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Baumuller b maXX 5000 BM5800 Series, Instruction Handbook Manual

The Baumuller b maXX 5000 BM5800 Series is a powerful and efficient motor controller designed for industrial applications. To fully utilize its capabilities, make sure to refer to the comprehensive Instruction Handbook Manual. You can easily download this manual for free from manualshive.com, enabling you to confidently operate and maintain your Baumuller device.

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Instruction handbook 

b maXX

 

5800

Document No. 5.16027.04

Baumüller Nürnberg GmbH

128

of 174

9.3

9.3

Repairs

In case of device damage, please inform your sales office or:

Baumüller Nürnberg GmbH

Ostendstr. 80 - 90 

 90482 Nuremberg

 Germany

Tel. +49 9 11 54 32 - 0

Fax: +49 9 11 54 32 - 1 30

Mail: [email protected]

Internet: www.baumueller.de

Summary of Contents for b maXX 5000 BM5800 Series

Page 1: ...tion handbook Read the Instruction handbook before starting any work Language English Translation Document No 5 16027 04 Part No 464136 Edition 22 May 2019 b maXX 5000 BM5800 Multi axis controller E 5 16027 04 ...

Page 2: ...omments so that we can take them into account and include them when transitioning from the preliminary information to the final information as reviewed by Baumüller The conditions stipulated in the following section under Obligatory are invalid in case of pre liminary information Obligatory This Instruction handbook are a part of the equipment machine This Instruction handbook must be available to...

Page 3: ...ve devices 17 2 7 Training of the personnel 18 2 8 Personal protective equipment 19 2 9 Special hazards 20 2 10 Fire fighting 21 2 11 Safety equipment 22 2 12 Conduct in case of danger or accidents 22 2 13 Signs and labels 23 3 Technical data 27 3 1 Dimensions 27 3 1 1 BM5807 S dimensions 28 3 1 2 BM5807 A dimension 29 3 2 Weight 29 3 3 Operating conditions 30 3 3 1 Requirements for control voltag...

Page 4: ...nting with mounting rail 67 6 3 2 Mounting without mounting rail 68 6 3 3 Mounting of the DC link bar 69 6 3 4 Demounting 70 7 Installation 71 7 1 Safety notes 71 7 2 Voltage test 73 7 3 Demands on the electrical mains 74 7 4 Requirements for the connection cables 75 7 5 PE connection and RCD compatibility 75 7 6 Grounding concept of MAR and side by side mounted system 76 7 7 Installation requirem...

Page 5: ...ection intervals maintenance notes 124 9 3 Repairs 128 10 Troubleshooting and Fault correction 129 10 1 Behavior in case of malfunctions 129 10 2 Monitoring functions 130 10 3 Error detection 133 10 4 Error handling 134 11 Accessories and spare parts 135 11 1 Cabling 135 11 1 1 Device mains cabling 135 11 1 2 Hybrid cable device encoder motor 136 11 1 3 Control voltage supply signal cable 142 11 1...

Page 6: ... 155 12 2 Requirements to the executing personnel 156 12 3 Shutdown 156 12 4 Demounting 156 12 5 Storage conditions 157 12 6 Recommissioning 157 13 Disposal 159 13 1 Safety regulations 159 13 2 Disposal facilities authorities 161 Appendix A Abbreviations 163 Appendix B Declaration of Conformity 165 Table of Figures 169 Index 171 Overview of Revisions 173 ...

Page 7: ...ly before beginning any work on the device The instruction handbook is part of the product and must be kept accessible to personnel at all times in the immediate vicinity of the device 1 2 Key to symbols Warning notes Warning notes are identified by symbols in these instruction handbook The notes are in troduced by signal words that express the extent of the danger It is imperative that these note...

Page 8: ...ccount of the latest technical changes to the explanations and representations described herein The user bears the responsibility for performing service and initial operation in accor dance with the safety regulations of the applicable standards and all other relevant gov ernmental or local regulations concerning the dimensioning and protection of conductors grounding disconnectors overcurrent pro...

Page 9: ...the device The consignment of the instruction handbook to third persons without the written permission of the manufacturer is prohibited 1 5 Other applicable documents Components of other manufacturers are integrated into the device For these purchased parts hazard assessments have been performed by the respective manufacturers The compliance of the design construction with the applicable European...

Page 10: ...es and conditions Anything else not presented here including the op eration of devices in mounted positions is not permitted and must be cleared with the plant on a case by case basis If the devices are operated in any other manner than as described within these instruction handbook then all guarantee and warranty rights are rendered null and void 1 9 Customer service Our customer service is avail...

Page 11: ...art No German Part No English Parameter manual b maXX 5000 5 09022 428331 431082 Parameter manual b maXX 5800 5 16029 470715 470716 Doc No Part No German Part No English Safety modules for b maXX 5000 BM5 O SAF 000 001 5 09013 428339 432449 Safety modules for b maXX 5000 BM5 O SAF 002 003 5 01046 354843 372666 Doc No Part No German Part No English Add on module IEE SIE 5 13030 448189 448190 Doc No...

Page 12: ...List of other applicable documents Instruction handbook b maXX 5800 Document No 5 16027 04 Baumüller Nürnberg GmbH 12 of 174 1 11 ...

Page 13: ... tasked with performing work on or with the device must have read and understood the instruction handbook before working with the device This also ap plies if the person involved with this kind of device or a similar one or has been trained by the manufacturer 2 2 Changes and modifications to the device In order to prevent hazards and to ensure optimum performance no changes additions or modificat...

Page 14: ...red as being used compliant with its intended purpose if all notes and information of these instruction handbook are adhered to WARNING Danger arising from usage for an unintended purpose Any usage that goes beyond the intended purpose and or any non compliant use of the device can lead to dangerous situations Therefore m Only use the device compliant with its intended purpose m Observe all specif...

Page 15: ...sufficient distance to the operating device Burn injuries Please note that the surface of the device can heat up considerably m Wear safety gloves Radiatedemission The high frequency electromagnetic fields within the operation environment must not ex ceed the field strength of the second environment according EN 61800 3 Internal or external ignition source Internal or external ignition sources are...

Page 16: ... To avoid additional damage in case of a short circuit in power cables n The connection between power supply and device or between device and motor must be laid without loop Device Motor cable or Device power connection Motor cable or power connection Figure 1 Wiring of the power cables Installation If a shielded cable is connected unshielded and this causes failure of the device danger to persons...

Page 17: ...ng conditions in the use area of the device These must then be implemented in the form of instruction handbook for operation of the device m These instruction handbook must be kept accessible to personnel working with the de vice at all times in the immediate vicinity of the device m The specifications of the instruction handbook must be adhered to completely and without exception m The device may...

Page 18: ...ed by qualified personnel m Qualified personnel n Electrical engineers authorized by Baumüller Nürnberg GmbH and qualified electri cians of the customer or a third party who have learned to install and maintain Baumüller drive systems and are authorized to ground and identify electrical power circuits and devices in accordance with the safety engineering standards of the com pany n Qualified perso...

Page 19: ...st be observed Wear for special work Protective work clothing should be snug fitting work clothes with low tearing resistance narrow sleeves and with no extending parts It serves to primarily protect against No rings or chains should be worn Hard hat to protect against falling down and flying around objects Safety shoes to protect against heavy objects falling down Protective gloves to protect han...

Page 20: ...w work on the electrical system to be performed by qualified personnel m Switch off the current when any kind of work is being performed on the electrical system and ensure safety before switching on again DANGER Risk of fatal injury from electrical current Stored electric charge Discharge time of the rack system discharge time of the device with the longest DC link discharge time in the rack syst...

Page 21: ...tion m Do not open any covering during operation m The amount of residual mechanical energy depends on the application Powered components still turn move for a certain length of time even after the power supply has been switched off Ensure that adequate safety measures are taken DANGER Risk of fatal injury from electrical current There is a risk of electric shock if an electrically conductive fire...

Page 22: ...device immediately with an EMERGENCY Stop m Initiate first aid measures m Evacuate persons from the danger zone m Notify the responsible persons at the scene of operations m Alarm medical personnel and or the fire department m Keep access routes clear for rescue vehicles WARNING Risk of fatal injury due to non functional safety equipment Safety equipment provides for the highest level of safety in...

Page 23: ... working materials marked correspondingly DANGER Risk of fatal injury from electrical current Stored electric charge Discharge time of the rack system discharge time of the device with the longest DC link discharge time in the rack system Refer to ZElectrical data from page 36 Therefore m Do not touch before taking into account the discharge time of the capacitors and electrically live parts m Hee...

Page 24: ...0 Document No 5 16027 04 Baumüller Nürnberg GmbH 24 of 174 2 13 Abbildung 2 Signs and labels BM58XX CAUTION Risk of injury due to hot surface When in operation the top of the device can heat up to temperatures 70 C Therefore m Wear protective gloves ...

Page 25: ...5 of 174 2 Signs and labels devices with safety level NOTE Only a device marked with the TÜV Rheinland certification label and the safety label fulfills a certified safety function within the meaning of PL classification according ISO 13849 or SIL according EN 61800 ...

Page 26: ...Signs and labels Instruction handbook b maXX 5800 Document No 5 16027 04 Baumüller Nürnberg GmbH 26 of 174 2 13 ...

Page 27: ... 1 Dimensions The following drawings show the main dimensions of the devices in millimeters mm The space requirements in the control cabinet are also determined based on these drawings To make the necessary drill holes cutout sections use the drawings inZDrilling pattern from page 65 ...

Page 28: ...nt No 5 16027 04 Baumüller Nürnberg GmbH 28 of 174 3 1 3 1 1 BM5807 S dimensions Figure 3 BM5807 S dimensions Observe minimum clearance Please follow the notes for mounting and ZCooling on page 35 Standard air cooling cooling within the control cabinet ...

Page 29: ...f 174 3 3 1 2 BM5807 A dimension Air cooling outside the control cabinet through hole air cooling 3 2 Weight Device Weight BM5807 S Max 12 kg BM5807 A Max 10 kg Figure 4 BM5807 A dimensions Observe minimum clearance Please follow the notes for mounting and ZCooling on page 35 ...

Page 30: ...dle these DC link volt ages If b maXX 5800 axis units are operated with a voltage controlled DC link e g BM51XX then the DC link voltage will be permanently not only in brake operation between 640 V and 760 V The connected motor must be designed to be operated at these voltages in continuous operation It is also possible to operate the devices at lower voltages e g 3 x 230 V A prerequisite however...

Page 31: ...range Vibration shock and continuous shock EN 61800 5 1 chapter 5 2 6 4 vibration test Max 0 5 g when operating Degree of contamination EN 61800 5 1 table 6 tab 2 2 1 If used in areas according to the category C2 of IEC 61800 3 2012 additional measures might be necessary In this case the plant manufacturer user has to provide evidence these additional measures take effect and the in IEC 61800 3 re...

Page 32: ... must be multi plied if the devices b maXX 5800 are used at operation conditions with different correc tion values The following correction values are to be considered if nothing other is specified at the Electrical data of the device 3 3 4 1 Correction values for the output current Operational temperature TU kT Correction value temperature Air cooled Water cooled Cold plate Figure 6 Correction va...

Page 33: ... output current Ipermitted adjusted output rated current is calculated accord ing following formula Irated Output rated current at 40 C and up to 1000 m refer to ZElectrical data from page 36 If kT kH 1 then Ipermitted Irated an output current higher than Irated is not possible NOTICE The following condition must always be met to prevent the device of overload If kT kH 1 the operation of the devic...

Page 34: ...79 Operation permitted Ipermitted Irated kT 40 C 1 kH 4000 m 0 7 kT 40 C kH 4000 m 0 7 0 79 Operation not permitted 3 3 4 2 Correction values DC link voltage BM58XX Output current DC link voltage V The device supplies the rated peak currents at rated DC link voltage The output currents must be reduced accordingly when operating with a DC link voltage is higher than 640 V and output power remains c...

Page 35: ... the entire intake area of the device 2 The cooling air requirement corresponds to at least that of a freely blowing device Freely blowing means that the air flow in and out are unobstructed Therefore when installing the device in a control cabinet it could be necessary to make use of additional fans in order that the necessary cooling air requirement is covered If the necessary cooling air requir...

Page 36: ...z 4 Output peak current IAC RMS 1 5 6 11 at 4 kHz 4 2 x 9 A 2 x 18 A Output peak current IAC RMS 1 5 6 11 at 8 kHz 4 2 x 6 3 A 2 x 12 6 A Output peak current IAC RMS 1 5 6 11 at 16 kHz 4 Short time operation KB 300 200 300 Max length of time peak current 6 Refer to ZLoad cycle according EN61800 6 from page 42 Power loss with regard to power supply Max 55 W Max 82 5 W Max 100 W Max 141 W Power loss...

Page 37: ...14 A 2 x 21 A Output rated current IAC RMS 1 2 5 11 at 16 kHz 4 2 x 4 8 A 2 x 8 A 2 x 12 A Output peak current IAC RMS 1 5 6 11 at 4 kHz 4 2 x 24 A 2 x 40 A 2 x 60 A Output peak current IAC RMS 1 5 6 11 at 8 kHz 4 2 x 16 8 A 2 x 28 A 2 x 42 A Output peak current IAC RMS 1 5 6 11 at 16 kHz 4 2 x 9 6 A 2 x 16 A 2 x 24 A Short time operation KB 200 Max length of time peak current 6 Refer to ZLoad cyc...

Page 38: ...t IAC RMS 1 2 5 11 at 8 kHz 4 2 1 A 3 15 A 4 2 A 5 9 A Output rated current IAC RMS 1 2 5 11 at 16 kHz 4 Output peak current IAC RMS 1 5 6 11 at 4 kHz 4 9 A 18 A Output peak current IAC RMS 1 5 6 11 at 8 kHz 4 6 3 A 12 6 A Output peak current IAC RMS 1 5 6 11 at 16 kHz 4 Short time operation KB 300 200 300 Max length of time peak current 6 Refer to ZLoad cycle according EN61800 6 from page 42 Powe...

Page 39: ...8 kHz 4 8 4 A 14 A 21 A Output rated current IAC RMS 1 2 5 11 at 16 kHz 4 4 8 A 8 A 12 A Output peak current IAC RMS 1 5 6 11 at 4 kHz 4 24 A 40 A 60 A Output peak current IAC RMS 1 5 6 11 at 8 kHz 4 16 8 A 28 A 42 A Output peak current IAC RMS 1 5 6 11 at 16 kHz 4 9 6 A 16 A 24 A Short time operation KB 200 Max length of time peak current 6 Refer to ZLoad cycle according EN61800 6 from page 42 Po...

Page 40: ... voltages with frequencies between fmax and 599 Hz and the controller allows that however the quality of this voltages cannot be guaranteed Typical the devices are marked with the max output frequency at 4 kHz switching frequency 0 450 kHz 5 The device supplies the rated peak currents at rated DC link voltage The output currents must be reduced accordingly when operating with a DC link voltage is ...

Page 41: ...rrent is required to assure a torque a force at standstill or n Applications in which blockage of the mechanical parts can occur e g when starting up cold extruders Thus typically the following applications are not affected n Generally typical positioning applications n Applications with motors that use a service brake when at standstill n Applications in which the higher level control unit has st...

Page 42: ...Hz Ib at 16 kHz SG 23XXXX 2 x 3 A 100 IN 2 x 2 1 A 70 IN SG 24XXXX 2 x 6 A 100 IN 2 x 4 2 A 70 IN XG 26XXXX 12 A 100 IN 8 4 A 70 IN 4 8 A 40 IN XG 27XXXX 20 A 100 IN 14A 70 IN 8 A 40 IN XG 28XXXX 30 A 100 IN 21A 70 IN 12 A 40 IN XG 31XXXX 2 x 12 A 100 IN 2 x 8 4 A 70 IN 2 x 4 8 A A 40 IN XG 32XXXX 2 x 20 A 100 IN 2 x 14 A 70 IN 2 x 8 A 40 IN XG 33XXXX 2 x 30 A 100 IN 2 x 21 A 70 IN 2 x 12 A 40 IN ...

Page 43: ...P 166 IN tp with IP 200 IN tp with IP 300 IN SG 23XXXX 10 s 3 3 s IP 6 A 1 1 s IP 9 A SG 24XXXX 10 s 3 3 s IP 12 A 1 1 s IP 18 A XG 26XXXX 18 s 6 s IP 24 A Not allowed XG 27XXXX 18 s 6 s IP 24 A Not allowed XG 28XXXX 18 s 6 s IP 24 A Not allowed XG 31XXXX 18 s 6 s IP 24 A Not allowed XG 32XXXX 18 s 6 s IP 24 A Not allowed XG 33XXXX 18 s 6 s IP 24 A Not allowed XG 34XXXX 16 s 7 s Not allowed Not al...

Page 44: ...Ib 3 6 A 4 8 s IP 18 A 12 8 s IP 12 A 600 s Ib 3 6 A 240 s IP 9 A XG 26XXXX 60 s Ib 7 2 A Not allowed 10 s IP 24 A 600s Ib 7 2 A 150 s IP 18 A XG 27XXXX 60 s Ib 12 A Not allowed 10 s IP 40 A 600s Ib 12 A 150 s IP 30 A XG 28XXXX 60 s Ib 18 A Not allowed 10 s IP 60 A 600s Ib 18 A 150 s IP 45 A XG 31XXXX 60 s Ib 7 2 A Not allowed 10 s IP 24 A 600s Ib 7 2 A 150 s IP 18 A XG 32XXXX 60 s Ib 12 A Not all...

Page 45: ...is is an active mains rectifier unit for supplying multi axis controllers BM5800 and other axis units via the DC link The applied AC voltage at the three phase power system is transformed by a rectifier on the input side into DC voltage The DC link capacitors smooth this DC voltage The active mains rectifier unit can feed back excess braking energy into the mains as sinusoidal electrical current b...

Page 46: ...0 rotated and standard air through hole A Depending on the required integrated axis modules 2 or 3 power types can be selected m 3 x 50 mm m 2 x 50 mm 1 x 75 mm m 1 x 50 mm 1 x 75 mm m 2 x 75 mm For example following combinations can be realized and so on Controller The controller unit controls the inverter of the power unit The controller is operated either by means of operating software or by me...

Page 47: ...Design and Operation Instruction handbook b maXX 5800 Document No 5 16027 04 47 of 174 4 4 2 Identification of the device 4 2 1 Part number Figure 14 Part number front ...

Page 48: ...ument No 5 16027 04 Baumüller Nürnberg GmbH 48 of 174 4 2 4 2 2 Type plate Examples of the locations where the type plate is affixed are shown in the figure Among other things the type plate also shows the type code of the device Figure 15 Affixing of the type plate ...

Page 49: ...dule safety optimized for peak current 7 Basic unit power module safety optimized for rated current water cooled 8 Multi axis controller safety BM58XX XX XXXXXX XXXXXX XXXXXX XXX XXXX XXXX EXX Housing size 07 175 mm width refer to ZDimensions from page 27 BM58XX XX XXXXXX XXXXXX XXXXXX XXX XXXX XXXX EXX Type of cooling S Air cooled with air supply and with air outlet in the control cabinet A Air c...

Page 50: ...XXXXXX XXXXXX XXX XXXX XXXX EXX Motor brake power unit 1 2 3 0 No axis module 2 With motor brake 3 Without motor brake BM58XX XX XXXXXX XXXXXX XXXXXX XXX XXXX XXXX EXX Encoder evaluation 0 No encoder or no axis module 1 HIPERFACE EnDat 2 1 SSI square wave and sine incremental encoder resolver 2 EnDat 2 2 3 HIPERFACE DSL BM58XX XX XXXXXX XXXXXX XXXXXX XXX XXXX XXXX EXX Safety function 0 No safety f...

Page 51: ... Varnished PCB 02 180 rotated BM58XX XX XXXXXX XXXXXX XXXXXX XXX XXXX XXXX EXX Firmware XXXX Incompatible firmware release XXXX Firmware release version BM58XX XX XXXXXX XXXXXX XXXXXX XXX XXXX XXXX EXX Software functionality 00 Standard device 01 SoftDrivePLC 02 Servo pump functionality V1 including SoftDrivePLC project 03 Servo pump functionality V2 including SoftDrivePLC project 04 CLDP function...

Page 52: ...ates after exceeding 200 of the motor full load ZConnections BM5800 from page 89 n Position of wiring terminals to indicate the proper connections for the power supply load control circuit and similar devices refer to ZPage 89 Connections ZPage 91 and ZPage 92 n Note tightening torque values marked for field terminals ZRequirements for the connection cables on page 75 n Use 60 75 copper wires only...

Page 53: ... the type refer to ZType code from page 49 Meaning BM58XX XX XXXXXX XXXXXX XXXXXX XX1 BM58XX XX XXXXXX XXXXXX XXXXXX XX7 ZLED EtherCAT on page 57 BM58XX XX XXXXXX XXXXXX XXXXXX XX2 ZLED VARAN on page 57 BM58XX XX XXXXXX XXXXXX XXXXXX XX4 ZLED POWERLINK on page 58 Figure 16 Display elements minimum configuration BM58XX NOTE Depending on the configuration not all display and operating elements are a...

Page 54: ...splay on page 55 LED H31 H32 H41 H42 Fieldbus depending on the type refer to ZType code from page 49 Meaning BM58XX XX XXXXXX XXXXXX XXXXXX XX1 BM58XX XX XXXXXX XXXXXX XXXXXX XX7 ZLED EtherCAT on page 57 BM58XX XX XXXXXX XXXXXX XXXXXX XX2 ZLED VARAN on page 57 BM58XX XX XXXXXX XXXXXX XXXXXX XX4 ZLED POWERLINK on page 58 Maximum configuration BM58XX Figure 17 Display elements maximum configuration ...

Page 55: ...torque direction H11 red Negative torque direction H12 1 2 green 1 2 red Axis Power on pulse enable 24 V available H12 green Power ON H12 red H13 1 3 Axis Current limit H13 red Device operates on current limit H14 1 4 Axis Error display H14 red Device error message H21 2 1 green 2 1 red Axis Torque direction H21 green Positive torque direction H21 red Negative torque direction H22 2 2 green 2 2 re...

Page 56: ...n 1 SWITCH ON INHIBIT Inhibit voltage e g quick stop active 2 READY TO SWITCH ON Drive shutdown Control word xxxx x110 Pulse enable 0 Quick stop 1 low active 3 SWITCHED ON Control word xxxx x111 Pulse enable 1 Quick stop 1 4 OPERATION ENABLED Control word xxxx 1111 Pulse enable 1 Quick stop 1 5 BETRIEB SPERREN AKTIV 6 OPERATION INHIBIT ACTIVE Pulse enable 0 7 QUICK STOP ACTIVE Quick stop 0 low act...

Page 57: ...Phy1 Phy2 H41 green X4 Link Act Off No connection On Connection Blinking Data transfer H42 yellow RUN Off ERROR INIT 500 ms on 500 ms off PREOPERATIONAL 200 ms on 1 s off SAFEOPERATIONAL On OPERATIONAL LED VARAN Naming on the front plate H31 green H41 green LINK On Connection between 2 PHYs physical interfaces is established H32 yellow H42 yellow ACTIVE On Data is received or transmitted Type code...

Page 58: ...transfer H32 yellow ERROR Off NMT_CT3 NMT_CT7 NMT_GT2 On NMT_CT11 NMT_GT6 Blinking Configuration error e g address seting H41 green X4 Link Act Off No connection On Connection Blinking Data transfer H42 green STATUS Off NMT_GS_OFF NMT_GS_INITIALISATION NMT_CS_NOT_ACTIVE 50 ms off 50 ms on NMT_CS_BASIC_ETHERNET 200 ms on 1 s off NMT_CS_PRE_OPERATIONAL_1 2 x 200 ms on 1 s off NMT_CS_PRE_OPERATIONAL_...

Page 59: ...C up to 70 C m Vibration shock continuous shock class 2 M 1 as per EN 60721 3 2 NOTICE Damage due to unauthorized transport Transport handled by untrained personnel can lead to a substantial amount of mate rial damage Therefore m The unloading of the packages upon delivery as well as the in house transport should only be done by trained personnel m Contact Baumüller Nürnberg GmbH sales office if n...

Page 60: ...onsible representative of Baumüller Nürnberg GmbH 5 4 Unpacking After having received the still packaged device h Avoid transport shocks and hard jolts e g when putting an item down If no transport damage is visible h Open the packaging of the device h Verify the delivery scope based on the delivery note File a claim with the responsible Baumüller representative if the delivery is incomplete 5 5 D...

Page 61: ...ual ified personnel Qualified personnel are persons who on account of their occupational training ex perience instruction and knowledge of relevant standards and stipulations accident prevention regulations and operating conditions are authorized by the persons re sponsible for the safety of the facilities to perform the respective activities that are necessary while at the same time recognizing a...

Page 62: ... Therefore m Only allow mounting to be performed by employees of the manufacturer or by oth er qualified personnel WARNING Danger of mechanical impact Secure devices against falling down Therefore m Take suitable measures such as supports hoists and assisting personnel to en sure that device cannot fall down m Use appropriate means of transport NOTICE Danger due to electrostatic discharge The conn...

Page 63: ...ted with unprotected hands during mounting palms or fingers can be cut If the device falls feet could be injured Figure 18 Danger area near the mechanical mounting Therefore m Ensure that only qualified personnel who are familiar with the safety notes and as sembly instructions mount this device Wear safety gloves Wear safety shoes ...

Page 64: ... contamination Therefore m When performing installation work of any kind it must be ensured that no foreign material e g drill shavings copper strands etc gets into the device as a result m If possible the drilling of the holes should be done before mounting the device and the configuring of the cables should take place outside of the control cabinet If this is not possible the device must be appr...

Page 65: ...ance specifications Drill hole dimensioning 0 2 mm Dimensioning openings 1 0 mm Relative tolerance of discretionary divisions 0 1 mm For air cooled versions BM5807 BM517X BM5807 S Relative tolerance of discretionary divisions 0 1 mm Figure 19 Drilling pattern with mounting rail for BM58XX S NOTE Consider the minimum clearances for cooling when making the drill holes All dimensions in millimeters m...

Page 66: ...thout mounting rail for all versions 6 3 Mounting instructions There are different mounting procedure Each mounting procedure is described in a drawing refer to ZFigure 21 on page 67 and ZFigure 22 on page 68 The screws and washers required for mounting are listed beneath the respective drawing Carry out mounting as follows 1 Provide suitable transport lifting equipment as needed 2 Keep suitable f...

Page 67: ...en tilt the device on the mounting plate 2 and slide onto the mounting rail 3 Finally tighten the upper fastening and grounding bolts 4 Figure 21 Mounting instructions BM58XX S with mounting rail Device BM5807 S A Screws 3 x M5 B Washers 3 x 5 3 x 10 C Screws n x M5 1 D Mounting rail 1000 mm Refer to Accessories and Spare Parts ZMounting rail from page 154 1 Number n depends on the length of the m...

Page 68: ...ithout mounting rail Push the device from below beneath the upper fastening bolts 1 Then tilt the device on the mounting plate 2 and slide into the fastening bolts 3 Finally tighten all fastening and grounding bolts 4 Abbildung 22 Mounting instructions BM580XX without mounting rail Device BM5807 A Screw 6 x M5 B Washers 6 x 5 3 x 10 ...

Page 69: ...ervice and ensures the captivity of the distance bushings Neck collar screw 1 DC link bar 2 Distance bushing 3 b maXX 5XXX DC link terminal 4 Figure 23 Correctly mounted DC link bar m Distance bushing and neck collar screw It is recommended to assemble the neck collar screw and the distance bushing to the DC link bar before mounting the DC link bar The correctly mounting of the distance bushings m...

Page 70: ...echanical stress affect to the drill hole WRONG CORRECT Figure 25 Mounting of the DC link bar 6 3 4 Demounting NOTE The DC link bar must not overlap the first or last fixing bolt of the rack system Cut the DC link bar therefore NOTE The yellow cover plate can be removed when mounting demounting air cooled devic es and there is not enough space above the device min 15 cm for lifting up the cover ...

Page 71: ... employees of the manufacturer or by other qualified personnel Qualified personnel are persons who on account of their occupational training ex perience instruction and knowledge of relevant standards and stipulations accident prevention regulations and operating conditions are authorized by the persons re sponsible for the safety of the facilities to perform the respective activities that are nec...

Page 72: ...age Therefore m Only allow installation and initial commissioning to be performed by employees of the manufacturer or by other qualified personnel DANGER Risk of fatal injury from electrical current Inevitably when operating this electrical device certain parts of it are energized with hazardous voltage Therefore m Pay heed to areas on the device that could be dangerous during the electrical in st...

Page 73: ...to the DC link the DC link discharge can take a much longer time In this case the necessary waiting period must itself be determined or a measurement made as to whether the equipment is de energized This discharge time must be posted together with an IEC 60417 5036 2002 10 warning symbol on a clearly visible location of the control cabinet DANGER Risk of fatal injury from electrical current During...

Page 74: ...e electrical mains can lead to malfunctioning of the device If the mains supply deviates too much from the requirements the device can be destroyed The destruction of the device can cause personal injury DANGER Risk of fatal injury from electrical current If the requirements for the electrical mains are not complied the device can be dam aged or destroyed thereby greatly endangering individuals Th...

Page 75: ...AAC or 10 mADC can flow through the protective ground conductor Consequently a stationary ground conductor connection in accordance with EN 61800 5 1 is required DANGER Risk of fatal injury from electrical current This product can cause direct and or alternating current in the protective ground con ductor The leakage current due to the functional principle of the device can lead to prema ture trig...

Page 76: ...MAR each device is connected with PE on its own Power supply PE rail Figure 27 Grounding concept MAR each device is connected with PE on its own 1 Active mains rectifier unit screw terminals for power supply connection and PE 2 Multi axis controller 175 mm screw terminals PE and motor connector 3 x 2 x 3 pin 3 Multi axis controller 175 mm screw terminals PE and motor connector 3 x 2 x 3 pin 4 Moun...

Page 77: ...evice to device 1 Active mains rectifier unit 2 Multi axis controller 175 mm 3 Multi axis controller 175 mm 4 Mounting plate thickness at least 3 mm NOTE The first and last device must be connected directly with PE if the PE connection is realized from device to device An accessories kit is available for the connection from device to device refer to ZAccessories kit PE connection from device to de...

Page 78: ...n the surface of the grounded mounting plate i e the least effective antenna height m When routing in parallel minimum clearance of 20 cm should be observed between signal and control cables vis à vis the power cables m Cables of different EMC categories e g signal cables mains cables and or motor ca bles should be crossed at a 90 angle m Contact the major cable shield when laying cables through w...

Page 79: ...mounting plate or with shield sheet refer to ZShielding con nection with shield sheet on page 80 7 8 1 Shielding connection mounting plate Establish a large area contact between the shield and the conductive and grounded mounting plate by means of a conductive clamp Refer to ZConnecting the shield from page 81 NOTE Baumüller Nürnberg GmbH recommends the shielding connection with shield sheet NOTE ...

Page 80: ...b maXX 5800 Document No 5 16027 04 Baumüller Nürnberg GmbH 80 of 174 7 8 7 8 2 Shielding connection with shield sheet 7 8 2 1 Mounting shield sheet Refer to ZAccessories kit shielding on page 153 Air cooled devices Figure 29 Mounting shield sheet air cooled devices ...

Page 81: ...to also ZAccessories kit shielding on page 153 1 Prepare motor cable according figure 2 Remove the motor temperature cable s shield from the cable 3 Wrap motor temperature cable around motor cable at least 1 turn form no loop RIGHT WRONG Shield motor cable Motor cable Motor temperature cable Shield motor temperature cable Figure 30 Wrap shield motor temperature cable around motor cable ...

Page 82: ... 7 8 4 from below wrap conductive metallic adhesive tape around Motor cable Motor temperature cable conductive metallic adhesive tape Figure 31 Tape shield motor temperature cable around NOTE The shielding of the motor temperature cable and the shielding of the motor cable is wrapped together with a conductive metallic adhesive tape ...

Page 83: ...e shield sheet note locking torque of the fixing screw Shield sheet Fixing screw Shielding clamp Motor cable Figure 32 Shield connection motor cable Motor tempera ture cable Wrapping with metallic adhe sive tape NOTE The shield must be connected to the mounting plate with a metallic clamp if the op tional shield sheet is not used ...

Page 84: ...emperature has been exceeded 1 Motor protection thermistor PTC as per DIN 44080 082 Axis module 1 2 3 BM5807 SG Locking torque 22XXXX 23XXXX 24XXXX 25XXXX 26XXXX 27XXXX 28XXXX 0 8 Nm cable diameter 5 20 mm shielding clamp width 24 mm 31XXXX 32XXXX 33XXXX 1 Nm cable diameter 5 28 mm shielding clamp width 31 mm NOTE The motor temperature sensor should be installed in such a manner that electrically ...

Page 85: ... conductor connection is absolutely mandatory 4 Connect 24 V power supply BM58XX via terminals X200 1 X200 2 5 Connect encoders refer to ZEncoder evaluation from page 96 6 Connect the temperature sensor of the motor Observe the proper polarity 7 Connect the motor brake option DANGER Risk of fatal injury from electrical current Electrically live parts are life threatening Therefore m Make certain t...

Page 86: ...l analog outputs X200 Connections for 24 V voltage supply refer to ZX200 SELV PELV on page 92 NOTE The identifiers 1C1 and 1D1 were taken over from DIN EN 60445 1C1 is the connec tion to the positive DC link cable bar and in the past was identified by Baumüller in some devices as ZK 1D1 is the connection to the negative DC link cable bar and in the past was identified by Baumüller in some devices ...

Page 87: ...re not assigned Encoder Figure 34 Connection diagram axis module 1 2 3 single axis module X1 1 X1 2 X1 3 Connection STO function refer to ZOption STO function on page 94 X2 1 X2 2 X2 3 Connections for digital inputs refer to ZFast digital inputs on page 95 X7 1 X7 2 X7 3 Encoder evaluation X107 1 X107 2 X107 3 Motor connection X207 1 X207 2 X207 3 Connection for motor temperature and motor brake r...

Page 88: ...2 3 double axis module X1 1 X1 2 X1 3 Connections STO function refer to ZOption STO function on page 94 X2 1 X2 2 X2 3 Connections for digital inputs refer to ZFast digital inputs on page 95 X7 1 X7 2 X7 3 Encoder evaluation 1 X8 1 X8 2 X8 3 Encoder evaluation 2 X107 1 X107 2 X107 3 Motor connection 1 X108 1 X108 2 X108 3 Motor connection 2 X207 1 X207 2 X207 3 Connections for motor temperature an...

Page 89: ...stallation Instruction handbook b maXX 5800 Document No 5 16027 04 89 of 174 7 7 11 4 Connections BM5800 DC link Back side X107 1 X108 1 X107 2 X108 2 X108 3 X107 3 Figure 36 Connections BM5800 top bottom ...

Page 90: ...ction X2 1 X2 2 X2 3 Digital inputs X7 1 X7 2 X7 3 Encoder 1 X8 1 X8 2 X8 3 Option encoder 2 X207 1 X207 2 X207 3 Motor 1 Brake and temperature X208 1 X208 2 X208 3 Motor 2 Connection diagrams Instruction handbook b maXX 5800 Document No 5 16027 04 Baumüller Nürnberg GmbH 90 of 174 7 11 Figure 37 Connections BM5800 front ...

Page 91: ...orque Max load capacity of the bar DC link 1C1 and 1D1 DC link bar Min 2 2 Nm Max 3 0 Nm 130 A Connection cross section at rated power connection Connection cross section terminal Connec tion method Torque Load capacity Motor X107 1 2 3 Motor 1 X108 1 2 3 Motor 2 1U2 1V2 1W2 22XXXX 23XXXX 24XXXX 25XXXX Min 0 75 mm a Max 2 5 mm a Plug connector threaded connector Min 0 4 Nm Max 0 5 Nm Limited by th...

Page 92: ...berg GmbH 92 of 174 7 11 Refer to ZRequirements for control voltage 24 V power supply on page 30 Connections on the front side X1 1 2 3 SELV PELV STO function refer to ZOption STO function from page 94 Max 1 5 mm Plug connector spring clamp con nection Max 8 0 A X2 1 2 3 SELV PELV Fast digital inputs refer to ZFast digital inputs from page 95 Max 1 0 mm Plug connector spring clamp con nection Max ...

Page 93: ...ut puts on page 108 D sub 9 pin Installation Instruction handbook b maXX 5800 Document No 5 16027 04 93 of 174 7 Connection cross section Connection method Load capacity X207 1 2 3 Motor temperature and motor brake motor 1 refer to ZMotor temperature and motor brake on page 102 Max 1 5 mm Plug connector spring clamp connection Max 2 A NOTE The input current of the 24 V power supply is limited to 1...

Page 94: ...axis module 1 2 3 double axis modules only 6 Not assigned 7 STO1 24V axis 2 of axis module 1 2 3 double axis modules only 8 STO1 24V axis 1 of axis module 1 2 3 9 STO2 24V axis 1 of axis module 1 2 3 10 Not assigned 11 Reserved internal connected with pin 7 STO1 24V axis 2 of axis module 1 2 3 double axis modules only 12 STO2 24V axis 2 of axis module 1 2 3 double axis modules only 13 Not assigned...

Page 95: ...ocoupler Short circuit resistant Current limited Pin assignment X2 1 X2 2 X2 3 1 4 Pin No Assignment 1 GND 24 V internal 2 GND digital inputs 3 Fast digital input 1 touch probe 1 4 Fast digital input 2 touch probe 2 NOTE Pin 1 and pin 2 can be connected if the device and the digital inputs are supplied by the same or different power supplies with identical ground Pin 2 must be connected with the g...

Page 96: ...may also be used Pole pair number The ratio between the pole pair number of the motor and the pole pair number of the encoder must be an integer Current input Max 160 mA Excitation frequency Approx 8 kHz Excitation current 160 mA Ratio 0 5 D sub connector 26 pin 1 GND encoder supply Ref 2 Reserved 3 Reserved 4 Reserved 5 Reserved 6 Reserved 7 Reserved 8 Reserved 9 Reserved 10 Resolver Ref 11 Reser...

Page 97: ...DC Signal level HIPERFACE specification of the process data channel 1 VSS REFSIN REFCOS 2 5V Current input Max 250 mA D sub connector 26 pin 1 GND encoder supply 2 10 V encoder supply 3 Reserved 4 COS 5 COS 6 SIN 7 SIN 8 Reserved 9 Reserved 10 Reserved 11 Reserved 12 Reserved 13 Reserved 14 Reserved 15 Reserved 16 Reserved 17 Temperature 18 Temperature 19 RS485 Data 20 RS485 Data 21 Reserved 22 Re...

Page 98: ...be used Voltage supply 5 VDC controlled Signal level 1 VSS Current input Max 250 mA D sub connector 26 pin 1 GND encoder supply 2 5 V encoder supply 3 Clock 4 A COS 5 A COS 6 B SIN 7 B SIN 8 Reserved 9 Reserved 10 Reserved 11 Sense GND 12 Sense Vcc 13 Clock 14 Reserved 15 Reserved 16 Reserved 17 Temperature 18 Temperature 19 Data 20 Data 21 Reserved 22 Reserved 23 Reserved 24 Reserved 25 Reserved ...

Page 99: ... VDC controlled Signal level 1 VSS Current input Max 250 mA D sub connector 26 pin 1 GND encoder supply 2 5 V encoder supply 3 Clock 4 Reserved 5 Reserved 6 Reserved 7 Reserved 8 Reserved 9 Reserved 10 Reserved 11 Sense GND 12 Sense Vcc 13 Clock 14 Reserved 15 Reserved 16 Reserved 17 Reserved 18 Reserved 19 Data 20 Data 21 Reserved 22 Reserved 23 Reserved 24 Reserved 25 Reserved 26 Reserved Do not...

Page 100: ...L for square wave incremental encoders 1 Vss for sine incremental encoders Current input Max 250 mA D sub connector 26 pin 1 GND encoder supply 2 5 V encoder supply 3 Reserved 4 RS422 A 5 RS422 A 6 RS422 B 7 RS422 B 8 RS422 0 9 RS422 0 10 Reserved 11 Sense GND 12 Sense VCC 13 Reserved 14 Reserved 15 Reserved 16 Reserved 17 Temperature 18 Temperature 19 Reserved 20 Reserved 21 Reserved 22 Reserved ...

Page 101: ... 1 GND encoder supply 2 10 V encoder supply 3 Reserved 4 Reserved 5 Reserved 6 Reserved 7 Reserved 8 Reserved 9 Reserved 10 Reserved 11 Reserved 12 Reserved 13 Reserved 14 Reserved 15 Reserved 16 Reserved 17 Reserved 18 Reserved 19 DSL 20 DSL 21 Reserved 22 Reserved 21 Reserved 22 Reserved 23 Reserved 24 Reserved 25 Reserved 26 Reserved Do not occupy NOTE The use of the standard accessory connecto...

Page 102: ...motor brake 2 Feedback signal motor brake 1 3 Motor temperature 1 4 Motor brake 1 5 Feedback signal motor brake 1 6 Motor temperature 1 X208 1 2 3 Not assigned if axis module 1 2 3 is a single axis module X208 1 2 3 Pin No Assignment 1 Motor brake 2 Motor 2 motor temperature and motor brake 2 Feedback signal motor brake 2 3 Motor temperature 2 4 Motor brake 2 5 Feedback signal motor brake 2 6 Moto...

Page 103: ... Pin assignment X2 1 10 Pin No Assignment 1 GND 24 V internal 2 GND digital inputs 3 Digital input 1 4 Digital input 2 5 Digital input 3 6 Digital input 4 7 Digital input 5 8 Digital input 6 9 Digital input 7 10 Digital input 8 NOTE Pin 1 and pin 2 can be connected if the device and the digital inputs are supplied by the same or different power supplies with identical ground Pin 2 must be connecte...

Page 104: ...M58XX XX XXXXXX XXXXXX XXXXXX XX1 Type code b maXX 5800 with EtherCAT SoE profile BM58XX XX XXXXXX XXXXXX XXXXXX XX7 X3 X4 EtherCAT IN EtherCAT OUT No of bus connections 1 IN 1 OUT Bus connection 2 x RJ 45 No of parameters Refer to parameter handbook b maXX 5800 Data width of parameters 16 32 Bit Baud rates 10 100 Mbit s 1 TX 2 TX 3 RX 4 Reserved 5 Reserved 6 RX 7 Reserved 8 Reserved X3 X4 ...

Page 105: ...ARAN profile BM58XX XX XXXXXX XXXXXX XXXXXX XX2 X3 X4 VARAN IN VARAN OUT No of bus connections 1 IN 1 OUT Bus connection 2 x RJ 45 No of parameters Refer to parameter handbook b maXX 5800 Data width of parameters 16 32 Bit Baud rates 10 100 Mbit s 1 TX 2 TX 3 RX 4 Reserved 5 Reserved 6 RX 7 Reserved 8 Reserved X3 X4 ...

Page 106: ...XX3 X3 X4 CANopen IN CANopen OUT Memory 4 kByte DP RAM 256 kByte RAM 1 MByte flash EPROM No of bus connections 2 there are no rules for slot assignment Bus connection 2 x RJ45 8 pin Baud rates 20 125 250 500 1000 kBit s Short circuit proof RJ45 connection Yes Potential separation Optocoupler DC DC converter 1 CAN High 2 CAN Low 3 GND 4 Reserved 5 Reserved 6 Reserved 7 GND 8 Reserved X3 X4 ...

Page 107: ...OWERLINK BM58XX XX XXXXXX XXXXXX XXXXXX XX4 X3 X4 POWERLINK IN POWERLINK OUT No of bus connections 1 IN 1 OUT Bus connection 2 x RJ 45 No of parameters Refer to parameter handbook b maXX 5800 Data width of parameters 16 32 Bit Baud rates 10 100 Mbit s 1 TX 2 TX 3 RX 4 Reserved 5 Reserved 6 RX 7 Reserved 8 Reserved X3 X4 ...

Page 108: ...uts Resolution 12 Bit Output voltage 10 V to 10 V Output current max 1 mA Refreshing rate 62 5 µs Short circuit proof Limited max 10 s Outputs 4 analog outputs are provided Pin No Assignment 1 Analog output 3 2 Analog output 4 3 Ground 4 Analog output 1 5 Analog output 2 6 Analog output 3 7 Analog output 4 8 Analog output 1 9 Analog output 2 Pin assignment X6 ...

Page 109: ...ronmental conditions are kept compliant during operation re fer to ZRequired environmental conditions on page 31 m Only qualified personnel may work on this device WARNING Risk of injury due to improper operation Improper operation can lead to severe personal injury or material damage Therefore NOTICE Environmental conditions that do not meet the requirements Environmental conditions that are non ...

Page 110: ...rding to EN 61496 WARNING In the unlikely event of a total failure of an internal driver IGBT or a control element a temporary excitation of the drive can occur also if STO is active The angular movement covered depends on the rotor position and the number of pole pairs of the motor The maximum is 180 number of pole pairs DANGER Danger due to moving engine parts The supply of the inputs by a conne...

Page 111: ...function STO Safe Torque Off m The drive is without torque in STO function m The activation of the power amplifier is reliable disabled m The STO function fulfills the stop category 0 according EN 60204 1 If no load is active on the motor shaft the drive will coast to a standstill For this reason no active danger is caused by the drive in case of an enabled STO function A restart of the drive is n...

Page 112: ...bitor is activated Thus the motor can no longer generate a rotating field The power supply is not disconnected from the motor when the shut down function is activated The safety relay function is based on the fail safe principle The safety function STO safe torque off is active as long as there is no voltage at the input terminals X1 1 X1 2 X1 3 Therefore the functioning of the safety function is ...

Page 113: ...ent No 5 16027 04 113 of 174 8 8 1 4 Timing Figure 38 Timing STO function Td 40 ms Td2 max 30 ms n The controller is enabled after max 40 ms when both voltages are activated n The controller is disabled after max 30 ms when one voltage is deactivated ...

Page 114: ... ensures that short circuits on the input side are detected In case of a short circuit on the input side the converter always switches to the STO Safe Torque Off status Figure 39 STO function Operation with emergency stop device WARNING The power supply unit for generating the 24 Volt electrical supply must meet the requirements for PELV according to EN 60204 1 STO_1A_24V X1 14 STO_2A_24V X1 11 ST...

Page 115: ...de The two channel shut down is then per formed by two safety outputs monitored by the safety sensor which provide the two channel supply for the STO function Figure 40 STO function Operation with safety light grid e g axis module 2 X1 2 STO1 GND axis 1 X1 2 1 STO2 GND axis 1 X1 2 2 STO1 24 V axis 1 X1 2 8 STO2 24 V axis 1 X1 2 9 STO1 24 V axis 1 X1 2 14 interne Verbindung Safety light grid Switch...

Page 116: ...T Type code b maXX 5800 with EtherCAT BM58XX XX XXXXXX XXXXXX XXXXXX XX1 CoE profile CANopen over EtherCAT BM58XX XX XXXXXX XXXXXX XXXXXX XX7 SoE profile Servodrive profile over EtherCAT Data can be transmitted to and from other nodes e g from the EtherCAT master via the b maXX 5800 with EtherCAT slave X3 and X4 on the front side of the device are the RJ45 connections for the EtherCAT fieldbus ref...

Page 117: ...y if using the CoE profile CoE CANopen over EtherCAT and the EtherCAT master has set the parameter 1C32 02 Cycle Time to a valid value or Distributed Clock is set to Sync0 When using the SoE profile Servodrive profile over EtherCAT the fieldbus cy cle time can be set via S parameter S 0 0002 or directly via controller parameter fieldbus cycle time In case Distributed Clock is activated the set fie...

Page 118: ...AN Out On the first b maXX 5800 node of a VARAN line X3 is connected with the VARAN master X4 is connected with X3 of the next b maXX 5800 slave in the line and so on The last node of a VARAN line has no connection of X4 or is connected with a PC tunneling of Ethernet frames via VARAN to the controller e g to communicate with ProDrive Each slave within the VARAN line can be addressed and parametri...

Page 119: ...te a Lasal Class2 project using the driver classes for b maXX 5800 drives for cy clic and service data communication 5 Start the VARAN control Parameters The parameter settings determine the behavior of the VARAN slave in operation Param eters are set with the software ProDrive 1 Start ProDrive 2 Click on Project Tree 3 Communication settings with ProDrive n Project Tree Configuration Fieldbus sla...

Page 120: ...b maXX 5800 with CANopen is correctly installed n CANopen connection cables are correctly wired 2 The control cabinet has been locked correctly and the safety devices have been put into operation 3 The b maXX 5800 device is ready to use Process of commissioning The test commissioning is divided into the following sections 1 Configuration of the CANopen slave 2 Testing of the CANopen slave Configur...

Page 121: ... m Ensure that the CANopen communication source only is able to communicate with the b maXX 5800 device Avoid a reset of the b maXX 5800 in the cyclical operation of the CANopen slave WARNING Risk of injury due to moving parts Rotating and or linearly moving parts can cause severe injuries If a reset of the b maXX 5800 device is released in the running cyclical operation or if the communication so...

Page 122: ...er information refer to ZEtherCAT VARAN POWERLINK cable on page 142 Commissioning The following preconditions must be fulfilled before commissioning 1 b maXX 5800 with POWERLINK is installed correctly n Ethernet connection cables are wired correctly 2 The control cabinet is properly locked and all safety devices are operating 3 The b maXX 5800 device is ready to use Parameters The parameter settin...

Page 123: ...e Pay heed to areas on the device that could be dangerous during the maintenance Pay heed to areas that could still be electrically energized after operation Figure 42 Danger areas during maintenance WARNING Risk of injury due to improperly performed maintenance work Improper maintenance can lead to severe personal injury and material damage Therefore DANGER Risk of fatal injury from electrical cu...

Page 124: ... tion and ensure a long service life It is recommended to have inspections performed reg ularly by qualified personnel Daily inspection Basic check points as to whether discrepancies have occurred during operation m Does the motor work as desired m Is the operating environment normal m Is the cooling system working normally m If an unusual vibration or noise is noticed during operation m Does the ...

Page 125: ...bjects in the vicinity Visual inspection O m Voltage Check points Methods and criteria Inspection intervals Daily Semi annu ally Annu ally Check the voltage of the power supply system and the control circuits Measurement and comparison with standard values O DANGER Risk of fatal injury from electrical current Stored electric charge Discharge time of the rack system discharge time of the device wit...

Page 126: ...e there any missing or loose screws Replace the screws or respectively tighten them O Is there any deformation cracking damage or color change on the device as a result of overheat ing or aging Visual inspection O Are there any dust or dirt deposits Visual inspection O m Connections and circuitry of the mains power supply Check points Methods and criteria Inspection intervals Daily Semi annu ally ...

Page 127: ...tors Tighten screws and firmly stick in plug connector O Are there any noticeable odors or color changes Visual inspection and odor check O Is there any cracking damage deformation or corrosion Visual inspection O Is there any leaking fluid or deformation of the capacitors Visual inspection O m Cooling system fans Check points Methods and criteria Inspection intervals Daily Semi annu ally Annu all...

Page 128: ...aumüller Nürnberg GmbH 128 of 174 9 3 9 3 Repairs In case of device damage please inform your sales office or Baumüller Nürnberg GmbH Ostendstr 80 90 90482 Nuremberg Germany Tel 49 9 11 54 32 0 Fax 49 9 11 54 32 1 30 Mail mail baumueller de Internet www baumueller de ...

Page 129: ...zed with hazardous voltage Therefore m Pay heed to areas on the device that could be dangerous WARNING Risk of injury due to improper fault correction Therefore m Only qualified personnel may work on this device m Personnel that work with the b maXX device must be trained in the safety regula tions and the handling of the device and be familiar with the correct operation of it In particular reacti...

Page 130: ...tive undervoltage X X X Overload monitoring Peak current not possible at this time X Heat sink temperature Temperature threshold 1 X X Temperature switch off threshold X X Internal temperature of device Temperature threshold 1 X X Temperature switch off threshold X X Motor temperature I2 t threshold exceeded X X Threshold 1 exceeded 2 X X Threshold 2 exceeded 2 X X Sensor short circuit and or temp...

Page 131: ...oder X X X 4 Cable break SIN2 COS2 X X X 4 Overspeed X X X 4 Cyclical specified value transmission to the fieldbus Time out during transmission X X X 4 Blocking monitoring Drive blocked X X X Monitoring function Warning error Warning Error Adjustable threshold Adjustable reaction Reaction inhibit pulses 1 Pulses are inhibited after a adjustable time period 2 Only if KTY PT1000 sensors are used 3 T...

Page 132: ... threshold then the controller signals a warning m If the temperature is higher than the maximum allowed device s internal temperature then the pulses are inhibited immediately Heat sink temperature This monitoring function checks the temperature of the heat sink m If the temperature is higher than the warning threshold then the controller signals a warning m If the temperature is higher than the ...

Page 133: ...is monitoring function checks the motor speed and the motor current If the following two conditions are met for at least the Blocking monitoring interval then the error message Drive blocked is generated by the controller and the pulses are inhib ited immediately m Motor speed 0 m The motor current output by the device is the same as the set maximal motor current current limit 10 3 Error detection...

Page 134: ...if deletion was possible on account of the error circumstances There are two methods of acknowledging an error m By means of write access to the control word m Via a digital input For further information on the subject of error acknowledgment refer to Parameter man ual b maXX 5800 NOTE The device is shipped with predefined error reactions With regard to the error mes sages identified with dependin...

Page 135: ...G 10 3 60 m 4 x 35 mm AWG 1 50 m 4 x 50 mm AWG 1 0 15 m Motor connector Flexible cable with wire end ferrule 31XXXX 32XXXX 33XXXX 34XXXX 35XXXX 4 x 4 to 16 mm AWG 20 4 Flexible cable with wire end fer rule clamp terminal Flexible cable with without wire end ferrule clamp terminal 1 Possible cross section Use a shielded Baumüller cable optical shield covering 85 no single wires For UL compliant mac...

Page 136: ...ne free FCKW free RoHS compliant additional lengths upon request Length Hybrid cable motor HIPERFACE DSL 15 A speedtec M23 20 A speedtec M23 21 A speedtec M40 28 A speedtec M40 36 A speedtec M40 Part No 3 m 464201 464217 464235 464278 464294 5 m 464202 464218 464236 464279 464295 7 m 464203 464219 464237 464280 464296 10 m 464204 464220 464238 464281 464297 15 m 464205 464221 464239 464282 464298 ...

Page 137: ...able with HIPERFACE DSL 15 A Cable 4G1 5 2x0 75 2x22AWG Shielding copper wires tinned Motor side Circular metal connector speedtec M23 8 pin Connect outside shielding and inside shielding with the connector housing Device side Metal D sub connector 45 26 pin with electronics part No 460219 Connect inside shielding with the connector housing Circular connector speedtec M23 Type of stranding Unconne...

Page 138: ...or cable with HIPERFACE DSL 20 A Cable 4G2 5 2x1 0 2x22AWG Shielding copper wires tinned Motor side Circular metal connector speedtec M23 8 pin Connect outside shielding and inside shielding with the connector housing Device side Metal D sub connector 45 26 pin with electronics part No 460219 Connect inside shielding with the connector housing Circular connector speedtec M23 Type of stranding Unco...

Page 139: ...r cable with HIPERFACE DSL 21 A Cable 4G2 5 2x1 0 2x22AWG Shielding copper wires tinned Motor side Circular metal connector speedtec M40 9 pin Outside shielding and inside shielding must be wired separately Device side Metal D sub connector 45 26 pin with electronics part No 460219 Connect inside shielding with the connector housing Circular connector speedtec M40 Type of stranding Unconnected wir...

Page 140: ...46 Motor cable with HIPERFACE DSL 28 A Cable 4G4 0 2x1 0 2x22AWG Shielding copper wires tinned Motor side Circular metal connector speedtec M40 9 pin Outside shielding and inside shielding must be wired separately Device side Metal D sub connector 45 26 pin with electronics part No 460219 Connect inside shielding with the connector housing Circular connector speedtec M40 Type of stranding Unconnec...

Page 141: ...tor cable with HIPERFACE DSL 36 A Cable 4G6 0 2x1 0 2x22AWG Shielding copper wires tinned Motor side Circular metal connector pin speedtec M40 9 pin Outside shielding and inside shielding must be wired separately Device side Metal D sub connector 45 26 pin with electronics part No 460219 Connect inside shielding with the connector housing Circular connector speedtec M40 Type of stranding Unconnect...

Page 142: ...AN POWERLINK cable m Available Ethernet connecting cables Type patch cable STP Type Length m Part number K ETH 33 0 0 5 0 5 325160 K ETH 33 0 01 1 325161 K ETH 33 0 02 2 325162 K ETH 33 0 03 3 325163 K ETH 33 0 04 4 325317 K ETH 33 0 05 5 325164 K ETH 33 0 10 10 325165 Additional lengths upon request Cross section 1 1 5 mm Maximum length without digital I O 2 Discretionary Maximum length with digi...

Page 143: ...71 BM4 CAN K 31 05 10 5 10 On request BM4 CAN K 32 01 RJ45 connector sub D female 1 346572 BM4 CAN K 32 02 2 On request BM4 CAN K 32 03 3 346573 BM4 CAN K 32 05 10 5 On request BM4 CAN K 33 01 RJ45 connector RJ45 connector 1 346577 BM4 CAN K 33 02 2 On request BM4 CAN K 33 03 3 On request BM4 CAN K 33 05 5 On request BM4 CAN K 33 10 10 On request m Terminated connector RJ45 Termination connector C...

Page 144: ...IEC 60754 1 Silicone free FCKW free RoHS compliant additional lengths upon request Length Resolver Encoder with HIPERFACE Sine square wave incremental encoder Part No Part No Part No speedtec speedtec speedtec 1 m 429914 448746 429958 448761 430015 448777 2 m 429915 448747 429959 448762 430016 448778 3 m 429916 448748 429960 448763 430017 448779 5 m 429917 448749 429961 448764 430018 448780 7 m 42...

Page 145: ...eedtec M23 1 m 429986 448796 458805 465906 2 m 429987 448797 458806 465907 3 m 429988 448798 458807 465908 5 m 429989 448799 458808 465909 7 m 429990 448800 458809 465910 10 m 429991 448801 458810 465911 15 m 429992 448802 458811 465912 20 m 429993 448803 458812 465913 25 m 429994 448804 458813 465914 30 m 429995 448805 458814 465915 35 m 429996 448806 458815 465916 40 m 429997 448807 458816 46591...

Page 146: ...m Cable Li9YC 1x2x0 25 Li9Y 2x2x0 25 Li9Y C11Y 1x2x0 34GN m High density D sub connector 26 pin male m Round connector 12 pin female e g from Interconnectron 2 Fully adjoin the cable shield with the housing of the round connector and with the shielding of the D sub connector Figure 48 Connecting cable for resolver NOTE The connecting cable must be made according to the figure shown above If there ...

Page 147: ... needed and also not connected m High density D sub connector 26 pin male m Round connector 12 pin female e g from Interconnectron 2 Fully adjoin the cable shield with the housing of the round connector and with the shielding of the D sub connector Figure 49 Connecting cable for encoder with HIPERFACE interface 5000_1102_rev01_int cdr 2 1 4 5 6 19 20 17 18 7 12 10 8 1 5 2 7 3 4 6 Æ 0 34 mm Æ 0 34 ...

Page 148: ...25 Li9Y C11Y 1x2x0 34GN Two cable pairs are not needed and also not connected m High density D sub connector 26 pin male m Round connector 17 pin female e g from Interconnectron 2 Fully adjoin the cable shield with the housing of the round connector and with the shielding of the D sub connector Figure 50 Connecting cable for encoder with EnDat or SSI NOTE The connecting cable must be made accordin...

Page 149: ...following materials m Cable 4 x 0 38 1 x 4 x 0 14 m High density D sub connector 26 pin male m Round connector 8 pin M12 female e g from Interconnectron 2 Fully adjoin the cable shield with the housing of the round connector and with the shielding of the D sub connector Figure 51 Connecting cable for encoder with EnDat 2 2 M12 NOTE The connecting cable must be made according to the figure shown ab...

Page 150: ... connector 26 pin male m Round connector 9 pin speedtec M23 female Intercontec 2 Fully adjoin the cable shield with the housing of the round connector and with the shielding of the D sub connector Figure 52 Connecting cable for encoder with EnDat 2 2 speedtec M23 NOTE The connecting cable must be made according to the figure shown above If there is a different pin assignment the cable is not funct...

Page 151: ...d and also not connected m High density D sub connector 26 pin male m Round connector 12 pin female e g from Interconnectron 2 Fully adjoin the cable shield with the housing of the round connector and with the shielding of the D sub connector Figure 53 Connecting cable for sine square wave incremental encoder 5000_1103_rev01_int cdr 2 1 4 5 6 8 9 12 11 17 18 7 12 10 5 6 8 3 4 2 11 7 9 1 Æ 0 34 mm ...

Page 152: ...2 X107 3 for axis modules up to 8 5 A Weidmüller for axis modules from 12 A to 30 A Weidmüller 7 mm 12 mm 436300 447103 Connector motor X108 1 X108 2 X108 3 for axis modules up to 8 5 A Weidmüller for axis modules from 12 A to 30 A Weidmüller 7 mm 12 mm 436299 447101 Connector motor temperature brake X207 1 X207 2 X207 3 Weidmüller 7 mm 479949 Connector motor temperature brake X208 1 X208 2 X208 3...

Page 153: ...elding NOTE Optional not included in delivery Axis module 1 Axis module 2 Axis module 3 Width Part No 22XXXX 23XXXX 24XXXX 25XXXX 22XXXX 23XXXX 24XXXX 25XXXX 22XXXX 23XXXX 24XXXX 25XXXX 175 mm 465889 22XXXX 23XXXX 24XXXX 25XXXX 22XXXX 23XXXX 24XXXX 25XXXX 26XXXX 27XXXX 28XXXX 29XXXX 30XXXX 31XXXX 32XXXX 33XXXX 175 mm 467842 ...

Page 154: ...bH 154 of 174 11 3 11 3 Connection rails m DC link bar Length Part No 1 m 424188 Accessories Part No DC link spacer bushing 424129 Screw 420020 m Mounting rail Length Part No 1 m 424187 m Accessories kit PE connection from device to device Accessories Part No Accessories kit PE connection 467439 ...

Page 155: ...ctrically live parts before taking into account the discharge time of the capacitors m Assure that all electric connections are current free and are safe against switch on m Before working check at the electrical connections with suitable measuring devic es that the connections are off circuit m Remove the connections not until the safe isolation from supply has been checked m If additional capaci...

Page 156: ...utes after switching off 3 Demount the connections and protect the connections according to the safety instructions 4 Document the shut down setting 12 4 Demounting m Ensure that only qualified personnel who are familiar with the safety notes and as sembly instructions demount this device mWear safety shoes m 1 Secure the device against falling off out 2 Loosen all mechanical connections 3 Lift th...

Page 157: ...ng m Reform the DC link capacitors n by supplying the device ready to operate for at least one hour with supply voltage n but do not transmit a pulse enable during this time m Consider that it is imperative to connect the accordingly prescribed line commu tating choke for this forming procedure Devices where no line commutating choke is necessary can directly be supplied with mains voltage Execute...

Page 158: ...Recommissioning Instruction handbook b maXX 5800 Document No 5 16027 04 Baumüller Nürnberg GmbH 158 of 174 12 6 ...

Page 159: ...e device with the longest DC link discharge time in the modular system Refer to ZElectrical data from page 36 Therefore m Do not touch before taking into account the discharge time of the capacitors and electrically live parts m Heed corresponding notes on the equipment m If additional capacitors are connected to the intermediate circuit the intermediate circuit discharge can take a much longer ti...

Page 160: ...el to en sure that device cannot fall down m Use appropriate means of transport NOTICE Avoid polluting the environment as a result of improper disposal Therefore m Only dispose in compliance with the health and safety regulations m Take heed of any special local regulations If you are unable to directly ensure safe disposal yourself commission a suitable disposal contractor m In the event of a fir...

Page 161: ...h all national regulations of the responsible disposal facilities and au thorities In case of doubt consult the bureau of commerce or environmental protection authority responsible for your company WARNING Danger as a result of faulty deinstallation The deinstallation and disposal requires qualified personnel with adequate experi ence Therefore m Only allow deinstallation and disposal to be perfor...

Page 162: ...Disposal facilities authorities Instruction handbook b maXX 5800 Document No 5 16027 04 Baumüller Nürnberg GmbH 162 of 174 13 2 ...

Page 163: ...cooling unit min Minute MSKL Motor protection thermistor n 0 rotational speed 0 nact Rotational speed actual value nmax Maximum rotational speed nmin Minimum rotational speed MSL Height above mean sea level No Number nset Rotational speed set value NTC Negative temperature coefficient thermistor PE Protected ground ground conductor connection PELV Protective extra low voltage with safe isolation g...

Page 164: ...Instruction handbook b maXX 5800 Document No 5 16027 04 Baumüller Nürnberg GmbH 164 of 174 ...

Page 165: ...165 of 174 Operation Manual b maXX 5800 Document no 5 16027 04 APPENDIX B DECLARATION OF CONFORMITY ...

Page 166: ...id to the safety instructions in the instruction handbook Nuremberg 29 Sep 2017 Location Date Subject to change of this declaration of EC conformity without notice Actual valid edition on request Standard Title DIN EN 62061 2010 05 Safety of Machines Functional safety of safety related electrical electronic and pro grammable electronic control systems DIN EN 61800 5 1 2008 04 Variable speed electr...

Page 167: ...ual This product is to be used in machinery and must not put into operation until the machinery into with it is incorporated has been declared to be in conformity with the Machinery Directive Nuremberg 29 Sep 2017 Location Date Subject to change of this declaration of EC conformity without notice Actual valid edition on request Standard Title EN 61800 5 2 2016 Adjustable speed electrical power dri...

Page 168: ...Operation Manual b maXX 5800 Document no 5 16027 04 Baumüller Nürnberg GmbH 168 of 174 ...

Page 169: ... for BM58XX S 65 Drilling pattern without mounting rail for all versions 66 Mounting instructions BM58XX S with mounting rail 67 Mounting instructions BM580XX without mounting rail 68 Correctly mounted DC link bar 69 Mounting of the neck collar screw 69 Mounting of the DC link bar 70 Hazard areas during electrical installation 72 Grounding concept MAR each device is connected with PE on its own 76...

Page 170: ...CE DSL 28 A 140 Motor cable with HIPERFACE DSL 36 A 141 Connecting cable for resolver 146 Connecting cable for encoder with HIPERFACE interface 147 Connecting cable for encoder with EnDat or SSI 148 Connecting cable for encoder with EnDat 2 2 M12 149 Connecting cable for encoder with EnDat 2 2 speedtec M23 150 Connecting cable for sine square wave incremental encoder 151 ...

Page 171: ...nnecting cable 142 F Fault correction 129 Fire fighting 21 G Guarantee provisions 10 H Hard hat 19 Hazards special 20 I Inspection intervals 124 Inspection daily 124 Inspection regularly scheduled 124 Installation 71 Installation procedure 85 K Key to symbols 7 L Limitation of liability 8 M Maintenance 123 Maintenance periodic 125 Malfunctions behavior 129 Modifications 13 Monitoring functions 130...

Page 172: ...s and labels 23 Spare parts 10 135 152 STO function 110 Storage conditions 157 T Technical data 27 Temperature range 31 Temperature sensor 84 Terminated connector 120 143 Transport 59 Transport inspection 60 Type code 49 Type plate 48 U Unpacking 60 Usage compliant with the intended purpose 14 V Voltage test 73 W Warning 7 116 130 Warning notes 7 Weight 29 ...

Page 173: ... 5 16027 04 173 of 174 Overview of Revisions Overview of Revisions Version Status Changes 5 16027 01 15 May 2017 First release 5 16027 02 1 Mar 2018 Safety certification 5 16027 03 5 Nov 2018 Revision 5 16027 04 22 May 2019 Risk assessment added ...

Page 174: ...Instruction handbook b maXX 5800 Document No 5 16027 04 Baumüller Nürnberg GmbH 174 of 174 Notes ...

Page 175: ......

Page 176: ... our permanent revision service Please notice that specifications data information are current values according to the printing date These statements are not legally binding according to the measurement computation and calculations Before you make any information given in this manual to the basis of your own calculations and or applications please make sure that you have the latest edition of the ...

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