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1. Product Overview and Working Principle

The RG148 series from ebm-papst utilizes EC (Electronically Commutated) motor technology, integrating a rectifier, inverter, and a brushless DC (BLDC) motor into a compact unit. Instead of using a traditional AC induction motor and external variable frequency drive (VFD), these fans convert AC mains to DC internally and use an IGBT inverter to generate three-phase PWM signals that drive the motor.

Key Advantages

• High Efficiency: No belt or rotor copper loss; system efficiency >90%.
• Brushless & Maintenance-Free: No mechanical commutation—electronic switching replaces brushes.
• Easy Speed Control: A simple 1–6 kHz PWM or 0–10 V analog input allows linear speed regulation.

These fans are ideal for applications requiring wide speed ranges, low maintenance, and energy savings of up to 30% compared to traditional setups.

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2. Connector Definitions and Wiring

The fan features a 5-pin control connector alongside L/N/PE power terminals. The connector is typically an AMP MATE-N-LOK or Molex Mini-Fit Jr. housing, with pin numbers (“1–5”) molded into the plastic shell.

Pin	Wire Color (Original Harness)	Function	Description
1	Blue	GND (Signal Ground)	SELV ground, isolated from chassis
2	Yellow	PWM IN / 0–10 V	1–6 kHz square wave; >20% for startup, >5% for run
3	—	N.C. (Not Connected)	Reserved
4	White	Tach Out	2 pulses/rev, open-collector output
5	Brown	+18 V Output	Max ~20 mA, for pull-up or optocoupler supply

How to identify pins:

1. Visually inspect the connector for molded pin numbers or orientation notch.
2. With power applied, use a multimeter: the only stable ~18 V pair indicates Pin 1 (GND) and Pin 5 (+18 V).
3. Injecting PWM into Pin 2 should spin the fan—this helps verify its identity.

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3. Minimal Wiring for Testing

Power Side: Connect L/N to 230 V AC (or 115 V for low-voltage variants). Add a 6 A slow-blow fuse. PE must be grounded for safety.

Control Side (minimum 3 wires):

• Pin 1 → Connect to your microcontroller or function generator GND
• Pin 2 → Feed a 0–5 V PWM signal through a 1 kΩ resistor
• Pin 4 / Pin 5 → Optional; leave unconnected during basic testing

Startup Procedure

1. With the fan powered off, complete wiring.
2. Power on with PWM = 0%.
3. Output a 30% duty PWM (e.g. 3 kHz); the fan should spin up smoothly.
4. Adjust duty cycle and observe speed changes.
5. Set PWM <3% to stop the fan.

This minimal setup allows safe testing without needing feedback circuits.

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4. Tuning Parameters and Performance Verification

Parameter	Recommended Value	Purpose
PWM Frequency	2–4 kHz	Avoids audible noise
Startup Duty	≥25%	Ensures soft start
Minimum Duty	>5%	Fan stops below this value
RPM Calculation	rpm = freq × 30	Based on Tach signal (2 p/rev)

By measuring the Tach frequency and correlating it with airflow or pressure, you can build a duty-RPM-airflow map for system tuning or PID feedback control.

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5. Common Faults and Troubleshooting

Symptom	Possible Cause	Check / Solution
No rotation	PWM <20%; no GND; internal fuse blown	Oscilloscope on Pin 2; verify Pin 1–5 = +18 V; check fuse
Whining or jittering	PWM freq too low; sharp duty changes	Set to 2–4 kHz; ramp the duty smoothly
No Tach pulse	Missing pull-up or overvoltage	Pull up Pin 4 to +18 V with 10 kΩ or use voltage divider
Overheat shutdown	Poor ventilation; ambient >60°C	Clean airflow path; reduce speed/load
EMI interference	Long unshielded wires	Use shielded twisted pairs; add 100 Ω damping resistors on Pin 2/4

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6. Maintenance and Advanced Configuration

• Routine Check: Every 3 months, clean the impeller and check grounding screws; test insulation yearly.
• Cable Management: For >1 m signal wires, use shielded twisted pairs and ground the shield at one end.
• EEPROM Configuration: Use ebm-papst EC-Control software via Bluetooth or RSB bus to tweak internal parameters (e.g. soft-start ramp, min RPM).
• Harmonic Filtering: For multiple fans on a shared supply, consider adding filters or 12-pulse rectifiers to reduce THDi.

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7. Conclusion

The RG148 EC fan series represents a highly efficient and compact solution for modern ventilation systems. With its integrated inverter and brushless motor, it provides wide-speed-range performance without external VFDs. By mastering the 3-wire minimal control method, understanding PWM tuning, and applying basic troubleshooting, engineers can easily integrate and commission these fans in test setups and production lines. For advanced applications, feedback via Tach signals and EEPROM customization further enhances control accuracy and energy efficiency.

This guide aims to provide a comprehensive, practical overview to help users get the fan up and running safely, optimize its performance, and resolve common issues in real-world scenarios.

1. Overview and Requirements of the Packaging Rope Production Line

The packaging rope production line is widely used for processing polypropylene (PP) and polyethylene (PE) materials. It primarily involves extrusion, stretching, twisting, and winding to produce the required packaging ropes. The production line involves several motors, heating control, tension control, and synchronization control. The stability and precision of the equipment are critical for production efficiency and product quality.

Main Equipment:

1. Extruder: Used for melting and extruding the raw material into a uniform melt.
2. Drawing Machine: Used for stretching the cooled fibers to increase strength and elasticity.
3. Twisting Machine: Used for twisting the stretched fibers into ropes.
4. Winding Machine: Used for winding the finished ropes into coils.

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2. Control System Design

1. Motor Control and Inverter Selection

Motor control is essential for precise production on the line. The speed of each device’s motor must be adjusted in real-time to meet the production process’s requirements. Longi 9000 series inverters will be used to control the speed of each motor.

Extruder Motor Control:

• Motor Power: Typically, 15-55 kW asynchronous motors are selected.
• Inverter Model: Longi 9000 series inverters are suitable for high-power motors, providing precise speed control.
• Wiring Method: The inverter’s input is connected to a three-phase power supply, and the output is connected to the motor terminals via cables, usually using a star connection for stable starting torque and reliability.

Extruder Motor Parameter Settings:

• Frequency Range: 0-60Hz (can be adjusted depending on production requirements, typically set at 30Hz).
• Acceleration/Deceleration Time: Set to 5-10 seconds for smooth starting and stopping, avoiding overload.
• Current Limiting: Set to 120% of rated motor current as protection.

Drawing Machine Motor Control:

The drawing machine is used to stretch the fibers, and its speed is directly linked to the extruder’s output speed. The drawing machine inverter will be synchronized with the extruder inverter.

• Motor Power: Typically, 5-15 kW asynchronous motors are selected.
• Inverter Model: Longi 9000 series inverters.
• Wiring Method: Similar to the extruder inverter, connected via bus for synchronized control.

Drawing Machine Motor Parameter Settings:

• Frequency Range: 0-100Hz to match stretching speed with the extruder.
• Acceleration/Deceleration Time: Set to 5-10 seconds to avoid fiber breakage from fast stretching.
• Speed Synchronization: Use the inverter’s multi-machine synchronization function to keep the drawing machine synchronized with the extruder.

Twisting Machine and Winding Machine Motor Control:

Both the twisting machine and winding machine require precise speed control, especially for tension control under different conditions.

• Motor Power: Twisting machine typically uses 2-5 kW motors, and winding machine uses 5-15 kW motors.
• Inverter Model: Longi 9000 series for precise speed regulation and starting/stopping control.
• Wiring Method: Standard three-phase connection, with the inverter connected to the motor.

Twisting Machine Motor Parameter Settings:

• Frequency Range: 0-60Hz.
• Acceleration/Deceleration Time: Set to 3 seconds for smooth twisting.
• Synchronization Function: Achieved through PLC coordination with the drawing and winding machines.

Winding Machine Motor Parameter Settings:

• Frequency Range: 0-60Hz, closely related to fiber tension.
• Acceleration/Deceleration Time: Set to 5 seconds for uniform winding.

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2. Heating Control System and Temperature Regulation

The heating system in the extruder is crucial for maintaining material quality. Temperature control must be precise. We will use Longi PLC (LX1000 series) along with temperature control modules to monitor and adjust the temperature.

Extruder Temperature Control Design:

• Heating Zones: The extruder has multiple heating zones, each equipped with a temperature control module to monitor and adjust the temperature.
• Wiring Method: The temperature control module’s output is connected to the heater, and the PLC adjusts the temperature using analog outputs (4-20mA).
• Temperature Sensor: Use PT100 sensors with an accuracy of ±0.5°C to provide real-time temperature feedback to the PLC.

Temperature Control Parameter Settings:

• Set Temperature Range: Typically set at 180-220°C for different zones, suitable for PP and PE melting temperatures.
• Temperature Adjustment Strategy: Use PLC’s PID control algorithm to maintain precise temperature, avoiding overheating or cooling, which may cause instability in the material quality.

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3. Tension Control System

Precise tension control is essential during the drawing and winding processes to prevent fiber breakage or uneven winding. We will integrate tension sensors with the Longi PLC to implement real-time tension monitoring and control.

Tension Control Design:

• Tension Sensors: Select high-precision tension sensors like the FMS series, installed at key points on the drawing and winding machines for real-time feedback.
• Control Method: The PLC receives signals from the tension sensors and adjusts the drawing and winding speeds to maintain consistent tension.
• Wiring Method: The tension sensors provide analog signals to the PLC, which adjusts the motor speeds for closed-loop tension control.

Tension Control Parameter Settings:

• Target Tension Range: Set between 0.5-2kg to ensure stable fiber stretching and winding.
• Feedback Method: PLC adjusts the drawing and winding machine speeds based on the tension feedback from sensors.

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4. Synchronization Control Scheme

Synchronization control between multiple devices is essential for smooth production. We will use Longi PLC’s high-speed counters and pulse output features to synchronize devices.

Synchronization Control Design:

• Master and Slave Synchronization: The extruder will be the master device, while the drawing machine, twisting machine, and winding machine will be slaves. The PLC will synchronize these machines via pulse output.
• Wiring Method: The PLC sends pulse signals to all devices using high-speed counters to synchronize their operation.
• Synchronization Adjustment: The PLC adjusts each device’s speed according to the main device’s status, ensuring coordinated operation.

Synchronization Control Parameter Settings:

• Synchronization Pulse Frequency: Set to 50Hz to synchronize all devices.
• Precision Requirements: The PLC’s pulse output precision is set to 1ms to ensure synchronization accuracy.

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3. System Architecture and Wiring Diagram

Below is the basic wiring and architecture diagram for the packaging rope production line control system:

Equipment Connection and Wiring Diagram:

[Raw Material Mixer] → [Extruder] → [Cooling Tank] → [Drawing Machine] → [Twisting Machine] → [Winding Machine]
       ↑                ↑                ↑               ↑
       |                |                |               |
   [Longi PLC] ←→ [Longi 9000 Inverter] ←→ [Temperature Control Module] ←→ [Tension Sensors]

System Architecture Diagram:

              +------------+                +-------------+
              |  Longi PLC  | ←--> [Inverter] ←--> [Motor] ←--> [Device]
              +------------+                +-------------+
                     ↑                            ↑
                  [Sensors] ←--> [Tension Control] ←--> [Heating Control]

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4. Conclusion

By integrating Longi 9000 series inverters, LX1000 series PLCs, and Longi plastic machine configuration software into the packaging rope production line, we can achieve precise motor control, temperature regulation, tension control, and synchronization control, ensuring efficient and stable production. The design is clear and logically sound, meeting the needs of modern packaging rope production lines for automation and intelligence.

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1. Application Background and Industry Pain Points

In enclosed or semi-enclosed environments such as underground parking lots, automobile repair workshops, welding workshops, paint booths, and other industrial sites, harmful gases like carbon monoxide (CO), emitted from vehicle exhaust, fuel combustion, or industrial processes, can accumulate over time. This presents a health risk to workers and affects the quality of air. Therefore, an intelligent, automated ventilation control system is needed to monitor and regulate air circulation in real time.

Traditional ventilation systems mostly run at fixed speeds, which are simple but result in high energy consumption, low efficiency, and slow response to fluctuating CO concentrations. To address these issues, this solution designs an intelligent ventilation system based on Longi 900 Series Variable Frequency Drives (VFD) and RKC PID controllers for automatically adjusting fan speed using PID closed-loop control, ensuring good air quality in a variety of settings.

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2. System Components and Working Principles

1. Key Components

Module Category	Product Selection	Function Description
VFD (Variable Frequency Drive)	Longi 900 Series VFD	Controls fan speed, adjusts airflow rate automatically
PID Controller	RKC CH102 or REX-C100	Receives CO sensor input and outputs control signals (4-20mA)
Carbon Monoxide Sensor	ZE25-CO (Winsen)	Detects CO concentration in real time, outputs analog signals
Ventilation Equipment	Centrifugal Fan or Duct Fan	Regulates exhaust air according to VFD adjustments
Control Panel	Custom-made	Displays status, allows manual/automatic switch

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2. Control Logic and Operation Principles

(1) CO Concentration Detection

The CO sensor (e.g., Winsen ZE25-CO) continuously monitors the CO concentration in the air, typically outputting a 4-20mA analog signal. When the concentration exceeds a set threshold, it triggers subsequent control actions.

(2) PID Controller Adjustment

The RKC PID Controller compares the actual CO concentration with the set target concentration (e.g., 30ppm) and calculates the required adjustment signal using proportional-integral-derivative (PID) logic. It then outputs a control signal (4-20mA).

(3) VFD Speed Regulation

The Longi 900 Series VFD receives the analog control signal from the PID controller and adjusts the fan motor speed accordingly. For example, if the CO concentration is high, the PID controller will instruct the VFD to increase the speed, thereby increasing the airflow for faster exhaust.

(4) Feedback and Protection

The system continuously monitors CO concentration, and when it exceeds a safe level, the fan speed is increased automatically. Once the concentration drops back to a safe level, the fan speed is reduced to the minimum. This process optimizes energy use while ensuring the safety of workers.

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3. Longi 900 Series VFD Advantages

Feature	Description
PID Control Support	Built-in PID control parameters for automatic regulation based on external input
Flexible Analog Input Interfaces	Supports 0-10V, 4-20mA, and other input signals, adaptable to various control needs
High Reliability	Multiple protection features including overload, overvoltage, and overheat safeguards
Energy Efficiency	Wide speed regulation range (0-500Hz), enabling precise fan speed adjustments to reduce energy consumption
Ease of Maintenance	User-friendly interface, easy to maintain, and extend device lifespan

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4. Suggested System Configuration

Name	Model	Quantity	Description
VFD	Longi 900 Series 900-0015G3 (1.5kW)	1 unit	Drives the fan, adjusts speed according to PID control signals
PID Controller	RKC CH102	1 unit	Receives CO sensor signal, outputs control signal (4-20mA)
CO Sensor	Winsen ZE25-CO	1 unit	Detects CO concentration, outputs analog signal
Fan and Motor	YVF2 1.5kW + Centrifugal Fan	1 set	Core of the system, performs exhaust tasks
Control Panel	Custom-made	1 unit	Includes operation buttons, display indicators, emergency stop

Suggested Parameter Settings

For Longi 900 Series VFD, the following parameters are recommended:

Parameter	Description	Suggested Value
F0-00	Command Source	1 (External Terminal Control)
F0-01	Main Frequency Source	2 (AI1)
F5-02	PID Feedback Source	1 (Analog Input)
F5-08	Sensor Type	1 (4-20mA)
F5-01	PID Setpoint	30ppm (Reference Value)
F0-04/05	Acceleration/Deceleration Time	5-10s

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5. System Deployment and Maintenance Recommendations

1. Installation and Layout

• Sensor Installation: CO sensors should be installed in central locations or at the end of exhaust ducts, approximately 1.5-2 meters above the floor, to ensure complete area monitoring.
• PID Controller: Should be installed in a location visible to the operator for easy adjustment of parameters.
• VFD and Fan Installation: VFD should be installed in an electrical control cabinet with adequate ventilation, avoiding high temperatures and humidity.

2. System Debugging and Operation

• Before powering up, verify that the wiring is correct, especially ensuring that the VFD output terminals (U/V/W) are not connected to the mains.
• Set the RKC PID Controller:
  • Setpoint (SV) to 30ppm.
  • Control mode to PID, output signal set to 4-20mA.
• After connecting the CO sensor, adjust PID parameters (proportional, integral, and derivative gains) for optimal system response.

3. Maintenance and Upkeep

Equipment	Maintenance Task	Frequency
CO Sensor	Zero-point calibration and functionality check	Every 6 months
PID Controller	Output signal and display check	Every 12 months
VFD	Heat sink cleaning and electrical check	Every 12-18 months
Fan Motor	Lubrication and current measurement	Every 3-6 months

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6. System Upgrades and Expansion Recommendations

1. Remote Communication Module

The Longi 900 Series VFD supports Modbus RTU communication. Add a remote communication module for cloud-based monitoring, data logging, and alarm notifications, enabling more advanced smart management.

2. Multi-Region Control

For large workshops or parking lots, deploy multiple independent ventilation units, each with its own CO sensor, to control fan speeds regionally, optimizing energy use.

3. Integration of Particulate Matter (PM2.5/PM10) Sensors

Expand the system to monitor and control particulate pollution, ensuring air quality across various industrial processes.

4. Lighting System Integration

Incorporate lighting control, turning on both the lights and the ventilation system when personnel enter a room, and turning them off after a delay once they exit, further reducing energy consumption.

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7. Conclusion and Value Proposition

With the Longi 900 Series VFD, RKC PID Controllers, and CO Sensor Integration, this system enables automatic fan speed adjustment to ensure air quality and worker safety. By utilizing energy-efficient, smart control, this solution meets the needs of environments like workshops, parking garages, and industrial sites, and provides significant benefits in terms of energy savings, safety, and environmental health.

This system is an ideal solution for maintaining high standards of air quality while optimizing energy use in industrial facilities.

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