification must be applied at input "F+". 5.2 Torque set value input function Note: Specify the torque set value to operate the motor. According to the illustration in Chapter 4.2 (analogue set value input "S2"), this input can be used to specify a set value via this input that corresponds to a torque in the range from 0 to 100 % (peak torque, see "I 2 t peak current limitation"). Within the specified tolerance range, the maximum attainable torque of the drive can be configured. In this way, movement operations can be limited to a maximum permitted torque if necessary. In conjunction with a corresponding speed set value, this function enables torque-controlled winding or coil processes to be implemented, for example. 5.3 Actual value output/encoder signal function For external monitoring of the actual speed of the drive, the two outputs "E" and "IST" are available. Each of the two outputs, which are switched as open collector, deliver a frequency signal with 6 pulses per revolution, for which the following relationship applies: Signal frequency * 10 = speed in rpm. Via the electrical phase offset of 90 of both signals to each other, when evaluating both channels, an encoder replacement signal with rotation direction information and 12 pulses per revolution are obtained. For special designs, a higher number of pulses can also be implemented with a limited speed range and limited maximum speed. For detailed information in this regard, refer to the respective product specification. Article No.: Version: V1.0 dated Page 8 of 14

9 5.4 Overvoltage/undervoltage protection function The protection function takes effect at the limit values listed in the specification (relative to the terminal voltage UZK). If one of the switching thresholds is reached, the output stage is switched off to protect the system and the drive starts freewheeling. If the drive exceeds the limits for short periods (< 250 ms, occurrence of any fault peaks in the power supply), it resumes running if the voltage range returns to a permitted level within this time. If the limits are exceeded for a longer period (>= 250 ms - interpreted as a fault in the system), the output stage is shut off and an fault-signal is output at status output "D". By acknowledging the enable input "C" (change of signal level 0 to 1), status output "D" is reset and the drive is again ready for operation. 5.5 Overtemperature protection function An NTC on the printed circuit board (close to the power stage) protects the drive from gradual overheating. If the NTC reaches a temperature of approx. 110 C, the output stage is shut off. The status output "D" outputs an fault-signal that remains pending until it is acknowledged successfully. After enable input "C" is "acknowledged" with a rising switching edge, the drive can be switched back on. If the motor switches off due to overtemperature, for thermal protection of the drive, successful acknowledgement is not possible until the NTC temperature falls back below 100 C. 5.6 I 2 t peak current limitation function The I 2 t peak current limitation function enables an increase of the torque to the respective specified peak torque. A so called threshold current is used to determine the amplitude at which the squaring of the portions of the current that lie above the threshold value begins. In the initial state, the threshold current is close to the maximum permitted winding current, so that depending on the environmental and operating conditions, it is well possible for the motor to be operated at peak torque for a number of minutes. If the internal temperature threshold value is reached, the threshold value of the current is lowered and squaring of the portions of the current in excess of the threshold value begins. With loading of the I 2 t memory, the available winding current is then lowered successively; as a result, the drive is increasingly limited in order to prevent an overload. 5.7 Acceleration and braking ramp function The maximum possible dynamic behaviour of the drive is defined via an internally defined parameter value that affects acceleration and braking in the same way. The slope of the ramp, specified as a max. possible change of speed per unit of time, is thus limited to the following values: 24 V drive version: max. 16 rpm/ms 48 V drive version: max. 25 rpm/ms Ex. for the 24 V drive version: For an external set value jump from 0 to 1600 rpm, the internal set speed of the motor increases from 0 to 1600 rpm via a corresponding ramp function within 100 ms. Usually, this limitation is noticeable only when the motor without load. In this case, it serves to optimise the control and transient response to the target speed. 5.8 Safe braking operation Activating the braking function via control inputs "A/B" or via a negative set value jump activates a controlled braking operation. The energy released during braking is fed back and the intermediate circuit voltage increases. To protect the drive, when the max. reverse voltage is reached, the braking operation is interrupted and the power stage is disabled for a short period (freewheeling). As soon as the voltage falls back below a threshold value defined by a hysteresis, the braking function is automatically re-enabled, braking energy is fed back and the intermediate circuit voltage increases again. This process repeats itself at short intervals until the motor has reached the new set value speed or has come to a standstill. 5.9 "Zero speed" function The "Hold zero speed" function can be activated either by specifying a corresponding speed set value or corresponding signal on the two digital inputs "A / B". If an attempt is made to move the motor shaft in this state, the deviation from the control-set-value is recognized and integrated over the time. The drive responds with a counterholding torque which increases to the peak torque depending on the displacement. The "Zero speed" function does not guarantee that a set position will be maintained exactly. Ensure that any slight movement does not have any harmful consequences. As a result of disturbances, even when the motor is without load, the rotor can turn a few degrees out of the original position over time in "Zero speed" operating state. Exactly maintaining a set position can not be guaranteed. Ensure that any slight movement does not have any harmful consequences Optional functions According to prior agreement, additional and/or customer-specific functions can be implemented. Examples of possible options here include: Adaptation of speed control ranges Adaptation of application-specific control parameters Adaptation of resolution for actual value or encoder signal (possible depending on speed) Speed set value input via PWM signal RS-485 as programming and communication interface For design details of such specific adaptations, refer to the corresponding product specification. Article No.: Version: V1.0 dated Page 9 of 14

10 6 CONNECTION AND START-UP 6.1 Connecting the mechanical system Fig.10: Connecting the mechanical system Motor is heavy. The motor can fall down and cause crushing injuries. Wear safety shoes. Dimensions and specifications from the product drawing (refer to Chapter 3.1) Adapt the mounting plate [3] to the centring diameter of the motor, pitch circle and size of the mounting holes. Drill the holes into the mounting plate [3]. Determine the suitable screw length [4]: Minimum screw length [4] = minimum depth of screw (6.5 mm) + material thickness of the mounting plate [3]. Maximum screw length [4] = maximum depth of screw (9.5 mm) + material thickness of the mounting plate [3]. Screw the self threading screws [5] through the mounting plate [3] into the motor flange [2]. Use self threading screws according to DIN Tighten the screws [5] equally and tightly, maximum screw-in torque 3 +/- 0.2 Nm. 6.2 Connecting the electrical system The extensive electrical interface of the motor offers a wide variety of options for operating the motor and evaluating the signals provided via the interface. The information from Chapter 4 must be observed. Connect the drive system as outlined in Chapter 4.1. Before switching on the voltage, ensure that the supply voltage is within the permitted range (refer to Chapter 3.2 Terminal configuration) The following illustration shows an overview of the possible terminal configurations of the motor. For additional information about the individual inputs and outputs, refer to Chapter 4 of these assembly instructions. The minimum terminal configuration includes the terminals that have to be connected at minimum in order to operate the drive. The optional terminals provide additional options that can be used, depending on the requirement, as status information, for evaluating the actual speed or for the separate feed of the logic power supply. These terminals are not necessary for basic operation. The last 3 terminals are intended for design variants or for factory-internal programming and must not be connected on the application side. Danger of damage to the bearing system. When mounting mechanical elements on the motor shaft, the maximum permitted static axial load of the bearing system can be exceeded. Danger of increased running noises, reduced life expectancy of the drive. Observe the maximum permitted static axial load of 300 N. Danger of being drawn in by rotating shaft. The rotating shaft can draw in body parts. Ensure adequate protection against accidental contact when installed. The motor gets hot during operation. Danger of burn injuries from hot surface. Ensure that sufficient protection against accidental contact is provided. Let the motor cool down before touching it. Fig.11 Terminal configuration Note: The unconnected strands must be shortened and/or routed such that no electrical contact between the wire ends can occur. Article No.: Version: V1.0 dated Page 10 of 14

11 6.3 Switching on and operating the drive The motor gets hot during operation. Danger of burn injuries from hot surface. Protect the surface of the motor from being touched. Let the motor cool down before touching it. For the sequence when switching on the drive, observe any requirements or basic conditions from the respective application. The following sequence is one possible example, which can be used depending on the situation or has to be adapted according to the requirements from the application. The limit values described in Chapter 4 must be observed. Switch on the power supply for power and logic. Apply the digital signals for inputs A / B. Adjust the set value input for the current limit (in the simplest case, +5 VDC for max. possible torque). Switch on the high level at the enable input "C" to make the drive ready for operation. Switch on/adjust the analogue set value for the speed (motor starts) until the desired operating point is reached. If the drive is plugged in or unplugged with the voltage turned on, high voltage peaks can occur. The integrated electronics can be damaged (drive is not "hotplug compatible"). Only plug in/unplug the drive system when the supply voltage is switched on/off. 6.4 Integrated protective functions The integrated protective functions ensure that the drive shuts off automatically under certain operating conditions or in case of certain faults. For a more detailed description, refer to Chapter 5. Article No.: Version: V1.0 dated Page 11 of 14

12 7 MAINTENANCE, MALFUNCTIONS, POSSIBLE CAUSES AND REMEDIES Do not perform any repairs on your drive system. Return the drive system to ebm-papst for repair or exchange. 7.1 Troubleshooting When switching on Malfunction / error Possible cause Possible remedy Missing set value signals at inputs S1 and S2 Specify desired set value Motor does not start, the power supply is switched on and within the specified range The motor does not turn, the power supply and control signals are connected. Motor accelerates briefly, then switches off and runs down, fault signal "D" is set. Missing digital signal at one of the inputs (A / B) Missing signal level change (change from 0 to 1) at input "C" to set the motor to ready state. Load/required start-up torque are too high. Mechanical blockage Faulty connection Drive defective High load or high acceleration with power supply that is not designed to bear this. Power supply reaches performance limit, voltage drops sharply and drive detects undervoltage. Connect at least one of the two inputs for the desired operating mode/direction of rotation Switch on signal level at Input C again (change from 0 to 1) Reduce load or check motor dimensioning. Switch off drive, remove mechanical blockage in the powertrain and attempt to restart Check that pin configuration and control signals are correct, see Chapter 4 and Chapter 6 Replace drive If possible, reduce load or acceleration. In the other case, check the dimensioning of the power supply and use a more powerful power supply. In operation Malfunction / error Possible cause Possible remedy Motor makes "clacking noises" when braking function is activated or there is a negative set value jump When operated for longer periods, the motor torque output declines When operated for longer periods, the motor stops turning Braking function: Motor goes into brake operation, the fedback energy causes a voltage increase in the intermediate circuit; when the max. reverse voltage is reached, controlled brake operation begins in order to protect the system (refer to Chapter 5.8). Thermal overload: Motor is operated too long at high load/at elevated ambient temperature. Motor heating causes lowering of the winding current by the I 2 t peak current limitation Thermal overload: Motor is operated too long at high load/at elevated ambient temperature. Motor heating finally causes a shutoff via the integrated temperature monitoring. Use set value ramps instead of set value jumps. If a fast brake reaction is needed, the fed-back energy can be removed more quickly via an additional brake chopper in the intermediate circuit. Check load point, ambient conditions and possibilities for heat dissipation. Reduce load, lower ambient temperature or provide better heat dissipation. Check load point, ambient conditions and possibilities for heat dissipation. Reduce load, lower ambient temperature or provide better heat dissipation. The drive cannot be switched on again until the NTC temperature falls back to <100 C. Article No.: Version: V1.0 dated Page 12 of 14

13 7.2 Restarting after a fault After a fault or safety shut-off occurs, an fault-signal is transmitted at output "D" and the power stage is switched off. The drive cannot be switched on again until the enable input "C" (switching with a rising switching edge) is acknowledged. If a fault remains even after you carry out the remedies described here, please contact ebm-papst. 7.3 Cleaning Possible damage of the drive system during cleaning Danger of malfunctions. Do not clean the drive system using a water jet or highpressure washer. Do not use any cleaners containing acids, bases or solvents. 7.4 Safety inspection Carry out the following visual inspection before each time you start up the drive system. Visual inspection for damage Visual inspection for adequate mechanical fastening Visual inspection for correctly routed connection lines and insulation. 7.5 Service and support If you have any questions or problems, the following contact options are available to you to provide support and consulting: The contact persons of the respective subsidiaries. Your responsible domestic regional contacts. The responsible contacts for support in inside sales Approval and marking ebm-papst St. Georgen GmbH & Co. KG does not mark the drive systems described in these assembly instructions with the "CE" mark and does not issue an EC Declaration of Conformity. This decision is based on consideration of the relevant EC Directives. Low voltage directive 2006/95/EC and EMC directive 2004/108/EC: The drive systems described in these assembly instructions do not fall within the scope of application of these two guidelines. Machinery Directive 2006/42/EC According to the definition of the term in Art. 2, lit. g), a drive system is an "partly completed machinery" and thus does not receive a CE mark, but falls under the process for incomplete machines according to Art. 13. (which is this document) to Annex IV and a Declaration of Incorporation (refer to Chapter 8 of the assembly instructions) to Annex II, Part1, Section B is available. The specific technical documents to Art. 13, Sect. (1), lit. a) have been created in-house and are archived for the government agencies of the individual countries. The products described in the assembly instructions fulfil the valid directives for RoHS-compliant products. Other toxic substances are not used in any unacceptable quantity or concentration. By request, we can create a material overview list for different specific requirements. Contact address: ebm-papst St. Georgen GmbH & Co. KG Hermann-Papst-Str. 1 D St. Georgen, Germany Phone: / 81-0 Fax: / info2@de.ebmpapst.com Article No.: Version: V1.0 dated Page 13 of 14

14 8 DECLARATION OF INCORPORATION Declaration of Incorporation For the incorporation of an incomplete machine acc. to Article 1, Par. 1, lit. g); Article 2, Par. g); Annex II, No. 1, Par. B of the Machinery Directive 2006/42/EC The manufacturer: Name: ebm-papst St. Georgen GmbH & Co. KG Address: Hermann-Papst-Straße 1 D St. Georgen i. Schwarzwald, Germany declares for the partly completed machinery specified below motor series that it is not an independently functioning machine as defined by Article 2 g) of the Machinery Directive specified below and, for this reason, does not conform in all parts to the Basic safety and health protection requirements (Annex I). the application and compliance with the following harmonised European Standards or other standards and/or technical requirements etc. Source Date of issue Reference to Directive EN ISO Machinery Directive 2006/42/EC EN Adjustable speed electrical power drive systems - Part 5-1: Safety requirements. Electrical, thermal and energy requirements EN Adjustable speed electrical power drive systems - Part 3: EMC requirements and specific test methods that the product(s) covered by this Declaration must not be put into service until the machinery into which this incomplete machine is to be incorporated or of which it is a component has been found and declared to be in conformity with the protection requirements of the Machinery Directive. that the specific Technical Documents in accordance with Annex VII B have been created and are available in their entirety. that by request, the specific documents can be transmitted to the government authorities via data medium, electronically or on paper. The protective rights remain with the manufacturer specified above. St.Georgen, Germany / Place/Date p.p. Martin Csermak, Development Manager Article No.: Version: V1.0 dated Page 14 of 14