W3G800-CU25-80

Operating instructions

ebm-papst Mulfingen GmbH & Co. KG 1. SAFETY REGULATIONS AND INFORMATION

Bachmühle 2
D-74673 Mulfingen Read these operating instructions carefully before starting work on the
Phone +49 (0) 7938 81-0 device. Observe the following warnings to prevent malfunctions or
Fax +49 (0) 7938 81-110 danger to persons.
info1@[Link] These operating instructions are to be regarded as part of the device.
[Link] The device is only to be sold or passed on together with the operating
instructions.
CONTENTS These operating instructions may be duplicated and distributed to inform
about potential dangers and their prevention.
1. SAFETY REGULATIONS AND INFORMATION 1
1.1 Hazard levels for warnings
1.1 Hazard levels for warnings 1
1.2 Staff qualifications 1 These operating instructions use the following hazard levels to indicate
1.3 Basic safety rules 1 potentially hazardous situations and important safety regulations:
1.4 Voltage 1
DANGER
1.5 Safety and protective features 2
Indicates an imminently hazardous situation which will result in
1.6 Electromagnetic radiation 2
death or serious injury if the specified actions are not taken.
1.7 Mechanical movement 2
Compliance with the instructions is imperative.
1.8 Emissions 2
1.9 Hot surface 2 WARNING
1.10 Transport 2 Indicates a potentially hazardous situation which can result in
1.11 Storage 3 death or serious injury if the specified actions are not taken.
Exercise extreme caution while working.
2. INTENDED USE 3
CAUTION
3. TECHNICAL DATA 4 Indicates a potentially hazardous situation which can result in
3.1 Product drawing 4 minor or moderate injury or damage to property if the specified
3.2 Nominal data 5 actions are not taken.
3.3 Data according to Commission Regulation (EU) 327/2011 5 NOTE
3.4 Technical description 5 A potentially harmful situation can occur and, if not avoided, can
3.5 Mounting data 6 lead to property damage.
3.6 Transport and storage conditions 6
3.7 Electromagnetic compatibility 6 1.2 Staff qualifications
4. CONNECTION AND STARTUP 6 The device may only be transported, unpacked, installed, operated,
4.1 Mechanical connection 6 maintained and otherwise used by suitably qualified, trained and
4.2 Electrical connection 6 authorized technical staff.
4.3 Connection in terminal box 8 Only authorized specialists are permitted to install the device, to carry
4.4 Factory settings 9 out a test run and to perform work on the electrical installation.
4.5 Connection diagram 10
1.3 Basic safety rules
4.6 Checking connections 12
4.7 Switching on the device 12 The safety hazards associated with the device must be assessed again
4.8 Switching off the device 12 following installation in the final product.
The locally applicable industrial safety regulations are always to be
Translation of the original operating instructions

5. INTEGRATED PROTECTIVE FEATURES 12 observed when working on the device.

Keep the workplace clean and tidy. Untidiness in the work area
6. MAINTENANCE, MALFUNCTIONS, POSSIBLE 12 increases the risk of accidents.
CAUSES AND REMEDIES Note the following when working on the device:
6.1 Cleaning 13
; Do not perform any modifications, additions or conversions on the
6.2 Safety inspection 14
device without the approval of ebm-papst.
6.3 Disposal 14
1.4 Voltage
; Check the device's electrical equipment at regular intervals; see
Chapter 6.2 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.

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W3G800-CU25-80
Operating instructions

WARNING 1.7 Mechanical movement

Live terminals and connections even with device
switched off DANGER
Electric shock Rotating device
Risk of injury to body parts coming into contact with the rotor or
→ Wait five minutes after disconnecting the voltage at all poles
the impeller.
before opening the device.
→ Secure the device against accidental contact.
CAUTION
→ Before working on the system/machine, wait until all
In the event of a fault, the rotor and the impeller will be
parts have come to a standstill.
energized
The rotor and the impeller have basic insulation. DANGER
→ Do not touch the rotor and impeller once installed. Ejected parts
Missing protective devices may cause balancing weights or
CAUTION broken fan blades to be ejected and cause injuries.
If control voltage or a stored speed set value is applied,
→ Take appropriate safety measures.
the motor will restart automatically, e.g. after a power
failure. WARNING
Risk of injury Rotating device
→ Keep out of the device’s danger zone. Long hair and dangling items of clothing, jewelry and the like
can become entangled and be pulled into the device. Injuries
→ When working on the device, switch off the line voltage
can result.
and ensure that it cannot be switched back on.
→ Do not wear any loose-fitting or dangling clothing or jewelry
→ Wait until the device comes to a stop.
while working on rotating parts.
→ After working on the device, remove any tools or other
→ Protect long hair with a cap.
objects from the device.
1.8 Emissions
1.5 Safety and protective features
WARNING
DANGER
Depending on the installation and operating conditions,
Guard missing and guard not functioning
the sound pressure level may exceed 70 dB(A).
Without a guard, hands may become caught up in the device
Risk of noise-induced hearing loss
during operation for example, resulting in serious injury. Loose
parts or items of clothing could be drawn in. → Take appropriate technical safety measures.
→ The device is a built-in component. As the owner, you are → Protect operating personnel with appropriate safety
responsible for ensuring that the device is adequately equipment such as hearing protection.
safeguarded.# Operate the device only with a fixed → Also observe the requirements of local agencies.
protective device and guard grill.
→ Stop the device immediately if a protective device is 1.9 Hot surface
found to be missing or ineffective. CAUTION
WARNING High temperature on electronics housing
Damage to guard grill, parts flying out Risk of burns
The guard grill is not suitable for heavy loads. Parts lying on the → Ensure sufficient protection against accidental contact.
guard grill or falling through the guard grill may be thrown out by
Translation of the original operating instructions

the fan when in operation. 1.10 Transport

→ Never step on the guard grill or subject the guard grill to load. WARNING
→ Do not place any objects on the guard grill. Transporting the fan
→ There must be sufficient space around the fan to be able Injuries from tipping or slipping
to get past the fan. → Wear safety shoes and cut-resistant safety gloves.
→ The fan is only to be transported in its original packaging.
1.6 Electromagnetic radiation
→ The fan is to be transported lying flat, i.e. the motor axis
Interference from electromagnetic radiation is possible, e.g. in conjunction must be vertical.
with open- and closed-loop control devices.
If impermissible radiation levels occur following installation, appropriate → Secure the fan(s) e.g. with a lashing strip to stop
shielding measures have to be taken by the user. anything slipping or tipping.

NOTE
Electrical or electromagnetic interference after installing
the device in customer equipment.
→ Verify that the entire setup is EMC-compliant.

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W3G800-CU25-80
Operating instructions

1.11 Storage ● Conveying highly corrosive air, e.g. salt spray. Exception: devices
designed for salt spray and correspondingly protected.
; Store the device, partially or fully assembled, in a dry place,
protected against the weather and free from vibration, in the original ● Conveying air with high dust content, e.g. suctioning off sawdust.
packaging in a clean environment. ● Operating the device close to flammable materials or components.
; Protect the device against environmental effects and dirt until final ● Operating the device in an explosive atmosphere.
installation. ● Using the device as a safety component or to perform safety-related
; We recommend storing the device for no longer than one year in functions.
order to guarantee trouble-free operation and the longest possible ● Operation with completely or partially disassembled or manipulated
service life. protective devices.
; Even devices explicitly intended for outdoor use are to be stored as ● In addition, all applications not listed among the intended uses.
described prior to commissioning.
; Maintain the storage temperature, see
Chapter 3.6 Transport and storage conditions.
; Make sure that all cable glands are fitted with dummy plugs.

2. INTENDED 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.
Intended use also includes
● The device is only to be used in power systems with grounded
neutral (TN/TT power systems), in power systems with phase
conductor grounding, or in IT power systems.
● The device is to be used in networks with network quality
characteristics as per EN 50160.
● Using the device only in stationary systems.
● Performing all maintenance work.
● Conveying air at an ambient air pressure between 800 mbar and
1050 mbar.
● Using the device within the permitted ambient temperature range; see
Chapter 3.6 Transport and storage conditions and
Chapter 3.2 Nominal data.
● Operating the device with all protective devices.
Translation of the original operating instructions

● Following the operating instructions.

Improper use
In particular, operating the device in the following ways is prohibited and
could be hazardous:
● Operating the device in an unbalanced state, e.g. due to dirt deposits
or ice formation.
● Resonant operation, operation with severe vibration. This also
includes vibration transmitted to the fan from the customer installation.
● Operation in medical equipment with a life-sustaining or life-support
function.
● Conveying solids in the flow medium.
● Painting the device
● Connections (e.g. screws) coming loose during operation.
● Opening the terminal box during operation.
● Conveying air that contains abrasive particles.

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W3G800-CU25-80
Operating instructions

3. TECHNICAL DATA

3.1 Product drawing

All dimensions in mm.

1 Direction of air flow "A"

2 Cable diameter min. 5 mm, max. 13 mm, tightening torque 4 ± 0.6 Nm
3 Tightening torque 3.5 ± 0.5 Nm
Translation of the original operating instructions

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W3G800-CU25-80
Operating instructions

3.2 Nominal data 3.4 Technical description

Motor M3G150-IF Weight 47.6 kg
Size 800 mm
Phase 3~ Motor size 150
Nominal voltage / VAC 400 Rotor surface Painted black
Nominal voltage 380 .. 480 Electronics housing Die-cast aluminum, painted black
range / VAC material
Frequency / Hz 50/60 Blade material Sheet aluminum insert (painted black),
Method of obtaining fa sprayed with PP plastic
data Fan housing material Sheet steel, galvanized and coated with
Speed (rpm) / min-1 1020 white aluminum plastic (RAL 9006)
Power consumption / W 1650 Guard grille material Steel, coated with white-aluminum plastic
Current draw / A 2.6 (RAL 9006)
Max. back pressure / Pa 190 Number of blades 5
Min. ambient -40 Blade pitch 0°
temperature / °C Airflow direction A
Max. ambient 70 Direction of rotation Counterclockwise, viewed toward rotor
temperature / °C Degree of protection IP55
ml = Max. load · me = Max. efficiency · fa = Free air Insulation class "F"
cs = Customer specification · ce = Customer equipment Moisture (F) / H2+T
Subject to change Environmental (H)
Occasional start-up at temperatures between -40 °C and -25 °C is protection class
permitted. For continuous operation at ambient temperatures below -25 Ambient temperature Occasional start-up at temperatures
°C (such as refrigeration applications), a fan design with special low- note between -40°C and -25°C is permitted.
temperature bearings must be used. For continuous operation at ambient
temperatures below -25°C (such as
3.3 Data according to Commission Regulation (EU) 327/ refrigeration applications), use must be
made of a fan design with special low-
2011
temperature bearings.
Actual Req. 2015 Installation position Shaft horizontal or rotor on top; rotor on
01 Overall efficiency ηes / % 38.8 35.8 bottom on request
02 Measurement category A Condensation On stator side
03 Efficiency category Static drainage holes
04 Efficiency grade N 43 40 Mode S1
05 Variable speed drive Yes Motor bearing Ball bearing
06 Year of manufacture The year of manufacture is specified on the Technical features - Output 10 VDC, max. 10 mA
product's rating label.
- Output 20 VDC, max. 50 mA
07 Manufacturer ebm-papst Mulfingen GmbH & Co. KG
Amtsgericht (court of registration) Stuttgart · - Output for slave 0-10 V
HRA 590344 - Operation and alarm display
D-74673 Mulfingen - Input for sensor 0-10 V or 4-20 mA
08 Type W3G800-CU25-80 - External 24 V input (parameter setting)
Translation of the original operating instructions

09 Power consumption Ped / kW 2.19 - External release input

09 Air flow qv / m³/h 16610 - Alarm relay
09 Pressure increase total psf / 175 - Integrated PID controller
Pa - Motor current limitation
10 Speed (rpm) n / min-1 1025 - PFC, passive
11 Specific ratio* 1.00 - RS-485 MODBUS-RTU
12 Recycling/disposal Information on recycling and disposal is - Soft start
provided in the operating instructions. - EEPROM write cycles: 100,000
13 Maintenance Information on installation, operation and
maximum
maintenance is provided in the operating
instructions. - Control input 0-10 VDC / PWM
14 Additional components Components used to calculate the energy - Control interface with SELV potential
efficiency that are not apparent from the safely disconnected from the mains
measurement category are detailed in the
CE declaration.
- Thermal overload protection for
electronics/motor
* Specific ratio = 1 + pfs / 100 000 Pa - Line undervoltage / phase failure
Data obtained at optimum efficiency level. The ErP data is determined using a motor-impeller detection
combination in a standardized measurement setup.
Touch current <= 3.5 mA
according to IEC
60990 (measuring
circuit Fig. 4, TN
system)

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W3G800-CU25-80
Operating instructions

Electrical hookup Terminal box a connection point with a Ssc value that is greater than or equal
Motor protection Reverse polarity and locked-rotor to 120 times the rated output of the arrangement.
protection
Protection class I (with customer connection of protective
earth) 4. CONNECTION AND STARTUP
Conformity with EN 61800-5-1; EN 50216-12; CE
standards 4.1 Mechanical connection
Approval CSA C22.2 No. 77 + CAN/CSA-
E60730-1; EAC; UL 1004-7 + 60730-1 CAUTION
Cutting and crushing hazard when removing device
With regard to cyclic speed loads, note that the rotating parts of from packaging
the device are designed for a maximum of one million load Blades can bend
cycles. If you have special questions, consult ebm-papst for
→ Carefully remove the device from its packaging, by the fan
support.
housing. Strictly avoid shocks.
; Use the device in accordance with its degree of protection.
→ Wear safety shoes and cut-resistant safety gloves.
Information on surface quality CAUTION
The surfaces of the products conform to the generally applicable industrial Device weighs over 25 kg! Heavy load when unpacking
standard. The surface quality may change during the production period. device.
This has no effect on strength, dimensional stability and dimensional Risk of physical injury, such as back injuries.
accuracy. → Use suitable hoisting equipment to remove the device from
The color pigments in the paints used perceptibly react to UV light over its packaging.
the course of time. This does not however in any way affect the
technical properties of the products. The product is to be protected against CAUTION
UV radiation to prevent the formation of patches and fading. Changes in The blades of the impeller could be damaged.
color are not a reason for complaint and are not covered by the warranty. → Carefully set down the fan on a soft surface. Make sure the
blades are not subjected to load.
3.5 Mounting data → Following installation, make sure the impeller moves
Any further mounting data required can be taken from the product easily and that the blades of the impeller are not deformed or
drawing or Section Chapter 4.1 Mechanical connection. bent and do not catch at any point.
Strength class of 8.8 NOTE
screws Damage to the device from vibration
Bearing damage, shorter service life
; Secure the screws against unintentional loosening (e.g. use self-
locking screws). → The fan must not be subjected to force or excessive vibration
from sections of the installation.
3.6 Transport and storage conditions → If the fan is connected to air ducts, the connection should
be isolated from vibration, e.g. using compensators or similar
Max. permitted +80 °C
elements.
ambient temp. for
motor (transport/ → Ensure stress-free attachment of the fan to the
storage) substructure.
Min. permitted -40 °C ; Check the device for transport damage. Damaged devices are not to
Translation of the original operating instructions

ambient temp. for be installed.

motor (transport/ ; Install the undamaged device in accordance with your application.
storage)
CAUTION
3.7 Electromagnetic compatibility Possible damage to the device
If the device slips during installation, serious damage can result.
EMC immunity to According to EN 61000-6-2 (industrial
→ Ensure that the device is securely positioned at its place of
interference environment)
installation until all fastening screws have been tightened.
EMC interference According to EN 61000-6-4 (industrial
emission environment) ● The fan must not be strained on fastening.

If several devices are switched in parallel on the supply side 4.2 Electrical connection
so that the line current of the arrangement is in the range of 16-
75 A, then this arrangement conforms to IEC 61000-3-12 DANGER
provided that the short-circuit power Ssc at the connection point Voltage on the device
of the customer system to the public power system is greater Electric shock
than or equal to 120 times the rated output of the arrangement. → Always connect a protective earth first.
It is the responsibility of the installation engineer or operator/ → Check the protective earth.
owner of the device to ensure, if necessary after consultation
with the network operator, that this device is only connected to

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W3G800-CU25-80
Operating instructions

DANGER Protective earth contact resistance according to EN 61800-5-1

Faulty insulation Compliance with the resistance specifications according to EN 61800-5-
Risk of fatal injury from electric shock 1 for the protective earth connection circuit must be verified in the end
→ Use only cables that meet the specified installation application. Depending on the installation situation, it may be necessary
regulations for voltage, current, insulation material, capacity, to connect an additional protective earth conductor by way of the extra
etc. protective earth terminal provided on the device. The protective earth
→ Route cables so that they cannot be touched by any terminal is located on the housing and provided with a protective earth
rotating parts. symbol and a hole.

DANGER 4.2.2 Supply connection and fuses

Electrical charge (>50 µC) between phase conductor and
Assignment of supply cable cross-sections and their required fuses (line
protective earth connection after switching off supply
protection only, no equipment protection).
with multiple devices connected in parallel.
Electric shock, risk of injury Nominal Fuse Automatic Cable Cable
→ Ensure sufficient protection against accidental contact. voltage circuit cross- cross-
Before working on the electrical hookup, short the supply breaker section section
and PE connections. VDE UL VDE mm² *AWG
3/PE AC 16 A 15 A C16A 1.5 16
CAUTION 380-480
Voltage VAC
The fan is a built-in component and has no disconnecting switch. 3/PE AC 20 A 20 A C20A 2.5 14
→ Only connect the fan to circuits that can be switched off with 380-480
an all-pole disconnection switch. VAC
→ When working on the fan, secure the system/machine in 3/PE AC 25 A 25 A C25A 4.0 12
which the fan is installed so as to prevent it from being 380-480
switched back on. VAC
NOTE * AWG = American Wire Gauge
Device malfunctions possible
Route the device's control lines separately from the supply line. 4.2.3 Reactive currents
→ Maintain the greatest possible clearance. Because of the EMC filter integrated for compliance with EMC
Recommendation: clearance > 10 cm (separate cable limits (interference emission and immunity to interference),
routing) reactive currents can be measured in the supply line even
NOTE when the motor is at a standstill and the line voltage is switched
Water ingress into wires or cables on.
Water ingress at the customer end of the cable can damage the ● The values are typically in the range < 250 mA
device. ● At the same time, the effective power in this operating state
→ Make sure the end of the cable is connected in a dry (operational readiness) is typically < 5 W.
environment.
4.2.4 Residual current circuit breaker (RCCB)
Only connect the device to circuits that can be switched off with
an all-pole disconnection switch. If the use of a residual current device (RCD) is required in your
installation, only AC/DC-sensitive residual current devices
Translation of the original operating instructions

(type B or B+) are permissible. As with variable frequency

4.2.1 Requirements
drives, residual current devices cannot provide personal safety
; Check whether the information on the nameplate matches the while operating the device. When the device power supply is
connection data. switched on, pulsed charging currents from the capacitors in the
; Before connecting the device, make sure the power supply matches integrated EMC filter can lead to the instant tripping of residual
the device voltage. current devices. We recommend the use of residual current
circuit breakers (RCCB) with a trip threshold of 300 mA and
; Only use cables designed for the current level indicated on the
delayed tripping (super-resistant, characteristic K).
nameplate.
For determining the cross-section, note the sizing criteria according 4.2.5 Leakage current
to EN 61800-5-1. The protective earth must have a cross-section
equal to or greater than that of the phase conductor. For asymmetrical power systems or if a phase fails, the
We recommend the use of 105 °C cables. Ensure that the minimum leakage current can increase to a multiple of the nominal value.
cable cross-section is at least
AWG 26 / 0.13 mm².

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W3G800-CU25-80
Operating instructions

4.2.6 Locked-rotor protection

Due to the locked-rotor protection, the starting current (LRA) is
equal to or less than the nominal current (FLA).

4.3 Connection in terminal box

4.3.1 Preparing cables for connection

Only strip the cable as far as necessary, ensuring that the cable gland is
sealed and there is no strain on the connections.
Only strip the cable as far as necessary, ensuring that the cable gland is
sealed and there is no strain on the connections. For tightening torques,
see Chapter 3.1 Product drawing.
NOTE
Tightness and strain relief are dependent on the cable
used.
→ This must be checked by the user.

Fig. 2: Connecting wires to terminals

Fig. 1: Recommended stripped lengths in mm (inside terminal box)
; Seal the terminal box.
Legend: CL = control lines
4.3.3 Cable routing
4.3.2 Connecting wires to terminals
Water must be prevented from reaching the cable gland along the cable.
WARNING
Live terminals and connections even with device NOTE
switched off Damage caused by moisture penetration.
Electric shock Moisture can penetrate into the terminal box if water is
constantly present at the cable glands.
→ Wait five minutes after disconnecting the voltage at all poles
before opening the device. → To prevent the constant accumulation of water at the cable
Translation of the original operating instructions

glands, the cable should be routed in a U-shaped loop

; Remove the cap from the cable gland.
wherever possible.
Only remove caps where cables are fed in.
→ If this is not possible, a drip edge can be produced by
; Equip the cable glands with the seals provided in the terminal box. fitting a cable tie directly in front of the cable gland for example.
; Route the wire(s) (not included in scope of delivery) into the terminal
box. Fans installed lying flat
; First connect the "PE" (protective earth). Make sure the cable is routed in a U-shaped loop.
; Connect the wires to the corresponding terminals.
Use a screwdriver to do so.
When connecting, ensure that no wire ends fan out.

Fig. 3: Fan installed lying flat, cable routed in a U-shaped loop.

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W3G800-CU25-80
Operating instructions

Fans installed upright

When routing the cable, make sure that the cable glands are located at
the bottom. The cables must always be routed downward.

Fig. 4: Cable routing for fans installed upright.

4.4 Factory settings

Factory settings made for the device by ebm-papst.
Mode parameter set 1 PWM control
Mode parameter set 2 PWM control
Fan/device address 01
Max. PWM / % 100
Min. PWM / % 5
Save set value to Yes
EEPROM
Set value requirement Analog (linear)
Direction of action Positive (heating)
parameter set 1
Direction of action Positive (heating)
parameter set 2
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W3G800-CU25-80
Operating instructions

4.5 Connection diagram

Translation of the original operating instructions

Drawing preliminary!

No. Conn. Designation Function/assignment

KL 1 1 L1 Supply connection, power supply; for nominal voltage range see technical data
KL 1 2 L2 Supply connection, power supply; for nominal voltage range see technical data
KL 1 3 L3 Supply connection, power supply; for nominal voltage range see technical data
PE PE Ground connection, PE connection
KL 2 1 NO Status relay, floating status contact, make for failure
KL2 2 COM Status relay, floating status contact, changeover contact, common connection, contact rating 250 VAC / max.
2 A (AC1) / min. 10 mA
KL2 3 NC Status relay, floating status contact, break for failure
KL 3 1 RSA Bus connection RS485, RSA, MODBUS-RTU; SELV
KL 3 2 RSB Bus connection RS485, RSB, MODBUS-RTU; SELV
KL 3 3 / 10 GND Reference ground for control interface; SELV
KL 3 4 Ain1 U Analog input 1, set value: 0-10 V, Ri = 100 kΩ, adjustable curve, only usable as alternative to input Ain1I;
SELV
KL 3 5 + 10 V Fixed voltage output 10 VDC, +10 V ±3%, max. 10 mA, short-circuit-proof power supply for external devices
(e.g. pot); SELV

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W3G800-CU25-80
Operating instructions

No. Conn. Designation Function/assignment

KL 3 6 Ain1 I Analog input 1, set value: 4-20 mA, Ri = 100 Ω, adjustable curve, only usable as alternative to input Ain1U;
SELV
KL 3 7 Din1 Digital input 1: enable electronics,
enable: pin open or applied voltage 5-50 VDC
disable: bridge to GND or applied voltage < 1 VDC
reset function: triggers software reset after a level change to < 1 VDC; SELV
KL 3 8 Din2 Digital input 2: Switching parameter sets 1/2, according to EEPROM setting, the valid or used parameter set
can be selected via bus or via digital input DIN2.
Parameter set 1: pin open or applied voltage 5-50 VDC
Parameter set 2: bridge to GND or applied voltage < 1 VDC; SELV
KL 3 9 Din3 Digital input 3: according to EEPROM setting, the integrated controller's direction of action can be selected via
bus or digital input Din3;
normal: pin open or applied voltage 5-50 VDC
inverse: bridge to GND or applied voltage < 1 VDC; SELV
KL 3 11 Ain2 U Analog input 2, measured value: 0-10 V, Ri = 100 kΩ, adjustable curve, only usable as alternative to input
Ain2I; SELV
KL 3 12 + 20 V Fixed voltage output 20 VDC, +20 V +25/-10%, max. 50 mA, short-circuit-proof power supply for external
devices (e.g. sensors); SELV
or: +24 VDC input for parameter setting without line voltage
KL 3 13 Ain2 I Analog input 2, measured value: 4-20 mA, Ri = 100 Ω, adjustable curve, only usable as alternative to input
Ain2U; SELV
KL 3 14 Aout Analog output 0-10 VDC, max. 5 mA, output of current motor modulation level / motor speed
adjustable curve; SELV
Translation of the original operating instructions

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W3G800-CU25-80
Operating instructions

4.6 Checking connections ; When disconnecting, be sure to disconnect the ground connection last.
; Ensure isolation from supply (all phases).
; Make sure a restart is impossible 5. INTEGRATED PROTECTIVE FEATURES
; Check the cables for proper fit.
The integrated protective functions cause the motor to switch off
; Screw the terminal box cover back on again. Terminal box tightening automatically in the event of the faults described in the table.
torque, see Chapter 3.1 Product drawing.
; Route the cables in the terminal box so that the terminal box cover Fault Safety feature description/
closes without resistance. function
Rotor position detection error An automatic restart follows.
; Use all screw plugs. Insert the screws by hand to avoid damage to
Blocked rotor ; After the blockage is
the threads.
removed, the motor restarts
; Make sure the terminal box is completely closed and sealed and that automatically.
all screws and cable glands have been properly tightened. Line undervoltage (line voltage ; If the line voltage returns to
outside of permitted nominal permitted values, the motor
4.7 Switching on the device voltage range) restarts automatically.
The device may only be switched on if it has been installed properly and Phase failure A phase of the supply voltage
in accordance with its intended use, including the required safety fails for at least 5 s.
mechanisms and professional electrical hookup. This also applies for ; When all phases are correctly
devices which have already been equipped with plugs and terminals or supplied again, the motor
similar connectors by the customer. automatically restarts after 10-40
s.
WARNING
Hot motor housing
Risk of fire
→ Ensure that no combustible or flammable materials are 6. MAINTENANCE, MALFUNCTIONS, POSSIBLE
located close to the fan. CAUSES AND REMEDIES
; Before switching on, check the device for visible external damage
Do not perform any repairs on your device. Send the device to ebm-
and make sure the protective devices are functional.
papst for repair or replacement.
; Check the fan's air flow paths for foreign matter and remove any
foreign matter found. WARNING
Live terminals and connections even with device
; Apply the nominal supply voltage.
switched off
; Start the device by changing the input signal. Electric shock
NOTE → Wait five minutes after disconnecting the voltage at all poles
Damage to the device from vibration before opening the device.
Bearing damage, shorter service life
CAUTION
→ Low-vibration operation of the fan must be ensured over the If control voltage or a stored speed set value is applied,
entire speed control range. the motor will restart automatically, e.g. after a power
→ Severe vibration can arise for instance from inexpert failure.
handling, transportation damage and resultant imbalance or Risk of injury
be caused by component or structural resonance.
Translation of the original operating instructions

→ Keep out of the device’s danger zone.

→ Speed ranges with excessively high vibration levels and → When working on the device, switch off the line voltage
possibly resonant frequencies must be determined in the and ensure that it cannot be switched back on.
course of fan commissioning.
→ Wait until the device comes to a stop.
→ Either run through the resonant range as quickly as
→ After working on the device, remove any tools or other
possible with speed control or find another remedy.
objects from the device.
→ Operation with excessively high vibration levels can
lead to premature failure. NOTE
If the device is not operated for a lengthy period in installed
4.8 Switching off the device condition in a dry environment, it is to be started up and
operated at full speed for one hour at least every four months. If
Switching off the device during operation: the device is not operated for a lengthy period in installed
; Switch off the device via the control input. condition in a damp environment (e.g. outdoors), it is to be
; Do not switch the motor (e.g. in cyclic operation) on and off via power started up and operated at full speed for at least three hours
supply. once a month to move the bearings and allow any condensate
Switching off the device for maintenance: that may have ingressed to evaporate.

; Switch off the device via the control input. Malfunction/fault Possible cause Possible remedy
; Do not switch the motor (e.g. in cyclic operation) on and off via power
supply.
; Disconnect the device from the power supply.

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W3G800-CU25-80
Operating instructions

Impeller not Imbalance in rotating Clean the device; Impermissible point of Correct the operating
running smoothly parts replace it if imbalance operation (e.g. back point. Let the device
persists after cleaning. pressure too high) cool down.
Make sure no To reset the error
weight clips are message, switch off
removed during the line voltage for at
cleaning. least 25 s and then
Motor not turning Mechanical blockage Switch off, isolate switch it on again.
from supply and Alternatively, reset
remove mechanical the error message by
blockage. applying a control
Line voltage faulty Check line voltage, signal of < 0.5 V to
restore power supply. Din1 or by shorting
Attention! The error Din1 to GND.
message resets
automatically. In the event of further malfunctions, contact ebm-papst.
Device restarts
automatically without
warning. 6.1 Cleaning
Faulty connection Isolate from supply,
correct connection; To ensure a long service life, check the fans regularly for proper
see connection operation and soiling. The frequency of checking is to be adapted
diagram. accordingly depending on the degree of soiling.
Broken motor winding Replace device DANGER
Deficient cooling Improve cooling. Let Risk of injury from rotating fan.
the device cool down. → Only clean when not in motion. Do not disconnect the fan
To reset the error from the power supply, just switch it off via the control input.
message, switch off This will prevent start-up of the fan.
the line voltage for at
; Dirt deposits on the motor housing can cause overheating of the motor.
least 25 s and then
switch it on again. ; Soiling of the impeller can cause vibration that will shorten the service
Alternatively, reset life of the fan.
the error message by ; Severe vibration can destroy the fan.
applying a control ; In such cases, switch off the fan immediately and clean it.
signal of < 0.5 V to
; The preferred method of cleaning is dry cleaning, e.g. using
Din1 or by shorting
compressed air.
Din1 to GND.
Ambient temperature Reduce the ambient ; Do not use aggressive cleaning agents!
too high temperature. Let the NOTE
device cool down. Damage to the device during cleaning
To reset the error Malfunction possible
message, switch off
→ Do not clean the device using a high-pressure cleaner.# Do
Translation of the original operating instructions

the line voltage for at

not use acid, alkali or solvent-based cleaning agents.
least 25 s and then
switch it on again. → Do not use any pointed or sharp-edged objects for
Alternatively, reset cleaning.
the error message by ; Completely remove any cleaning agents used.
applying a control ; If severe corrosion is visible on load-bearing or rotating parts, switch
signal of < 0.5 V to off the device immediately and replace it.
Din1 or by shorting
; Repair of load-bearing or rotating parts is not permitted!
Din1 to GND.
; Operate the fan for 2 hours at maximum speed so that any water that
has ingressed can evaporate.
; If cleaning does not eliminate vibrations, the fan may need to be
rebalanced. To have it rebalanced, contact ebm-papst.
; The fan is equipped with maintenance-free ball bearings. The lifetime
lubrication of the ball bearings is designed for a service life of 40,000
hours.
; If bearing replacement is necessary after that period, contact ebm-
papst.
; Adapt the maintenance intervals to the actual level of dust exposure.

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W3G800-CU25-80
Operating instructions

6.2 Safety inspection 6.3.2 Disassembly

NOTE Disassembly of the product must be performed or supervised by

High-voltage test qualified personnel with the appropriate technical knowledge.
The integrated EMC filter has Y capacitors. The tripping current The product is to be disassembled into suitable components for disposal
is exceeded when AC testing voltage is applied. employing standard procedures for motors.
→ Test the device with DC voltage when you perform the WARNING
legally required high-voltage test. The voltage to be used Heavy parts of the product may drop off. Some of the
corresponds to the peak value of the AC voltage required by product components are heavy. These components
the standard. could drop off during disassembly.
This can result in fatal or serious injury and material damage.
What to check How to check How often What action?
Contact Visual inspection At least every Repair or → Secure components before unfastening to stop them falling.
protection 6 months replacement of 6.3.3 Component disposal
cover for device
intactness or The products are mostly made of steel, copper, aluminum and plastic.
damage Metallic materials are generally considered to be fully recyclable.
Device for Visual inspection At least every Replacement of Separate the components for recycling into the following categories:
damage to 6 months device ● Steel and iron
blades and ● Aluminum
housing
● Non-ferrous metal, e.g. motor windings
Fastening the Visual inspection At least every Fasten
cables 6 months ● Plastics, particularly with brominated flame retardants, in accordance
Insulation of Visual inspection At least every Replace cables with marking
cables for 6 months ● Insulating materials
damage ● Cables and wires
Tightness of Visual inspection At least every Retighten, ● Electronic scrap, e.g. circuit boards
cable gland 6 months replace if
damaged Only ferrite magnets and not rare earth magnets are used in external
rotor motors from ebm-papst Mulfingen GmbH & Co. KG.
Condensation Visual inspection At least every Open holes
drainage holes 6 months ; Ferrite magnets can be disposed of in the same way as normal iron
for clogging, and steel.
where necessary Electrical insulating materials on the product, in cables and wires are
Welds for crack Visual inspection At least every Replace device made of similar materials and are therefore to be treated in the same
formation 6 months manner.
Abnormal acoustic At least every Replace device The materials concerned are as follows:
bearing noise 6 months ● Miscellaneous insulators used in the terminal box
● Power cables
6.3 Disposal
● Cables for internal wiring
For ebm-papst, environmental protection and resource preservation are ● Electrolytic capacitors
top priority corporate goals.
ebm-papst operates an environmental management system which is Dispose of electronic components employing the proper procedures for
electronic scrap.
Translation of the original operating instructions

certified in accordance with ISO 14001 and rigorously implemented

around the world on the basis of German standards. → Please contact ebm-papst for any other questions on disposal.
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.
6.3.1 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.

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