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Baumuller b maxx BM4400, Instruction Handbook Manual

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Baumuller b maxx BM4400 Instruction Handbook Manual Download Page 229

229

of 358

 Instruction handbook 

b maXX

 

BM4400, BM4600, BM4700 

Document No.: 5.12008.07 

9

T

ROUBLESHOOTING

 

AND

 

FAULT

 

CORRECTION

9.1

Behavior in case of malfunctions

Basic information

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.

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, reacting to error indications and conditions requires that the oper-
ator must have special knowledge.

Summary of Contents for b maxx BM4400

Page 1: ... handbook before starting any work Language English Translation Document No 5 12008 07 Part No 444496 Status 7 Jul 2016 b maXX 4000 BM4400 BM4400 ES BM4600 BM4600 ES BM4700 BM4700 ES Basic Units Power modules with Servo Controller E 5 12008 07 ...

Page 2: ...mments 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: ...f the personnel 19 2 7 Personal protective equipment 20 2 8 Special hazards 21 2 9 Fire fighting 22 2 10 Safety equipment 23 2 11 Conduct in case of danger or accidents 23 2 12 Signs and labels 24 3 Technical Data 31 3 1 Dimensions 31 3 1 1 Dimensions BM441X 32 3 1 2 Dimensions BM442X 33 3 1 3 Dimensions BM4X3X 35 3 1 4 Dimensions BM4X4X 37 3 1 5 Dimensions BM4X5X 39 3 1 6 Dimensions BM4X6X 44 3 1...

Page 4: ...ata BM442X power modules 96 3 5 2 Electrical data BM443X power modules 98 3 5 3 Electrical data BM444X power modules 100 3 5 4 Electrical data BM445X power modules 102 3 5 5 Electrical data BM446X power module 104 3 6 Additional data referring to water cooled brake resistors 106 3 7 Output frequency dependent continuous current derating BM4XXX 112 3 8 Output frequency dependent maximum current der...

Page 5: ...otection of the device and the cable 168 7 6 PE connection and RCD compatibility 169 7 7 Installation requirements with regard to EMC 169 7 8 Requirements for the motor temperature sensors 170 7 9 Installation procedure 171 7 10 Wiring diagrams 173 7 10 1 Connection diagrams 173 7 10 1 1 BM44XX BM46XX BM47XX basic units 173 7 10 1 2 BM44XX BM46XX BM47XX power module 176 7 10 2 Terminal overviews 1...

Page 6: ...essages error reactions 240 9 4 2 1 Error messages 2nd level 241 9 4 2 2 Sub error messages 3rd level 250 9 4 3 Warnings 258 10 Maintenance 261 10 1 Safety notes 261 10 2 Environmental condition 262 10 3 Inspection intervals maintenance notes 262 10 3 1 Periodic maintenance 264 10 4 Repairs 266 11 Accessories and Spare Parts 267 11 1 Cabling 268 11 1 1 Cables power supply device 268 11 1 2 Cables ...

Page 7: ...ilities authorities 319 Appenidx A Abbreviations 321 Appenidx B Declaration of Conformity 323 B 1 Declaration of conformity 323 Appenidx C Safe stop 327 C 1 Methods to avoid an unexpected starting 327 C 2 Safe Torque Off STO 330 C 2 1 Safety classifications and safety notes 330 C 2 2 Function principle STO 333 C 2 2 1 Shutdown paths 334 C 2 2 2 Sequence diagram 335 C 2 2 3 Connection diagrams 338 ...

Page 8: ...Instruction handbook b maXX BM4400 BM4600 BM4700 Document No 5 12008 07 Baumüller Nürnberg GmbH 8 of 358 Table of Contents ...

Page 9: ...pecified safety notes and procedural in structions Additionally the valid accident prevention regulations and general safety regulations ap plicable to the scope of application the device must be complied with Read the instruction handbook particularly the safety notes chapter completely before beginning any work on the device The instruction handbook is part of the product and must be kept access...

Page 10: ...ent accidents personal injury and material damage Recommen dations DANGER points out an immediately dangerous situation that will lead to severe injuries or death if not avoided WARNING points out a potentially dangerous situation that could lead to severe injuries or death if not avoided CAUTION points out a potentially dangerous situation that could lead to minor or slight inju ries if not avoid...

Page 11: ...local regulations concerning the dimensioning and protection of conductors grounding disconnectors overcurrent protection etc The person who carried out the mounting or installation is liable for any damage incurred when assembling or connecting the device 1 4 Copyright protection EnDat is a registered trademark of Dr Johannes Heidenhain GmbH 83301 Traunreut Germany EtherCAT is a registered tradem...

Page 12: ...nt parts See also ZDisposal on page 317 1 8 Guarantee provisions The guarantee provisions are stated in a separate document of the sales documents The devices described herein may only be operated in accordance with the stipulated methods procedures 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...

Page 13: ... 12008 444495 444496 Doc No Part No German Part No English Analog I O module BM4 F AIO XX or AIO XX 5 01045 354844 372665 Digital I O module BM4 F DIO FIO XX or DIO FIO XX 5 01046 354843 372666 Encoder module BM4 F ENC XX or ENC XX 5 01042 354842 372861 Incremental encoder emulation module BM4 F IEE XX or IEE XX 5 02020 354858 376728 SSI encoder emulation module BM4 F SIE XX or SIE XX 5 03056 3771...

Page 14: ...roller programming handbook 5 03045 376757 377294 SERCOS slave module BM4 O SER 01 5 04012 380910 381069 SERCOS slave module BM4 O SER 01 parameter handbook 5 04013 381652 381653 EtherCAT slave module BM4 O ECT 01 ECT 01 5 06003 394953 394954 Ethernet with EtherCAT master for b maXX drive PLC 5 07001 407996 407997 Ethernet with EtherCAT master for b maXX drive PLC application handbook 5 07002 4079...

Page 15: ...ho is 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 who is 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 ...

Page 16: ...ant with its intended purpose m Observe all specifications of these instruction handbook m Ensure that only qualified personnel work with on this device m When configuring ensure that the device is always operated within its specifica tions m Mount the device on a wall that can sufficiently bear the load m The device must always be operated within a control cabinet m Ensure that the power supply c...

Page 17: ... m The operating company must inform himself about the applicable work health and safe ty regulations and ascertain in a hazard assessment any additional hazards that could arise from the special working 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 pers...

Page 18: ... All devices BM4400 BM4600 BM4700 must be installed in an appropriate control cab inet to meet the protection classification required in EN 61800 5 1 chapter 4 2 3 3 IP 30 only upper horizontal surfaces IP 20 all other surfaces DANGER Risk of fatal injury from electrical current There is an immediate risk of fatal injury if live electrical parts are contacted Therefore m The device must be in oper...

Page 19: ... 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 personnel have had o...

Page 20: ... present in each working area must 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 ...

Page 21: ... 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 system See ZElect...

Page 22: ... components during operation 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 elec...

Page 23: ...diately 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 a facility...

Page 24: ...ed persons may not touch 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 See ZElectrical data basic units from page 63 Therefore m Do not touch before taking into account the discharge time of the capacitors an...

Page 25: ...400 BM4600 BM4700 Document No 5 12008 07 25 of 358 2 Figure 1 Signs and labels BM4X1X CAUTION Risk of injury due to hot surface Therefore m Wear protective gloves NOTE When in operation the top of the device can heat up to temperatures 70 C ...

Page 26: ...Signs and labels Instruction handbook b maXX BM4400 BM4600 BM4700 Document No 5 12008 07 Baumüller Nürnberg GmbH 26 of 358 2 12 Figure 2 Signs and labels BM4X3X BM4X4X ...

Page 27: ...Safety Instruction handbook b maXX BM4400 BM4600 BM4700 Document No 5 12008 07 27 of 358 2 Figure 3 Signs and labels BM4X5X ...

Page 28: ...Signs and labels Instruction handbook b maXX BM4400 BM4600 BM4700 Document No 5 12008 07 Baumüller Nürnberg GmbH 28 of 358 2 12 Figure 4 Signs and labels BM4X6X BM4X7X ...

Page 29: ...nbau Einzelleistun gseinheit 3x400V 480V AC 50 60Hz Eingang 3x0 400V 460V AC 3x150A 125A 0 450Hz Ausgang GBK 130 1min Betriebsart 06500275 Ser Nr 311035532 Art Nr BM4453 FI 01244 S01 03 Typ BAUMÜLLER NÜRNBERG GMBH Ostendstr 80 90 D 90482 Nürnberg www baumueller de Made in Germany Einbau Einzelleistun gseinheit 3x400V 480V AC 50 60Hz Eingang 3x0 400V 460V AC 3x150A 125A 0 450Hz Ausgang GBK 130 1min...

Page 30: ...Signs and labels Instruction handbook b maXX BM4400 BM4600 BM4700 Document No 5 12008 07 Baumüller Nürnberg GmbH 30 of 358 2 12 ...

Page 31: ... cabinet are deter mined The dimension drawings in ZDrilling patterns from page 147 must be used in or der to do the required drilling segments NOTE All dimensions in mm NOTE Only the basic controller has a design cover NOTE The following devices are shown with design cover The ES controller is designed without a design cover The depth of the device was reduced by 66 5 mm due to this It must be co...

Page 32: ...umüller Nürnberg GmbH 32 of 358 3 1 3 1 1 Dimensions BM441X With design cover Without design cover Design cover Figure 6 Dimensions BM441X Observe minimum clearance Observe ZCooling from page 61 Dimensions specified with design cover The ES controller is not equipped with a design cover ...

Page 33: ...BM4600 BM4700 Document No 5 12008 07 33 of 358 3 3 1 2 Dimensions BM442X Figure 7 Dimensions BM442X S A Observe minimum clearance Observe ZCooling from page 61 Dimensions specified with design cover The ES controller is not equipped with a design cover ...

Page 34: ...earance Observe ZCooling from page 61 Dimensions specified with design cover The ES controller is not equipped with a design cover Dimensions Instruction handbook b maXX BM4400 BM4600 BM4700 Document No 5 12008 07 Baumüller Nürnberg GmbH 34 of 358 3 1 ...

Page 35: ... BM4700 Document No 5 12008 07 35 of 358 3 3 1 3 Dimensions BM4X3X Figure 9 Dimensions BM443X S Z BM443X A F Observe minimum clearance Observe ZCooling from page 61 Dimensions specified with design cover The ES controller is not equipped with a design cover ...

Page 36: ...m clearance Observe ZCooling from page 61 Dimensions specified with design cover The ES controller is not equipped with a design cover Dimensions Instruction handbook b maXX BM4400 BM4600 BM4700 Document No 5 12008 07 Baumüller Nürnberg GmbH 36 of 358 3 1 ...

Page 37: ... BM4700 Document No 5 12008 07 37 of 358 3 3 1 4 Dimensions BM4X4X Figure 11 Dimensions BM444X S Z BM464X S Z Observe minimum clearance Observe ZCooling from page 61 Dimensions specified with design cover The ES controller is not equipped with a design cover ...

Page 38: ...mum clearance Observe ZCooling from page 61 Dimensions specified with design cover The ES controller is not equipped with a design cover Dimensions Instruction handbook b maXX BM4400 BM4600 BM4700 Document No 5 12008 07 Baumüller Nürnberg GmbH 38 of 358 3 1 ...

Page 39: ...nt No 5 12008 07 39 of 358 3 3 1 5 Dimensions BM4X5X Figure 13 Dimensions BM445X S Z BM465X S Z Observe minimum clearance Observe ZCooling from page 61 Dimensions specified with design cover The ES controller is not equipped with a design cover Width including screw heads ...

Page 40: ...n cover The ES controller is not equipped with a design cover Width including screw heads Dimensions Instruction handbook b maXX BM4400 BM4600 BM4700 Document No 5 12008 07 Baumüller Nürnberg GmbH 40 of 358 3 1 NOTE The device BM4X5X AX 0XXX was extended by about 70 mm downwards with an additional protective plate against contact ...

Page 41: ...4600 BM4700 Document No 5 12008 07 41 of 358 3 Observe minimum clearance Observe ZCooling from page 61 Dimensions specified with design cover The ES controller is not equipped with a design cover Figure 15 Dimensions BM465X FXX 3XXXX and BM475X FXX 3XXXX ...

Page 42: ...ent No 5 12008 07 Baumüller Nürnberg GmbH 42 of 358 3 1 Observe minimum clearance Observe ZCooling from page 61 Dimensions specified with design cover The ES controller is not equipped with a design cover Figure 16 Dimensions BM465X FXX 3XXXX RYY BM475X FXX 3XXXX RYY ...

Page 43: ...00 BM4700 Document No 5 12008 07 43 of 358 3 Observe minimum clearance Observe ZCooling from page 61 Dimensions specified with design cover The ES controller is not equipped with a design cover Figure 17 Dimensions BM465X ZXX 3XXXX RYY BM475X ZXX 3XXXX RYY ...

Page 44: ...008 07 Baumüller Nürnberg GmbH 44 of 358 3 1 3 1 6 Dimensions BM4X6X Figure 18 Dimensions BM446X S Z Observe minimum clearance Observe ZCooling from page 61 Dimensions specified with design cover The ES controller is not equipped with a design cover Width including screw heads ...

Page 45: ...BM446X A F and BM466X A F Observe minimum clearance Observe ZCooling from page 61 Dimensions specified with design cover The ES controller is not equipped with a design cover Width including screw heads NOTE The device BM4X6X AX 0XXX was extended by about 80 mm downwards by an ad ditional protective plate against contact ...

Page 46: ... BM4400 BM4600 BM4700 Document No 5 12008 07 Baumüller Nürnberg GmbH 46 of 358 3 1 Observe minimum clearance Observe ZCooling from page 61 without brake resistor with brake resistor Figure 20 Dimensions BM466X FXX 3XXXX and BM476X FXX 3XXXX ...

Page 47: ...erve minimum clearance Observe ZCooling from page 61 Figure 21 Dimensions BM466X Z 3XXXX and BM476X Z 3XXXX Technical Data Instruction handbook b maXX BM4400 BM4600 BM4700 Document No 5 12008 07 47 of 358 3 ...

Page 48: ...ent No 5 12008 07 Baumüller Nürnberg GmbH 48 of 358 3 1 3 1 7 Dimensions BM4X7X Figure 22 Dimensions BM447X F BM477X F Observe minimum clearance Observe ZCooling from page 61 Dimensions specified with design cover The ES controller is not equipped with a design cover ...

Page 49: ...maXX BM4400 BM4600 BM4700 Document No 5 12008 07 49 of 358 3 Figure 23 Dimensions BM447X A Observe minimum clearance Observe ZCooling from page 61 Dimensions specified with design cover The ES controller is not equipped with a design cover ...

Page 50: ...ons for the device BM447X F and BM477X FXX 3XXXX are specified The specified depth is the total depth of the device See ZFigure 23 on page 49 Device Dimensions W x H x D Weight with controller without plug in modules BM441X 1 80 x 347 x 263 mm 105 5 x 347 x 263 mm 4 0 4 4 kg BM442X 2 105 5 x 428 x 340 mm 7 0 kg BM443X 2 BM463X 2 155 x 540 x 340 mm 15 7 kg BM444X 2 BM464X 2 190 x 665 x 374 mm 26 4 ...

Page 51: ...hed by using an isolating transformer or an independent current source generator battery If the low impedance ground fault is adequate an upstream fuse within the TN system or the TT system responds At a high impedance ground fault a fuse does not respond This ground current residual currents can be dangerous Therefore sensitive circuit breakers are used for residual current monitoring At a ground...

Page 52: ...47X BM477X min uk 4 max uk 6 Rated supply voltage frequency 1 2 UAC device 3 x 400 V 50 60 Hz Absolute minimum supply voltage device1 2 UAC Absolute maximum supply voltage device1 2 UAC 3 x 207 V 50 60 Hz 3 x 528 V 50 60 Hz Absolute minimum frequency5 Absolute maximum frequency 5 47 Hz 63 Hz Overvoltage category EN 61800 5 1 chapter 4 3 6 III Harmonics power supply voltage EN 61800 3 chapter 5 2 1...

Page 53: ...57 3 The control voltage must accord to PELV EN 61800 5 1 chapter 3 21 or SELV EN 61800 5 1 chap 3 35 At control voltage of 24 V the ventilation power output is reduced Therefore it may be necessary to reduce the output currents as well 4 Required for UL 508C only 5 Rate of change of the power supply frequency 1 Hz s at a maximum EN 61000 2 4 class 3 6 The connection and operation of a device with...

Page 54: ...age may rise up to 780 V to 800 V in braking operation The connected motor must be designed for these DC link voltages The DC link voltage remains between 640 V and 760 V continuously not only in the brak ing operation if the BM4400 BM4600 BM4700 power modules are operated at a volt age controlled DC link e g BM51XX The connected motor must be able to operate at these voltages continuously The dev...

Page 55: ...urable range Vibration shock and repetitive shock EN 61800 5 1 section 5 2 6 4 Vibration test max 0 5 g during operation Degree of pollution EN 61800 5 1 table 6 Tab 2 2 1 For the operation in an environment of category C2 according to IEC 61800 3 2012 additional measures may be required The manu facturer of the installation user must provide the following evidence in this case The additional meas...

Page 56: ...ice 3 3 5 1 Mounting height If the devices BM4400 BM4600 BM4700 are operated above an absolute altitude of 1000 m then the output power must be reduced against the rated power according to the following curve Figure 24 Reducing of the output power in dependence of the absolute altitude Output power Rated power Mounting height 0 20 40 60 80 100 120 0m 1 000m 2 000m 3 000m 4 000m 5 000m NOTE Baumüll...

Page 57: ...temperature complies with the environmental temperature of air cooled de vices with the water temperature of water cooled devices and the surface temperature of the cold plate mounting panel of devices with cold plate cooling 3 3 5 3 Supply voltage Above rated supply voltage The rated voltage is 3 x 400 V When having input voltages above the rated supply voltage the output currents must ac cording...

Page 58: ...input voltage Output power Output voltage device System voltage 207 V 400 V 528 V 177 V 370 V 498 V Output power device PRated Continuous operation permit ted System voltage Figure 27 Reducing the output power in dependence of the system voltage The output power of the device is obtained by multiplying the output current with the output voltage SOut UOut x IOut x 3 It is necessary to reduce the ou...

Page 59: ...rrent from the dimensioning cycle i t I 1 I 2 I 3 T t t1 t2 t3 I 1 I 2 I 3 t1 t2 t3 Figure 28 Calculation of the thermal rms current Ieff In 2 tn T n 1 k I1 2 t1 T I2 2 t2 T I3 2 t3 T m Coherence between peak current and rated current for the dimensioning of a motion cycle i t I peak T t tpeak I peak T tpeak Figure 29 Coherence between peak current and rated current tpeak T Irated Ipeak 2 ...

Page 60: ... current of drive and the braking peak current Imax phase acceleration Imax phase braking UDC link braking UDC link acceleration 1 Motor 2 Assumptions Pshaft acceleration Pshaft braking cos accelerate cos braking Typical values UDC link braking 780 V UDC link acceleration 540 V Motor 0 9 Typically resulting in Imax phase braking 0 56 Imax phase acceleration ...

Page 61: ...tion Hot water heating cooling water inlet to cooling water outlet 3 K 14 35 l min kW K powerloss kW cooling water flow l min Pressure loss at the water cooler 3 0 5 bar at 10 l min Mounting board temperature with cold plate 6 min Cooling air temperature 1 to max 55 C rated temperature 40 C at water cooling 5 water outlet temperature 40 C surface temperature 42 C 1 Air temperature in the entire su...

Page 62: ...face roughness and the evenness A light damage of the surface can lead to a significant deterioration of the heat dissipation to the mounting plate The sensitive functional surface therefore must be protected against damage when handling the parts 7 At BM44XX FXX BM44XX ZXX BM46XX FXX 0XXXX BM46XX FXX 3XXXX and BM47XX FXX 3XXXX only NOTE Instead of a continuous flow of the water coolers it is poss...

Page 63: ... power up processes 12 at least 60 s Output voltage 1 2 UAC 3 x 0 V to 3 x 370 V Output frequency at 4 kHz 12 0 Hz to 450 Hz Rated output current 1 4 5 6 13 IAC at 4 kHz 3 2 5 A 4 5 A 5 5 A 7 5 A Rated output current 1 4 5 6 13 IAC at 8 kHz 3 2 5 A 4 5 A 5 0 A 5 0 A Output peak current 1 4 5 7 13 IAC at 4 kHz 3 5 0 A 9 0 A 20 0 A 20 0 A Output peak current 1 4 5 7 13 IAC at 8 kHz 3 5 0 A 9 0 A 12 ...

Page 64: ...y voltage V Output current Derating of the output current Supply voltage V Output current Derating of the output current Supply voltage V Figure 31 Derating of output current BM441X universal units 6 Between 40 C and 55 C the output current must be reduced See correction factors at changed operating conditions ZEnvironmental temperature on page 57 7 The peak output current is supplied for the maxi...

Page 65: ...urrent controller frequency fI R fI R 1 cycle time current controller The maximum output frequency fmax generated with high quality is calculated as follows fmax fI R Kpf typical KPf 18 Furthermore the controller sets an upper limit for the output frequency of 599 Hz please contact the responsible Baumüller sales de partment keyword export restriction The range of the output frequency is defined a...

Page 66: ...ses 9 at least 60 s Output voltage 1 3 UAC 3 x 0 V to 3 x 370 V Output frequency at 4 kHz 11 0 Hz to 450 Hz Rated output current 1 5 6 7 IAC at 4 kHz 4 7 5 A 11 0 A 15 0 A Rated output current 1 5 6 7 IAC at 8 kHz 4 6 0 A 8 8 A 12 0 A Output peak current 1 5 6 8 IAC at 4 kHz 4 15 0 A 22 0 A 30 0 A Output peak current 1 5 6 8 IAC at 8 kHz 4 12 0 A 17 6 A 24 0 A Max peak current period 8 60 s Power ...

Page 67: ...ed DC link voltage 1 UDC 540 VDC DC link capacity internal 705 F 1020 F DC link discharging time internal DC link capacity 510 s 695 s DC link capacity external permitted see ZFigure 34 on page 69 Period between two power up processes 9 at least 60 s Output voltage 1 3 UAC 3 x 0 V to 3 x 370 V Output frequency 11 0 Hz to 450 Hz Rated output current 1 5 6 7 IAC at 4 kHz 4 15 0 A 22 5 A 12 27 0 A 12...

Page 68: ...rent Derating of the output current Power voltage V Output current Derating of the output current Power voltage V Output current Derating of the output current Power voltage V Figure 33 Derating the output current BM442X universal units 7 The input current must be reduced between 40 C and 55 C see correction factors at changed operating conditions ZEnvironmental temperature on page 57 8 The peak o...

Page 69: ... the ratio between output frequency and current controller frequency fI R fI R 1 cycle time current controller The maximum output frequency fmax generated with high quality is calculated as follows fmax fI R Kpf typical KPf 18 Furthermore the controller sets an upper limit for the output frequency of 599 Hz please contact the responsible Baumüller sales de partment keyword export restriction The r...

Page 70: ...wer up processes none Output voltage 1 3 UAC 3 x 0 V to 3 x 370 V Output frequency at 4 kHz10 0 Hz to 450 Hz Rated output current 1 5 6 7 13 IAC at 4 kHz 4 22 5 A 30 0 A 45 0 A 60 0 A Rated output current 1 5 6 7 13 IAC at 8 kHz 4 18 0 A 24 0 A 36 0 A 48 0 A Output peak current 1 5 6 8 13 IAC at 4 kHz 4 45 0 A 60 0 A 90 0 A 90 0 A Output peak current 1 5 6 8 13 IAC at 8 kHz 4 36 0 A 48 0 A 72 0 A ...

Page 71: ... Output current Derating of output current BM4X32 Power supply voltage V Output current Derating of output current BM4433 Power supply voltage V Output current Derating of output current BM4434 Power supply voltage V Output current Derating of output current BM4435 Power supply voltage V Figure 35 Derating the output current BM443X universal units 7 The input current must be reduced between 40 C a...

Page 72: ...müller sales de partment keyword export restriction The range of the output frequency is defined as follows PWM frequency Current controller cycle time Range of the output frequency 2 kHz 250 µs 0 225 Hz 4 kHz 8 kHz 125 µs 0 450 Hz The controller allows the device to generate output voltages with frequencies between fmax and 599 Hz However the quality of this volt ages cannot be guaranteed Typical...

Page 73: ... current 1 5 6 7 15 IAC at 4 kHz 4 80 A 100 A 130 A 150 A Rated output current 1 5 6 7 15 IAC at 8 kHz 4 75 A 72 A 94 A 105 A Output peak current 1 5 6 8 15 IAC at 4 kHz 4 120 A 130 A 170 A 200 A Output peak current 1 5 6 8 15 IAC at 8 kHz 4 90 A 94 A 130 A 150 A Max peak current period 8 9 60 s Power supply DC link terminals 11 max 90 kW Brake resistor current permitted Î max 67 A max 100 A Brake...

Page 74: ...utput current Derating of the output current BM4446 Power supply voltage V Figure 36 Derating the output current BM444X universal units 7 The input current must be reduced between 40 C and 55 C See correction factors at changed operating conditions ZEnvironmental temperature on page 57 8 The peak output current is supplied for the maximum peak current period for the motor at the first acceleration...

Page 75: ...ction The range of the output frequency is defined as follows PWM frequency Current controller cycle time Range of the output frequency 2 kHz 250 µs 0 225 Hz 4 kHz 8 kHz 125 µs 0 450 Hz The controller allows the device to generate output voltages with frequencies between fmax and 599 Hz However the quality of this volt ages cannot be guaranteed Typical the devices are marked with the max output fr...

Page 76: ...put current 1 5 6 7 IAC at 4 kHz 4 120 A 14 150 A14 210 A 13 Rated output current 1 5 6 7 IAC at 8 kHz 4 96 A14 116 A14 150 A 13 Output peak current 1 5 6 8 IAC at 4 kHz 4 180 A 14 195 A14 260 A 13 Output peak current 1 5 6 8 IAC at 8 kHz 4 144 A 14 150 A14 185 A 13 Max peak current period 8 60 s Power input DC link terminals max 110 kW Brake resistor current permitted Î max 150 A Brake resistor e...

Page 77: ... supply voltage the output currents must be reduced at constant output power Output current Derating of output current BM4452 Power supply voltage V Output current Derating of output current BM4453 Power supply voltage V Output current Derating of output current BM4454 Power supply voltage V Figure 37 Reducing of output current BM445X universal units 7 The input current must be reduced between 40 ...

Page 78: ...er sales de partment keyword export restriction The range of the output frequency is defined as follows PWM frequency Current controller cycle time Range of the output frequency 2 kHz 250 µs 0 225 Hz 4 kHz 8 kHz 125 µs 0 450 Hz The controller allows the device to generate output voltages with frequencies between fmax and 599 Hz However the quality of this volt ages cannot be guaranteed Typical the...

Page 79: ...0 Hz to 450 Hz Rated output current 1 5 6 7 15 IAC at 4 kHz 4 250 A 300 A 350 A Rated output current 1 5 6 7 15 IAC at 8 kHz 4 200 A 240 A 240 A Output peak current 1 5 6 8 15 IAC at 4 kHz 4 325 A 390 A 450 A Output peak current 1 5 6 8 15 IAC at 8 kHz 4 260 A 312 A 312 A Max peak current period 8 60 s Power input DC link terminals max 160 kW Brake resistor current permitted Î max 230 A max 236 A ...

Page 80: ...the rated power supply voltage the output currents must be reduced at constant output power Output current Derating of output current BM4462 Power supply voltage V Output current Derating of output current BM4463 Power supply voltage V Output current Derating of output current BM4466 Power supply voltage V Figure 38 Reducing of output current BM 446X universal units 7 The input current must be red...

Page 81: ... frequency is defined as follows PWM frequency Current controller cycle time Range of the output frequency 2 kHz 250 µs 0 225 Hz 4 kHz 8 kHz 125 µs 0 450 Hz The controller allows the device to generate output voltages with frequencies between fmax and 599 Hz However the quality of this volt ages cannot be guaranteed Typical the devices are marked with the max output frequency at 4 kHz switching fr...

Page 82: ...z 4 585 A 800 A Output peak current 1 5 6 8 15 IAC at 8 kHz 4 439 A 545 A Max peak current period 9 60 s Power input DC link terminals max 250 kW max 315 kW Brake resistor current permitted Î max 300 A Brake resistor external 2 6 Brake resistor threshold Û 12 780 V Brake resistor peak power 234 kW Permitted continuous power brake resistor external 180 kW Power loss referring to power input 4700 W ...

Page 83: ... on page 54 13 If UL508C is complied with The permitted typical motor output is limited to 295 kW at a maximum The device BM4473 belongs to the category 400 HP 298 kW ratings complying with table 45 1 of UL508C Therefore the short circuit test using 18k A can be executed Baumüller does not offer devices in the class 600 HP 447 kW with 30 kA short circuit current in accordance with UL508C 14 The ra...

Page 84: ...with 1 25 s peak current at a total cycle of 5 s see ZFigure 29 on page 59 The units are not developed for using at standstill or output frequencies lower than 10 Hz with peak current For this units the ZOutput fre quency dependent continuous current derating BM4XXX on page 112 and the ZOutput frequency dependent maximum current derating BM46XX on page 113 NOTE The acceleration units require a con...

Page 85: ...370 V Output frequency at 4 kHz 10 0 Hz to 450 Hz Rated output current 1 5 6 7 12 IAC at 4 kHz 4 60 A Rated output current 1 5 6 7 12 IAC at 8 kHz 4 48 A Output peak current 1 5 6 8 12 IAC at 4 kHz 4 120 A Output peak current 1 5 6 8 12 IAC at 8 kHz 4 96 A Max peak current period 8 1 25 s Power input DC link terminals 9 max 10 0 kW Brake resistor current permitted Î max 70 0 A Brake resistor exter...

Page 86: ...ined by the overload monitoring of the device 9 The sum of the mean effective power which is transmitted via the DC link terminals and the mean effective power at the motor terminals may not exceed the specified value continuously 10 The range of the output frequency is based on a stationary operation in the linear range of the PWM i e without overmodulation The quality of the generated output vol...

Page 87: ... at 8 kHz 4 128 A 150 A Max peak current period 8 1 25 s Power input DC link terminals 10 max 60 kW 120 kW 1 s Brake resistor current permitted Î max 100 A Brake resistor external v 8 Brake resistor threshold Û 780 V Brake resistor peak power 80 kW Permitted continuous power brake resistor external 58 kW Power loss referring to power input 1350 W Power input referring to control voltage max 75 W P...

Page 88: ...the specified value continuously 11 The range of the output frequency is based on a stationary operation in the linear range of the PWM i e without overmodulation The quality of the generated output voltages depends on the ratio between output frequency and current controller frequency fI R fI R 1 cycle time current controller The maximum output frequency fmax generated with high quality is calcul...

Page 89: ... A 330 A 400 A Output peak current 1 5 6 8 13 IAC at 8 kHz 4 194 A 264 A 300 A Max peak current period 8 1 25 s Power input DC link terminals max 110 kW Brake resistor current permitted Î max 150 A Brake resistor external 5 Brake resistor threshold Û 11 780 V Brake resistor peak power 120 kW Permitted continuous power brake resistor external 80 kW Power loss referring to power input 2100 W 2300 W ...

Page 90: ...ncy is based on a stationary operation in the linear range of the PWM i e without overmodulation The quality of the generated output voltages depends on the ratio between output frequency and current controller frequency fI R fI R 1 cycle time current controller The maximum output frequency fmax generated with high quality is calculated as follows fmax fI R Kpf typical KPf 18 Furthermore the contr...

Page 91: ...ut peak current 1 5 6 8 14 IAC at 8 kHz 4 374 A 450 A Max peak current period 8 1 25 s Power input DC link terminals max 160 kW Brake resistor current permitted Î max 230 A Brake resistor external 3 4 Brake resistor threshold Û 11 780 V Brake resistor peak power 179 kW Permitted continuous power brake resistor external 130 kW Power loss referring to power input 3500 W 4200 W Power input referring ...

Page 92: ... the linear range of the PWM i e without overmodulation The quality of the generated output voltages depends on the ratio between output frequency and current controller frequency fI R fI R 1 cycle time current controller The maximum output frequency fmax generated with high quality is calculated as follows fmax fI R Kpf typical KPf 18 Furthermore the controller sets an upper limit for the output ...

Page 93: ... A 305 A 495 A Ausgangs Spitzenstrom 1 5 6 8 13 IAC bei 4 kHz 4 260 A 450 A 800 A Ausgangs Spitzenstrom 1 5 6 8 13 IAC bei 8 kHz 4 185 A 305 A 545 A max Spitzenstromdauer 8 not limited 60 s Anschlussleistung Zwischenkreisklemmen max 160 kW max 360 kW Ballaststrom zulässig Î max 236 A max 300 A Ballastwiderstand extern 5 3 33 2 6 Ballasteinschaltschwelle Û 11 780 V Ballastspitzenleistung 120 kW 183...

Page 94: ...utput current BM4755 Power supply voltage V Output current Derating of output current BM4766 Power supply voltage V Output current Derating of output current BM4773 Power supply voltage V Figure 44 Derating the output current BM47XX continuous current units 7 The input current must be reduced between 40 C and 55 C See correction factors at changed operating conditions ZEnvironmental temperature on...

Page 95: ...keyword export restriction The range of the output frequency is defined as follows PWM frequency Current controller cycle time Range of the output frequency 2 kHz 250 µs 0 225 Hz 4 kHz 8 kHz 125 µs 0 450 Hz The controller allows the device to generate output voltages with frequencies between fmax and 599 Hz However the quality of this volt ages cannot be guaranteed Typical the devices are marked w...

Page 96: ... A 15 0 A 15 0 A Rated output current 1 4 5 6 9 IAC at 8 kHz 3 6 0 A 8 8 A 12 0 A 12 0 A Output peak current 1 4 6 7 9 IAC at 4 kHz 3 15 0 A 22 0 A 30 0 A 40 0 A Output peak current 1 4 6 7 9 IAC at 8 kHz 3 12 0 A 17 6 A 24 0 A 32 0 A Max peak current period 7 60 s 1 s Power loss referring to power input 83 W 122 W 166 W Power input referring to control voltage max 63 W Current of the integrated b...

Page 97: ...ge of the PWM i e without overmodulation The quality of the generated output voltages depends on the ratio between output frequency and current controller frequency fI R fI R 1 cycle time current controller The maximum output frequency fmax generated with high quality is calculated as follows fmax fI R Kpf typical KPf 18 Furthermore the controller sets an upper limit for the output frequency of 59...

Page 98: ...0 A 60 0 A Rated output current 1 4 5 6 9 IAC at 8 kHz 3 18 0 A 24 0 A 36 0 A 48 0 A Output peak current 1 4 6 7 9 IAC at 4 kHz 3 45 0 A 60 0 A 90 0 A 90 0 A Output peak current 1 4 6 7 9 IAC at 8 kHz 3 36 0 A 48 0 A 72 0 A 72 0 A Max peak current period 7 60 s Power loss referring to the power input 250 W 318 W 490 W 685 W Power input referring to the control voltage max 88 W Current of the integ...

Page 99: ...ge of the PWM i e without overmodulation The quality of the generated output voltages depends on the ratio between output frequency and current controller frequency fI R fI R 1 cycle time current controller The maximum output frequency fmax generated with high quality is calculated as follows fmax fI R Kpf typical KPf 18 Furthermore the controller sets an upper limit for the output frequency of 59...

Page 100: ...od 7 60 s Power loss referring to the power input 800 W 1000 W 1300 W 1400 W Power input referring to the control voltage max 75 W Power input of the device fan referring to 230 VAC 8 87 W Current of the integrated brake control max 8 0 A 11 Cooling air requirement power heat sinks 260 m h 210 m h Cooling air requirement internal space 60 m h 1 All rated values refer to a DC link voltage of 540 VD...

Page 101: ...epends on the ratio between output frequency and current controller frequency fI R fI R 1 cycle time current controller The maximum output frequency fmax generated with high quality is calculated as follows fmax fI R Kpf typical KPf 18 Furthermore the controller sets an upper limit for the output frequency of 599 Hz please contact the responsible Baumüller sales de partment keyword export restrict...

Page 102: ...5 610 IAC at 8 kHz 3 96 A 116 A 150 A Output peak current 1 4 5 7 10 IAC at 4 kHz 3 180 A 195 A 260 A Output peak current 1 4 5 7 10 IAC at 8 kHz 3 144 A 150 A 185 A Max peak current period 7 60 s Power loss referring to the power input 1470 W 1860 W 2690 W Power input referring to the control voltage max 75 W Power input of the device fan referring to 230 VAC 8 190 W Current of the integrated bra...

Page 103: ... of the PWM i e without overmodulation The quality of the generated output voltages depends on the ratio between output frequency and current controller frequency fI R fI R 1 cycle time current controller The maximum output frequency fmax generated with high quality is calculated as follows fmax fI R Kpf typical KPf 18 Furthermore the controller sets an upper limit for the output frequency of 599 ...

Page 104: ... 1 4 5 7 11 IAC at 8 kHz 3 260 A 312 A Max peak current period 7 60 s Power loss referring to the power input 3230 W 3920 W Power input referring to the control voltage max 80 W Power input of the device fan referring to 230 VAC 8 174 W Current of the integrated brake control max 8 0 A 9 Cooling air requirement power heat sinks 400 m h Cooling air requirement device internal space 200 m h 1 All ra...

Page 105: ...t controller The maximum output frequency fmax generated with high quality is calculated as follows fmax fI R Kpf typical KPf 18 Furthermore the controller sets an upper limit for the output frequency of 599 Hz please contact the responsible Baumüller sales de partment keyword export restriction The range of the output frequency is defined as follows PWM frequency Current controller cycle time Ran...

Page 106: ...ak power PSmax 3 Brake continuous power PDmax 2 3 Constants for calculation C1 C2 C3 BM4434 ZIX FIX XXXXXR16 BM4435 ZIX FIX XXXXXR16 BM4632 ZIX FIX XXXXXR16 16 49 A 20 mm 38 kW 2 kW 0 139 K W 0 05081 K Ws 6 7751 s 1 BM4444 ZIX FIX XXXXXR10 BM4445 ZIX FIX XXXXXR10 BM4446 ZIX FIX XXXXXR10 BM4641 ZIX FIX XXXXXR10 BM4642 ZIX FIX XXXXXR10 10 78 A 35 mm 61 kW 1 5 kW 0 200 K W 0 01605 K Ws 0 9169 s 1 BM4...

Page 107: ...above the devices Do not install cables or cable channels above the de vices At the devices BM443X and BM444X do not install the connection cables directly above the mounting plate of the device where the hot air rises When dimensioning consider that 10 of brake resistor power is not dissipated via the cooling water but is an additional power loss which heats the cabinet Provide an ade quate fresh...

Page 108: ... cycle PDmax Maximum continuous brake power see ZTechnical data brake resistors on page 106 n Number of brake operations within one cycle PS_1 to PS_n Brake peak power numbered in chronological order ton_1 to ton_n Brake time periods toff_1 to toff_n Off time periods between the brake time periods Tcycle total cycle C1 C2 C3 Constants see ZTechnical data brake resistors on page 106 brake on_1 off_...

Page 109: ...if Ps_n PSmax and T 0 K T 20 K Increase T0 e g 10 K followed by the recalculation of all values e g 10 K followed by the recalculation of all values Decrease T0 PS_n PSmax ton_n 1 s Start End ton_1 ton_n 1 s The internal brake resistor cannot be used for this application 0 T 20 K Tcycle ton_n toff_n 1 n 1 n PD 1 2 Ps_1 ton_1 Ps_n ton_n Tcycle TM PD C1 T0 PD C1 T1 T0 C2 Ps_1 ton_1 T2 T1 TM e C 3 t ...

Page 110: ... kW ton_1 0 15 s 1 s toff_1 1 11 s PS_2 13 kW 61 kW ton_2 0 15 s 1 s toff_2 1 79 s PS_3 20 kW 61 kW ton_3 0 15 s 1 s toff_3 6 85 s PS_4 23 kW 61 kW ton_4 0 15 s 1 s toff_4 1 85 s PS_5 24 kW 61 kW ton_5 0 15 s 1 s toff_5 5 65 s Tcycle 5 0 15s 1 11s 1 79s 6 85s 1 85s 5 65s 18 s PD 0 417 kW 417 W PDmax 1 5 kW internal brake resistor can be used TM P0 C1 417 W 0 2 K W 83 4 K Start value T0 P0 C1 417 W...

Page 111: ...C3 toff_2 TM C2 Ps_3 ton_3 132 06K 83 4K e 0 9169s 1 1 79s 83 4K 0 01605K Ws 20000W 0 15s T4 T3 TM e C3 toff_3 TM C2 Ps_4 ton_4 140 92K 83 4K e 0 9169s 1 6 85s 83 4K 0 01605K Ws 23000W 0 15s T4 TM e C3 toff_4 TM C2 Ps_5 ton_5 138 81K 83 4K e 0 9169s 1 1 85s 83 4K 0 01605K Ws 24000W 0 15s T5 TM e C3 toff_5 TM 151 29K 83 4K e 0 9169s 1 5 65s 83 4K 151 29K 83 4K e 0 9169s 1 5 65s 83 4K The internal b...

Page 112: ...ed control operations without positioning n Standstill operations if current is required to keep a torque a force n At operations if it is likely that the mechanics block for example when starting cold ex truders The following operations are not affected n Typical positioning operations n Operating motors which use an operating brake at standstill n Operations where the higher level control has a ...

Page 113: ... kHz Figure 53 Reduction BM46XX max current and PWM frequency at output frequencies 10 Hz The maximum current of the drive must be limited more severely at output frequencies below 10 Hz if no PWM frequency reduction is possible Figure 54 Reduction BM46XX only max current at output frequencies 10 Hz 10 Hz 75 100 0 4000_0753_rev01_int Output peak current Automatical reduction of the PWM frequency t...

Page 114: ...rd devices Ixt types Device identification PT1 model Integration model Size 1 BM441X BM4412 BM4413 BM4414 Size 2 BM442X BM4420 BM4421 BM4422 BM4423 BM4424 BM4425 BM4426 Size 3 BM443X BM4432 BM4433 BM4434 BM4435 Size 4 BM444X BM4442 BM4443 BM4444 BM4445 BM4446 Size 5 BM445X BM4452 BM4453 BM4454 Size 6 BM446X BM4462 BM4463 BM4465 BM4466 BM4464 Size 7 BM447X BM4473 BM4472 Special devices Ixt types De...

Page 115: ...ted current of the devices reach from 2 5 A to 720 A The devices differ in size pow er equipment hard and software and cooling types for further information refer to ZType code from page 126 Power unit Controller part standard controller or ES controller Design cover only standard controller BM4XXX XXX XX1XX BM4XXX XXX XX2XX BM4XXX XXX XX3XX Standard controller BM4XXX XXX XX4XX BM4XXX XXX XX5XX ES...

Page 116: ...cations Characteristic for these devices is that the peak current is twice as large as the rated current even at large output currents The devices were de veloped for a cycle which could provide the peak current for 1 25 s at a whole cycle du ration of 5 s according to ZFigure 29 on page 59 This units are not developed for peak current using at standstill or output frequencies low er than 10 Hz Fo...

Page 117: ...the controller functionality with function and option modules e g encoder modules analog inputs outputs or field bus connec tions m ES controller with not exchangeable function and option modules NOTE Only the controller part without function option modules is described in this Instruc tion handbook A corresponding instruction handbook is available for each function option module see ZList of othe...

Page 118: ... This controller unit is available only in the BM441X XXX X0XXX 2 rowed This version is a 2 row equipped controller unit in a 3 rowed installation space Controller interface RS232 or Ethernet This controller unit is available for every BM4000 except for the BM441X XXX X0XXX and BM441X XXX X1XXX This version is a 2 row equipped controller unit in a 2 rowed instal lation space Controller interface R...

Page 119: ...e slots Slot D can initiate an interrupt Therewith slot D is particularly suitable for measur ing modules Optional modules can not be inserted into these slots B C D E F Controller module not exchangeable with RS232 or Ethernet interface 2 and 3 rowed G The controller communicates via the BACI bus with plug in modules in these slots Function modules can not be inserted into these slots H 3 rowed J...

Page 120: ...pen master BM4 O ECT 01 EtherCAT slave for PLC BM4 O ECT 02 Ethernet EtherCAT master BM4 O ECT 03 Ethernet EtherCAT cluster A X o o o o o B X o o o X o C o o o V o D o X X X E X X o o F Controller unit G o o o o o o o X X X X X X X H X X X X X X X o o o o o o J P P o o o o K P P o o o o o o o L P P o o o o o o o M P P o o o o o o o Steckkarten_Rev20_e X o P V preferred slot Baumüller Nürnberg GmbH...

Page 121: ...amaged In case another BM4X X XXX plug in module is plugged in an unsuitable slot it will not operate We have made sure that neither the module nor the device are dam aged narrow In this type up to 5 additional function option modules can be installed Controller interface RS232 or Ethernet This controller unit is available only in the BM441X XXX X1XXX wide In this type up to 5 additional function ...

Page 122: ... encoder emulation BM4 F SIE XX SSI encoder emulation BM4 O ECT 01 EtherCAT slave for controller BM4 O PLK 01 POWERLINK Controlled Node for controller BM4 O VAR 01 VARAN slave for controller BM4 O SER XX Sercos slave for controller BM4 O PRO XX Profibus slave for controller BM4 O CAN 03 CANopen slave for controller BM4 O EIP 01 Ethernet IP for controller BM4 O PLC XX SPS A X o o o o B X o o o X C ...

Page 123: ...egmann SRM50 60 BM4 F ENC 12 Sine cosine encoder module with Hiperface inter face without termination in communication Sine cosine encoder singleturn Stegmann SCS60 70 Stegmann SRS50 60 Sine cosine encoder multiturn Stegmann SCM50 60 Stegmann SRM50 60 BM4 F ENC 03 5V square wave incremental encoder module 5 V square wave incremental encoder RS422 output signals TTL Heidenhain ROD 426 SickSteg mann...

Page 124: ...x mode The prerequisites are n A waiting time of 6 s must be observed before the drive can be enabled pulse enable enabling the torque n The total DC link capacity of all connected devices must be lower than 20 mF BM4 F ENC 17 Sine cosine encoder module with SSI interface and 5 V power supply 5 V sine cosine encoder output sig nals 1Vss Baumer Hüb ner MHGA400 BM4 F ENC 27 Encoder module with SSI i...

Page 125: ...eration Instruction handbook b maXX BM4400 BM4600 BM4700 Document No 5 12008 07 125 of 358 4 4 4 Type plate On the type plate you will find besides others the type code of the device Figure 55 Position of type plate ...

Page 126: ...ousing 1 to 7 from housing size 1 there are two different wide versions BM4XXX XXX XXXXX Ryy XXXXXXXX XXX XX Current grading output rated current 0 to 6 current value is dependent on the size of housing BM4XXX XXX XXXXX Ryy XXXXXXXX XXX XX Cooling type S A Z F C air cooled with air supply and with air outlet in the control cabinet air cooled with air supply and air outlet outside the control cabin...

Page 127: ...without brake resistor transistor UDC 540 V Mains inverter and active mains inverter without brake resistor transistor UDC 540 V short model for BM465X BM466X BM475X and BM476X BM4XXX XXX XXXXX Ryy XXXXXXXX XXX XX Type of controller box 0 1 2 No modules can be plugged 1 row Modules in slots A to H pluggable standard controller or ES controller 2 rows Modules in slots A to M pluggable standard cont...

Page 128: ...igital IO 4 x IN 4 x OUT see Analog IO 2 x IN 2 x OUT 16 bit see Analog IO 2 x IN 2 x OUT 12 bit see Analog I O 2x In 16Bit 4 20mA 2x Out 16Bit Square wave encoder emulation see Square wave encoder emulation see SSI encoder emulation see Digital I O without PE connection 4x IN 4x OUT Fast digital I O without PE connection 4x IN 4x OUT see SSI encoder with 24 V see BM4 F ENC 21 BM4 F ENC 02 BM4 F E...

Page 129: ...ing right EtherCAT for controller SoE special 16 bit RFG EtherCAT for controller CoE standard EtherCAT for controller SoE standard VARAN slave see POWERLINK controlled node see BM4 O SER XX BM4 O PRO XX BM4 O CAN XX BM4 O PLC XX BM4 O ETH XX BM4 O VAR XX BM4 O PLK XX BM4XXX XXX XXXXX Ryy XXXXXXX XXX XX Safety functionality option S01 Safety function STO BM4XXX XXX XXXXX Ryy XXXXXXX XXX XX Software...

Page 130: ...nberg GmbH 130 of 358 4 5 4 5 2 Explanation version code The version code is added on the type code NOTE Only version codes necessary for the user are explained XXXX X XXX XXX Design version power unit 3004 from 3006 BM443X generation 1 BM443X generation 2 XXXX X XXX XXX Design version controller ...

Page 131: ...erature 60 C n Maximum water pressure 3 bar 300 kPa in the cooling circuit m ZRequired environmental conditions on page 55 n Use the device only in a pollution degree 2 environment n Observe the maximum environmental temperature and the derating m ZRequirements to the energy supply supply system on page 52 n Observe the short circuit current capability The device is rated for a maximum Short Circu...

Page 132: ...Both upper LEDs UH1 and UH2 are reserved The four lower LEDs H1 to H4 show information about the operating status and are also displayed in the operating software ZStandard controller on page 196 shows the position of the display elements m ES controller BM4XXX XXX XX4XX and BM4XXX XXX XX5XX On the front side of the device there are 6 LEDs Both upper LEDs UH1 and UH2 are reserved The four lower LE...

Page 133: ...LED H1 shows only the torque direction it cannot be used to show the direction of rotation green orange flashing green orange green with short orange flashing or orange with short green flashing Pulse enable The motor is supplied by the power unit Power ON the device is ready to operate In case the LED lights up orange colored during opera tion maybe the pulse enable is missing or the quickstop wa...

Page 134: ... reached m adapt your threshold or set no reaction red continuously Error m Identify and then remove the error with help of the operating program ProDrive or the 7 segment display For further information see ZTroubleshooting and fault correction from page 229 red flashing Warning m Identify the warning with help of the operating program ProDrive Warning messages do not affect the operation of the ...

Page 135: ... and warnings are not dis played see ZFault detection from page 234 Display Status Meaning 0 Not ready to start Initialization phase pulses inhibited 1 Inhibit start Pulses inhibited initialization completed error free 2 Ready to start Pulses inhibited 3 Switched on Pulses for field generation at asynchronous machines enabled no torque generation yet 4 Operation enabled Pulses enabled drive functi...

Page 136: ...ddress S1 to S4 The IP address of the controller consists of 32 bits or 4 bytes e g 192 168 125 203 Both of the first bytes are set with the base address 192 168 at the factory Both of the last bytes are set by means of the address switches S1 S2 S3 and S4 In the process S1 and S2 as well as S3 and S4 each represent an 8 bit value The IP address 192 168 0 0 is not permitted or respectively is rese...

Page 137: ...Design and Operation Instruction handbook b maXX BM4400 BM4600 BM4700 Document No 5 12008 07 137 of 358 4 ...

Page 138: ...Display and operation elements Instruction handbook b maXX BM4400 BM4600 BM4700 Document No 5 12008 07 Baumüller Nürnberg GmbH 138 of 358 4 7 Figure 56 EtherCAT Address switch setting ...

Page 139: ...on handbook b maXX BM4400 BM4600 BM4700 Document No 5 12008 07 139 of 358 4 CANopen Type code ES controller with CANopen BM4XXX XXX XXXXX Ryy 2X with CANopen interface Baud rate S2 20 kBit s 125 kBit s 250 kBit s 500 kBit s 1 MBit s ...

Page 140: ...Display and operation elements Instruction handbook b maXX BM4400 BM4600 BM4700 Document No 5 12008 07 Baumüller Nürnberg GmbH 140 of 358 4 7 Address S3 S4 Figure 57 CANopen address switch ...

Page 141: ...25 C up to 70 C m Vibration shock continuous shock class 2 M 1 as in 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...

Page 142: ...act the responsible 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 inco...

Page 143: ...d 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 and preve...

Page 144: ...al damage 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...

Page 145: ...e is lifted with unprotected hands during mounting palms or fingers can be cut If the device falls feet could be injured Figure 58 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 146: ...ductive 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 ...

Page 147: ... the control cabinet see ZDimensions from page 31 Tolerance specifications Drill hole dimensioning 0 2 mm Dimensioning openings 1 0 mm Relative tolerance of discretionary divisions 0 1 mm 6 2 1 1 Drilling patterns BM441X Figure 59 Drilling pattern BM441X NOTE Consider the minimum clearances for cooling when making the drill holes All dimensions in millimeters mm Further notes see ZDimensions from ...

Page 148: ...andbook b maXX BM4400 BM4600 BM4700 Document No 5 12008 07 Baumüller Nürnberg GmbH 148 of 358 6 2 6 2 1 2 Drilling patterns BM442X Figure 60 Drilling pattern BM442X 6 2 1 3 Drilling patterns BM4X3X Figure 61 Drilling pattern BM443X BM463X ...

Page 149: ...Mounting Instruction handbook b maXX BM4400 BM4600 BM4700 Document No 5 12008 07 149 of 358 6 6 2 1 4 Drilling patterns BM4X4X Figure 62 Drilling pattern BM444X BM464X ...

Page 150: ...andbook b maXX BM4400 BM4600 BM4700 Document No 5 12008 07 Baumüller Nürnberg GmbH 150 of 358 6 2 6 2 1 5 Drilling patterns BM4X5X Figure 63 Drilling pattern BM445X BM465X Hole Figure 64 Drilling pattern BM465X FXX 3XXXX BM475X FXX 3XXXX ...

Page 151: ...Mounting Instruction handbook b maXX BM4400 BM4600 BM4700 Document No 5 12008 07 151 of 358 6 6 2 1 6 Drilling patterns BM4X6X Figure 65 Drilling pattern BM446X BM466X ...

Page 152: ...Preparing for mounting Instruction handbook b maXX BM4400 BM4600 BM4700 Document No 5 12008 07 Baumüller Nürnberg GmbH 152 of 358 6 2 Figure 66 Drilling pattern BM466X FXX 3XXXX BM4766 FXX 3XXXX ...

Page 153: ...Mounting Instruction handbook b maXX BM4400 BM4600 BM4700 Document No 5 12008 07 153 of 358 6 6 2 1 7 Drilling patterns BM4X7X Figure 67 Drilling pattern BM447X F BM477X F ...

Page 154: ...Preparing for mounting Instruction handbook b maXX BM4400 BM4600 BM4700 Document No 5 12008 07 Baumüller Nürnberg GmbH 154 of 358 6 2 Figure 68 Drilling pattern BM447X A ...

Page 155: ...59 The screws and washers required for mounting are listed beneath the respective graphic Carry out mounting as follows 1 Provide suitable transport lifting equipment as needed 2 Keep suitable fastening components readily available 3 For cold plate devices n check the surface quality of device s rear panel mounting plate refer to ZRequire ments mounting plate for cold plate on page 162 4 Mount the...

Page 156: ...Figure 69 Mounting instruction BM441X BM442X S BM4X3X S Z BM444X S Z BM464X S Z Device BM441X XXX XO X1 BM441X XXX X2 BM442X S BM443X S Z BM463X Z BM444X S Z BM464X Z A Screws 2 x M5 4 x M5 4 x M5 4 x M5 4 x M5 B Washers 2 x 5 3 x 10 4 x 5 3 x 10 4 x 5 3 x 10 4 x 5 3 x 10 4 x 5 3x15 c Mounting space c 5 mm c 5 mm c 5 mm c 5 mm c 5 mm ...

Page 157: ...00 BM4700 Document No 5 12008 07 157 of 358 6 Figure 70 Mounting instruction BM445X S Z BM465X S Z BM446X S Z BM466X S Z Device BM445X S Z BM465X Z BM446X S Z BM466X Z A Screws 4x M8 4x M8 B Washers 4x 8 4x21 4x 8 4x21 C Mounting space c 7 mm c 7 mm ...

Page 158: ...nt No 5 12008 07 Baumüller Nürnberg GmbH 158 of 358 6 3 Figure 71 Mounting instruction BM447X A F BM477X FXX 3XXXX Device BM447X A BM447X F BM477X FXX 3XXXX A Screws 38 x M6 22 x M6 B Spring washers 38 x DIN6796 6 FST 22 x DIN6796 6 FST C Washers 38 x 6 4 x 12 5 22 x 6 4 x 12 5 ...

Page 159: ...X A F Z C BM443X A F C BM463X F BM444X A F BM464X F BM445X A F BM465X F BM446X A F BM466X F A Screws 4 x M5 14 x M4 16 x M5 16 x M8 20 x M8 B Washers 4 x 5 3 x 10 14 x 4 3 x 9 16 x 5 3 x 15 16 x 8 4x21 20 x 8 4x21 Device BM465X FXX 3XXXX BM475X FXX 3XXXX BM466X FXX 3XXXX BM476X FXX 3XXXX A Screws 18x M6 18 x M8 B Washers 18 x 6 4x17 18 x 8 4x21 ...

Page 160: ...ss for water cooled through hole devices IP54 WARNING Danger because of conductive fluid in connection with electricity 1 The mounting drills are outside of the gasket With non waterproof fastening holes e g the liquid coolant can ingress into the control cabinet m Seal the mountings against water Use e g waterproof draw in bolts and sealants between screws and bolts NOTE The following required co...

Page 161: ...Mounting Instruction handbook b maXX BM4400 BM4600 BM4700 Document No 5 12008 07 161 of 358 6 Figure 73 Control cabinet mounting BM442X A F ...

Page 162: ...ounting plate For this reason while handle the units protect the sensitive function surface to avoid dam age 6 3 2 Connecting the water cooler With water cooled devices BM44XX F BM46XX F BM47XX F and BM44XX Z BM46XX Z BM47XX Z you connect the coolant circulation before electric installation The water cooler has on its bottom side two pressfitting transition pieces 15 mm x R 1 2 AG for flat seals h...

Page 163: ... be performed by 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 activit...

Page 164: ...er situations or large damage of property Therefore m Only personnel from manufacturer or qualified personnel operate while installation and initial commissioning 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 ...

Page 165: ...are connected to the DC link the DC link discharge can take a much longer time In this case the necessary waiting period must be deter mined 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 warn ing symbol on a clearly visible location of the control cabinet DANGER Risk of fatal injury from electrical curre...

Page 166: ...lead to malfunctioning of the device If the power supply deviates too much from the requirements the device can be destroyed The devices may only be operated in industrial networks The destruction of the device can cause personal injury DANGER Risk of fatal injury from electrical current If the requirements for the power supply are not complied the device can be dam aged or destroyed thereby great...

Page 167: ...ructions at special power supply systems Note Not valid for b maXX power modules n Single phase connection BM441X Figure 74 Single phase connection BM441X n Connection to single phase grounded power supply systems BM442X for IT systems BM443X BM447X right wrong Figure 75 Single phase connection BM442X BM447X basic units ...

Page 168: ...to account IEC EN 60204 1 Chapter 13 when selecting the cable h The protective ground cross section of the cable must be compliant with IEC EN 60204 1 Section 5 2 Tab 1 h A fixed connection for the protective ground conductor is mandatorily specified for op eration of the device h Use copper cable approved for a minimum of 60 C drives 3 x 100 A or 75 C drives 3 x 100 A if comply with UL 508C For f...

Page 169: ...RCD of the type B is permitted on the power supply side of the device m Otherwise a different protective measure must be utilized such as separation from the surroundings by means of double or enhanced isolation or separation from the power supply system by means of an isolating transformer for example NOTE The emission of radio frequency interference RFI is to a great extent dependent on the wiri...

Page 170: ...e grounded mounting plate smallest possible effective aerial height m When routing in parallel maintain a minimum clearance of 20 cm between signal and control cables vis à vis the power cables m Cross cables with different EMC categories signal cables supply cables or motor ca bles only in a 90 angle m Contact the major cable shield when laying cables through walls which separate dif ferent EMC a...

Page 171: ...er modules 4 Connect the power choke L1 at the mains filter output not necessary for BM441X BM442X except BM4426 and for power modules 5 Connect the device via the power supply terminals 1U1 1V1 and 1W1 to the power choke output not necessary for power modules 6 Connect the protective conductor to the terminal PE a fixed ground conductor con nection is mandatorily specified 7 Connect 24 V power su...

Page 172: ...rminals X3 4 X3 3 12 Perhaps connect dependent on the application not necessary for power modules a brake resistor RB via terminals Ba Ba 13 Connect the brake of the motor option Terminals X101 1 2 and X101 3 4 14 Connect the safety relay if existing via X102 3 and X102 4 as well as X103 3 and X103 4 connection data safety relay also see ZC 5 Technical data safety relay mod ule on page 350 NOTE Pl...

Page 173: ...X101 3 X101 4 X101 5 X101 6 9 15 3 M R S3 X1 L1 L2 S1 S2 X1 A PE V U W X36 L X36 N B M 24 V X102 2 X103 2 X100 2 X100 3 X100 4 X100 5 X100 6 1U2 1V2 1W2 PE BM4 ENC XX 24 V 24 V 24 V M 24 V M 24 V PC ProDrive SUB D 1 1 1U1 1V1 1W1 PE ENC X100 1 Ba 1C1 1D1 Ba X102 3 X103 3 X102 4 X103 4 X102 1 X103 1 24 V 230 V M 24 V M 24 V 24 V 24 V Motor temperature bra Mains bus Ballast bus Figure 77 Connection ...

Page 174: ...SELV PELV on page 194 or if you consider UL508C and the current of the brake is greater 4 A Perhaps consider a limited operating voltage range of the brake because of the internal voltage drop up to max 2 6 V HINWEIS If the motor brake is connected directly via X101 2 and X101 3 see ZFigure 77 on page 173 the shown direct installation is allowed only It is not allowed within a multi axis installat...

Page 175: ...X101 1 X101 3 X101 4 X101 5 X101 6 9 15 4000_0568_rev03_int cdr 3 M X1 L1 L2 S1 S2 X1 A PE V U W X36 L X36 N M 24 V X102 2 X103 2 X100 2 X100 3 X100 4 X100 5 X100 6 1U2 1V2 1W2 PE BM4 ENC XX 24 V 24 V 24 V M 24 V M 24 V PC ProDrive SUB D 1 1 1U1 1V1 1W1 PE ENC X100 1 Ba 1C1 1D1 Ba X102 3 X103 3 X102 4 X103 4 X102 1 X103 1 230 V M 24 V M 24 V 24 V 24 V 24 V R S3 B Motor temperature bra Brake voltag...

Page 176: ... 15 3 M X1 S2 X1 A X36 L X36 N M 24 V X102 2 X103 2 X100 2 X100 3 X100 4 X100 5 X100 6 1U2 1V2 1W2 PE BM4 ENC XX 24 V 24 V 24 V M 24 V M 24 V PC ProDrive SUB D 1 1 ENC X100 1 X102 3 X103 3 X102 4 X103 4 X102 1 X103 1 24 V 230 V M 24 V M 24 V 24 V 24 V PE PE Motor temperature bra UDC link Connection to other BM41XX or BM44XX units 1C1 1D1 U R S3 B Ba 1C1 1D1 Ba S4 Mains bus Ballast bus Figure 79 Co...

Page 177: ...age 194 or if you consider UL508C and the current of the brake is greater 4 A Perhaps consider a limited operating voltage range of the brake because of the internal voltage drop up to max 2 6 V NOTE If the motor brake is connected directly via X101 2 and X101 3 see ZFigure 77 on page 173 the shown direct installation is allowed only It is not allowed within a multi axis installation e g to connec...

Page 178: ... X101 1 X101 3 X101 4 X101 5 X101 6 9 15 4000_0613_rev01_int cdr 3 M X1 S2 X1 A PE X36 L X36 N M 24 V X102 2 X103 2 X100 2 X100 3 X100 4 X100 5 X100 6 1U2 1V2 1W2 PE BM4 ENC XX 24 V 24 V 24 V M 24 V M 24 V PC ProDrive SUB D 1 1 PE ENC X100 1 X102 3 X103 3 X102 4 X103 4 X102 1 X103 1 230 V M 24 V M 24 V 24 V 24 V 24 V Motor temperature bra Brake voltage UDC link Connection to other BM41XX or BM44XX...

Page 179: ...ure 82 on page 181 and the following S1 Fuse cable device see ZFuses from page 273 S2 Fuse fan S3 Fuses brake resistor circuit required for BM447X BM477X see ZFuses BM447X on page 292 S4 DC link fuse L1 Power choke not necessary for BM441X and BM442X except BM4426 L2 Mains filter X1 Serial interface RS 232 see ZFigure 91 on page 196 X3 Connections for ready for use quick stop pulse enable see ZFig...

Page 180: ...ZX103 0ption Safety relay on page 194 A X1 Encoder module see documentation 5 01042 SELV PELV ENC Encoder BRA Brake PE 1W2 Connections for motor see ZFigure 82 on page 181 and the following NOTE When having a switched off safety relay it is not possible to use the brake at BM441X and BM442X NOTE The characterization 1C1 and 1D1 is from the standard DIN EN 60445 1C1 is the connection to the positiv...

Page 181: ...tallation Instruction handbook b maXX BM4400 BM4600 BM4700 Document No 5 12008 07 181 of 358 7 7 10 2 1 Terminals BM4412 BM4413 Figure 82 Electrical connections for power supply motor for BM4412 and BM4413 ...

Page 182: ...agrams Instruction handbook b maXX BM4400 BM4600 BM4700 Document No 5 12008 07 Baumüller Nürnberg GmbH 182 of 358 7 10 7 10 2 2 Terminals BM4414 Figure 83 Electrical connections for power supply motor for BM4414 ...

Page 183: ...ction handbook b maXX BM4400 BM4600 BM4700 Document No 5 12008 07 183 of 358 7 7 10 2 3 Terminals BM442X Do not apply terminals when using a power module Figure 84 Electrical connections for power supply motor for BM442X ...

Page 184: ...XX BM4400 BM4600 BM4700 Document No 5 12008 07 Baumüller Nürnberg GmbH 184 of 358 7 10 7 10 2 4 Terminals BM443X BM463X Do not apply terminals when using a power module Figure 85 Electrical connections for power supply motor for BM443X BM463X ...

Page 185: ...X BM4400 BM4600 BM4700 Document No 5 12008 07 185 of 358 7 7 10 2 5 Terminals BM444X BM464X Do not apply terminals when using a power module only BM444X S A BM464X S A Figure 86 Electrical connections for power supply motor for BM444X BM464X ...

Page 186: ... Terminals BM445X BM446X BM465X BM466X Do not apply terminals when using a power module only BM445X S A BM465X S A and BM446X S A BM466X S A Figure 87 Electrical connections for power supply motor for BM445X BM465X BM446X BM466X NOTE The brake resistor is connected at BM445X and BM446X between Ba and 1C1 Also see ZFigure 77 on page 173 ...

Page 187: ...tallation Instruction handbook b maXX BM4400 BM4600 BM4700 Document No 5 12008 07 187 of 358 7 7 10 2 7 Terminals BM466X BM476X Figure 88 Electrical connections for power supply motor for BM466X and BM476X ...

Page 188: ...agrams Instruction handbook b maXX BM4400 BM4600 BM4700 Document No 5 12008 07 Baumüller Nürnberg GmbH 188 of 358 7 10 7 10 2 8 Terminals BM4755 Figure 89 Electrical connections for power supply motor for BM4755 ...

Page 189: ...on Instruction handbook b maXX BM4400 BM4600 BM4700 Document No 5 12008 07 189 of 358 7 7 10 2 9 Terminals BM447X BM4773 only BM447X A Figure 90 Electrical connections for power supply motor for BM447X and BM4773 ...

Page 190: ...rent Therefore After attaching all power cables to the device BM447X and BM477X screw on the cover careful to all screwing points by using the enclosed screws 6xM4x12 and washers The cover only must be able to be removed from the device with use of tools The use of semiconductor fuses is obligatory at the power supply connection of BM447X BM477X devices Semiconductor fuses are required in the brak...

Page 191: ... 185 mm2 Also see ZCables power supply device from page 268 3 One cable of the mentioned cross section is sufficient for the operation 4 See also ZExplanation type code on page 126 Power system 1U1 1V1 1W1 PE Max cross section of connection Connection technology Torque Load capacity BM441X 2 5 mm2 Plug in contact see ZFuses from page 273 not valid for power modules BM442X 4 0 mm2 Screw terminal mi...

Page 192: ...f 358 7 10 1 Not short circuit proof consider maximum load See Brake resistor external in chapter ZTechnical Data from page 31 2 Not short circuit proof consider maximum load See connected load DC link in chapter ZTechnical Data from page 31 3 See permitted brake resistor continuous power in chapter ZTechnical Data from page 31 4 The cable lug may be 25 mm wide at most The maximum cable diameter i...

Page 193: ... the cable lug which you use can safely clamp a stronger cable than 95 mm2 you may also use stronger cables than 95 mm2 Also see ZCables power supply device from page 268 2 The cable lug may be 35 mm wide at most The maximum cable diameter is dependent on the cable lug In case the cable lug which you use can safely clamp a stronger cable than 185 mm2 you may also use stron ger cables than 185 mm2 ...

Page 194: ...act X101 1 bis X101 4 min 0 1 A max 1 0 A BM444X BM464X 1 5 mm2 Plug in contact X101 1 bis X101 4 min 0 1 A max 4 0 A BM445X BM446X BM447X BM465X BM466X BM47XX 1 5 mm2 Plug in contact X101 1 bis X101 4 min 0 1 A max 8 0 A if you consider UL508C max 4 0 A X102 option Safety relay Max cross section of connection Connection technology Load capacity voltage level SELV PELV 1 5 mm2 Plug in contact see ...

Page 195: ...nsider UL508C limit the current to 4 A 2 Do not apply voltage to the terminals X100 3 or X100 4 if the device is not supplied via X100 1 2 with voltage The signals mains on and brake resistor are internal digital control signals of the system b maXX 4000 They are used at applications with DC link connection 3 The PSI module may not be attached or withdrawn if the b maXX 4000 24 V pow er supply is ...

Page 196: ... 1 UH1 reserved UH2 reserved H1 green torque direction 1 yellow torque direction 2 H2 green enabling yellow Power ON H3 red current limit reached H4 red error X4 reserved X1 depends on controller type see ZPage 198 H5 7 segment display 4 also see ZDisplay and operation elements from page 132 X2 Connection for Baumüller memory module PSI 3 4 X3 1 Ready for use ON normally open contact SELV PELV X3 ...

Page 197: ...Address switch S1 S4 only ES controller from page 136 X1 depends on controller type see ZPage 198 X2 Connection for Baumüller memory module PSI 3 4 X3 1 Ready for use ON normally open contact SELV PELV X3 2 Ready for use ON change over SELV PELV X3 3 Reference for 4 and 5 SELV PELV X3 4 Quick stop SELV PELV X3 5 Pulse enable SELV PELV X3 6 Ready for use ON normally closed contact SELV PELV X4 1 An...

Page 198: ...y Remark LIYCY 6x2x0 14 mm2 D sub 9 pin available as cable set see ZCable RS232 on page 304 WARNING Risk of injury because of mechanical hazard If a PC is not connected via an isolated transformer the machine can do unexpected actions Therefore Connect the PC via an isolated transformer or use a battery operated PC e g lap top notebook without connecting a charger NOTE In case you don t use an opt...

Page 199: ...yy XX with Ethernet interface Ethernet cables are available as accessories see ZAccessories Ethernet EtherCAT on page 305 X1 1 TX 2 TX 3 RX 4 reserved 5 reserved 6 RX 7 reserved 8 reserved Name Meaning H11 off no activity yellow half duplex green full duplex H12 off no connection yellow 10 Mbit green 100 Mbit H11 H12 ...

Page 200: ...5 IN H51 H52 1 TX 2 TX 3 RX 4 reserved 5 reserved 6 RX 7 reserved 8 reserved X6 OUT H61 H62 1 TX 2 TX 3 RX 4 reserved 5 reserved 6 RX 7 reserved 8 reserved depends on ES controller type BM4XXX XXX XXXXX Ryy 1X with EtherCAT interface Max cross section of connection Connection technology Load capacity voltage level 1 5 mm2 Plug in contact Ready for use ON X3 1 X3 2 and X3 6 max 0 2 A Quick stop X3 ...

Page 201: ... on page 305 Name Meaning Flashing pattern H51 green X5 Link Act off no connection on connection flash data transmission H52 yellow ERROR on ERROR receiver error Phy1 Phy2 H61 green X6 Link Act off no connection on connection flash data transmission H62 yellow RUN off ERROR INIT 500 ms on 500 ms off PREOPERATIONAL 200 ms on 1 s off SAFEOPERATIONAL on OPERATIONAL ...

Page 202: ...nterface The LEDs have no function CAN cables are available see ZAccessories CANopen on page 306 X5 IN 1 CAN high 2 CAN low 3 Ground GND 4 reserved 5 reserved 6 not connected 7 Ground GND 8 not connected X6 OUT 1 CAN high 2 CAN low 3 Ground GND 4 reserved 5 reserved 6 reserved 7 Ground GND 8 reserved H51 H52 H61 H62 NOTE Setting the IP address see ZCANopen from page 139 ...

Page 203: ...cables from page 307 All encoders which comply to the following technical specifications may also be used NOTE For further information see Instruction Handbook Encoder modules 5 01042 Number of pole pairs The ratio between the number of motor pole pairs and of the number of pole pairs of the encoder must be integer 1 Permitted current input max 160 mA Excitation frequency 4 kHz Excitation current ...

Page 204: ...ed Number of pole pairs resolver 2 2 Requirements to the temperature sensor Type Additional requirements Insulation KTY84 SELV PELV NTC MSKL R 1K at Tprotection Imax 2mA SELV PELV Pin assignment Pin no Pin assignment D sub socket 15 pin 1 Resolver ref 2 Resolver ref 3 Reserved 4 Reserved 5 Resolver COS 6 Reserved 7 Resolver SIN 8 Resolver SIN 9 Resolver COS 10 Reserved 11 Reserved 12 Reserved 13 R...

Page 205: ...lation KTY84 SELV PELV NTC MSKL R 1 k at Tprotection Imax 2mA SELV PELV 2 Power supply 8 V DC Signal level Hiperface specification of operation data channel 1Vss REFSIN REFCOS 2 5V Permitted current input max 250 mA Pin assignment Pin no Pin assignment D sub socket 15 pin 1 GND encoder supply 2 8V encoder supply 3 Reserved 4 Reserved 5 COS 6 Reserved 7 SIN 8 SIN 9 COS 10 Temperature sensor 1 2 11 ...

Page 206: ...422 incremental encoder track B 6 Reserved 7 RS422 incremental encoder track A 8 RS422 incremental encoder track A 9 RS422 incremental encoder track B 10 Reserved 11 Reserved 12 Sense 5V encoder supply 13 Sense GND encoder supply 14 Reserved 15 Reserved do not assign Some encoders are listed in ZEncoder modules slot position A and B on page 123 pre assembled encoder cables see ZEncoder cables from...

Page 207: ...S A 9 SIN B 10 Reserved 11 Reserved 12 5 V Sense 13 0 V Sense 14 Reserved 15 Reserved do not assign Some encoders are listed in ZEncoder modules slot position A and B on page 123 pre assembled encoder cables see ZEncoder cables from page 307 All encoders which comply to the following technical specifications may also be used Power supply 8 V DC stabilized to 5 V at the encoder Signal level 1Vss Pe...

Page 208: ...ule is provided with a bidirectional synchronous serial En Dat interface via the position data and parameters with a data rate of max 2MBit s are exchanged between control electronics and encoder Some encoders are listed in ZEncoder modules slot position A and B on page 123 pre assembled encoder cables see ZEncoder cables from page 307 All encoders which comply to the following technical specifica...

Page 209: ... 15 CLK The encoder module is only provided with a bidirectional synchronous serial EnDat in terface via the position data and parameters with a data rate of max 8 MBit s are ex changed between control electronics and encoder Some encoders are listed in ZEncoder modules slot position A and B on page 123 All encoders which comply to the following technical specifications may also be used Power supp...

Page 210: ...OS A 9 SIN B 10 Clock 11 Clock 12 Reserved 13 A_GND 14 Data 15 Data do not assign The sine cosine encoder module is provided with a synchronous serial SSI standard in terface via the position data and parameters with a data rate of max 2 MBit s are ex changed between control electronics and encoder All encoders are listed in ZEncoder modules slot position A and B on page 123 can be used Power supp...

Page 211: ...Use the following materials m Cable LIYCY 5 x 2 x 0 14 2 x 0 5 mm Cu braiding with at least 85 opt overlap m D sub connector 15 pin male m Suitable encoder plug 2 Connect the cable shield with the cabinet of the circular connector and with the shield of the D sub connector Figure 92 Connection cable BM4 F ENC 07 ...

Page 212: ...0 Clock 11 Clock 12 5 V Sense 13 0 V Sense 14 Data 15 Data do not assign The sine cosine encoder module is provided with a synchronous serial SSI standard in terface via the position data and parameters with a data rate of max 2 MBit s are ex changed between control electronics and encoder All encoders are listed in ZEncoder modules slot position A and B on page 123 may be used Power supply 8 V DC...

Page 213: ...se the following materials m Cable LIYCY 5 x 2 x 0 14 2 x 0 5 mm Cu braiding with at least 85 opt overlap m D sub connector 15 pin male m Suitable encoder plug 2 Connect the cable shield with the cabinet of the circular connector and with the shield of the D sub connector Abbildung 93 Connection cable BM4 F ENC 17 ...

Page 214: ...ules slot posi tion A and B on page 123 may be used Power supply 24 V DC according encoder specification 0 5 V Signal level differential Permitted current input encoder max 200 mA Pin assignment encoder Pin no Pin assignment X2 D sub socket 9 pin 1 Data 2 Data 3 Reserved 4 Reserved 5 Reserved 6 24 V DC 7 0 V 8 Clock 9 Clock do not assign NOTE Only if the cable break monitoring is supported see Pro...

Page 215: ...t least 85 opt overlap m D sub connector 9 pin male m Suitable encoder plug circular connector 7 pin female 2 Connect the cable shield with the cabinet of the circular connector and with the shield of the D sub connector 1 6 7 8 9 2 3 4 5 1 2 3 4 5 6 1 2 8 9 6 7 0 5 mm 0 5 mm 1 4 2 5 3 7 6 Encoder plug e g Temposonics Plug view Figure 94 Connection cable BM4 F ENC 27 NOTE The connection cable is n...

Page 216: ... 0 V Sense 14 C 15 C do not assign To this encoder module you can connect sine cosine encoders with sinusoidal commuta tion Encoders are listed in ZEncoder modules slot position A and B on page 123 can be used Power supply 8 V DC stabilized to 5 V at the encoder Signal level Incremental encoder signals A and B 1Vss Commutation signals C and D 1Vss Permitted current input max 250 mA NOTE A broken w...

Page 217: ...se the following materials m Cable LIYCY 6 x 2 x 0 14 2 x 0 5 mm Cu braiding with at least 85 opt overlap m D sub connector 15 pin male m Suitable encoder plug 2 Connect the cable shield with the cabinet of the circular connector and with the shield of the D sub connector Abbildung 95 Connection cable BM4 F ENC 08 ...

Page 218: ... in slot E in standard controller The mod ule BM4 F AIO 02 03 or 04 can be plugged in slot D or E NOTE Choose position E in ProDrive for configuration of analog inputs outputs AIO 01 con nector X4 in ES controller Further information referring to analog inputs outputs see manual BM4 F AIO XX 5 01045 Pin assignment Pin No Pin assignment D sub male terminal 9 pin 1 IN 1 2 IN 2 3 OUT 1 OUT 2 4 OUT 1 ...

Page 219: ...bit Type Differenzeingang Input resistance ca 50 k ca 100 Max input current 200 µA 20 mA Min input current 4 mA Sampling rate inputs one input used 125 µs Sampling rate inputs both input used 250 µs Analog input voltage 10 V bis 10 V 2 V No of outputs 2 1 No of I O assignments output 2 Max output current 1 mA Resolution 8 bit 16 bit 12 bit 16 bit Update rate fast outputs 125 µs Update rate slow ou...

Page 220: ...osition D of ES controller The module BM4 F DIO FIO can be used in all slots of the standard controller but preferred should be slot D NOTE Further information referring to digital inputs outputs see manual BM4 F DIO FIO 5 01046 Pin assignment Pin No Pin assignment Multi pin connector 10 pin 1 IN 1 2 IN 2 3 IN 3 4 IN 4 5 OUT 1 6 OUT 2 7 OUT 3 8 OUT 4 9 24 V 10 M 24 V Max cross section of connectio...

Page 221: ... DIO 01 DIO 11 1 FIO 01 FIO 11 1 Power supply 24 V 19 to 28 V 3 Current consumption 24 V 2 0 A Current consumption internal max 50 mA No of inputs 4 Evaluation inputs edges 2 inputs can be used for writing on one parameter Number of I O linking groups input 4 Max input current 2 mA 5 mA Typical transit time delay input side 4 ms 10 µs Digital input voltage 0 LOW 0 to 5 V 1 HIGH 12 to 28 V Number o...

Page 222: ...Controller terminals Instruction handbook b maXX BM4400 BM4600 BM4700 Document No 5 12008 07 Baumüller Nürnberg GmbH 222 of 358 7 11 ...

Page 223: ...ng any work ensure that all coverings and protective devices are installed and are functioning properly m The control cabinet in which the device is installed should be protected against contact with electrically live parts Keep all doors of the control cabinet closed during operation NOTICE Environmental conditions that do not meet the requirements Environmental conditions that are non compliant ...

Page 224: ... In case of an error the service engineer can with the help of Pro Drive determine the error 8 2 1 Enable signals These signals must have a signal level of 24 V DC and must be connected to the termi nals X3 4 and X3 5 ZFigure 91 on page 196 Pulse enable During operation the signal pulse enable must constantly be available so that the de vice supplies power Additionally the pulse enable has to be g...

Page 225: ...n the thyristors a sawtooth shaped voltage with power supply frequency is generated This synchronous voltage is compared with a voltage decreasing from a start value to 0 V within ca 10 seconds If the current values of both voltages are equal a thyristor is turned on and current flows from power supply to the DC link capacitor The maximum chargeable total capacity is limited by the power rating of...

Page 226: ...from BM 4 4 3 X X X X XXXXX Ryy XXX XX xx 3006 X XXX XXX BM 4 4 4 X X X X XXXXX Ryy XXX XX xx 4006 X XXX XXX BM 4 4 5 X X X X XXXXX Ryy XXX XX xx 5004 X XXX XXX BM 4 4 6 X X X X XXXXX Ryy XXX XX xx 6004 X XXX XXX BM 4 4 7 X X X X XXXXX Ryy BM 4 6 3 2 X X X XXXXX Ryy BM 4 6 4 X X X X XXXXX Ryy BM 4 6 5 X X X X XXXXX Ryy BM 4 6 6 X X X X XXXXX Ryy BM 4 7 X X X X X XXXXX Ryy For technical status high...

Page 227: ...use an abrupt charging and a tripped fuse No charging is started at failure of one or two mains phases The external chargeable capacity is not limited because the height of the loading current of the DC link capacitor is approx constant But the time until the complete charge of the DC link is increased proportional to the capacity that has to be charged Error 089 pow er unit not ready to operate i...

Page 228: ...no other error The advantages of the current controlled charging are in short m The maximum chargeable DC link capacity is higher than without the current controlled charging m The dependency of the DC link capacity on the charging current is reduced The self protection level of the device against incorrect dimensioning is improved 8 3 6 Table of charging times Device Inductance power choke Intern...

Page 229: ... energized 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...

Page 230: ...ound X IS Overcurrent Overcurrent motor X IS DC link DC link overvoltage X IS DC link undervoltage relative X Overload monitoring Peak current not possible at the moment X Temperature heat sink Temperature threshold 1 X X P0018 Temperature shutdown threshold X IS P0019 Temperature internal space Temperature threshold 1 X X P0016 Temperature shutdown threshold X IS P0017 Temperature motor I2t thres...

Page 231: ...p up option modules Error at module initialization X X IS P0838 P0838 Cyclical set value trans mission to the optional modules Transmission timeout X X X 5 P0839 P0298 Safety relay Supply voltage is missing or safety relay faulty X IS Safety relay warning X Blocking monitoring Drive blocked X X IS P1260 P1260 Monitoring function Warning error Warning Error Threshold adjustable Reaction adjustable ...

Page 232: ...pulse inhibit This monitoring function doesn t exist by BM441X and BM442X Overcurrent This monitoring function checks if the motor current is greater than 1 3 x output peak cur rent It serves as Disaster prevention in case of an output sided short circuit DC link This monitoring function checks the voltage of the DC link In case the voltage is below a value which was internally specified about 50 ...

Page 233: ...emperature switch or in the PTC sensor is exceeded the error overtemperature is generated by the controller and the pulses are inhibited immediately Position controller This monitoring function checks the position deviation limit statical dynamical In case the position deviation error is statical dynamical greater than the set position deviation error limit there is an error message position devia...

Page 234: ...d with help of ZError param eters error messages error reactions from page 240 The displayed error is without ex ception an LEVEL 2 error P0201 P0216 The display of an error code starts therewith that F is displayed for 1 5 s Then the three characters of the error code are displayed The separate characters are displayed for about 0 8 s interrupted by a short break If there are other errors these a...

Page 235: ...software version of the controller and the ProDrive version is not compatible following message is displayed also see online help ProDrive Figure 98 ProDrive version conflict NOTE The controller software version and the operating software version must be compat ible to use ProDrive with all functions NOTE Please contact Baumüller Nürnberg GmbH or visit our website www baumueller de for download th...

Page 236: ...M4600 BM4700 Document No 5 12008 07 Baumüller Nürnberg GmbH 236 of 358 9 3 Start screen Figure 99 ProDrive start screen Display the error message in ProDrive h Open navigation with click on in front of Management Figure 100 Project navigation in ProDrive ...

Page 237: ...order The newly occurring messages are added to the end of the list when communication is active Figure 101 Drive manager ProDrive NOTE If you are not able to start the motor although the red LED H4 is not lighting up and although the LED H2 is lighting up green check the parameterization of the b maXX 4000 with the parameter list in ProDrive Error possibilities are e g torque limit 0 has been set...

Page 238: ... response of the drive are saved chronologically in this error memory A read access to the error memory is done element by element with an index parameter P0258 and a value parameter P0259 The error memory will be deleted completely at error acknowledgment bit No 7 1 in control word For a further description see parameter P0257 in the Parameter Manual Error display If an error appears the accordin...

Page 239: ... 7 generated by the control system or by operating software via input to parameter list Note The drive control must be active see parameter P1001 Communication source for the selected communication source m Via a digital input A digital input of a DIO module can be selected via parameter P0575 digital input for error acknowledgement can be selected for error reset A rising edge on this input re se...

Page 240: ...or handling Instruction handbook b maXX BM4400 BM4600 BM4700 Document No 5 12008 07 Baumüller Nürnberg GmbH 240 of 358 9 4 9 4 2 Error parameters error messages error reactions Figure 103 Survey error list ...

Page 241: ...level In the column Reaction the reaction of the system to the error is shown m IS pulse inhibit m adjustable the error reaction can be set via ProDrive Window Drive management toolbar button Error reaction m no reaction means the drive is continuing to work and the red error LED is blinking P0201 Error processor NOTE 3rd level errors are only displayed in ProDrive separated by a decimal point fro...

Page 242: ...e default values are written to the flash by switching off and on 26 Power unit is not supported IS Use an appropriate power unit or contact Baumüller Nürnberg GmbH 27 to 31 reserved not assigned 0 Error No Meaning Reaction Troubleshooting 32 Timeout protocol adjustable Restart b maXX 4000 33 Protocol structure adjustable 34 Wrong module type adjustable Contact Baumüller Nürnberg GmbH 35 Too many ...

Page 243: ...T signal of the slaves IS Restart b maXX 4000 60 CRC error in SPI transmission Module f controller adjustable Error indicates high EMC interferences please reduce these Contact Baumüller Nürnberg GmbH 61 CRC error in SPI transmission Controller f module adjustable 62 to 63 reserved not assigned 0 Error No Meaning Reaction Troubleshooting 64 Power supply failure adjustable Connect the power supply ...

Page 244: ...ing error messages exchange the controller 89 Power unit not ready to operate IS Make sure that the power unit is ready to operate Check the rotating field of the power supply 90 Up to FW 03 08 phase failure From FW 03 09 reserved IS Check the correct connection and voltage level of all phases 91 Power supply failure From FW 03 09 reserved IS Make power supply available 92 Power supply undervoltag...

Page 245: ... with temperature sensor 125 Memory capacity in the encoder for electronic type plate too small adjustable Use another encoder with a greater memory 126 to 127 reserved not assigned 0 Error No Meaning Reaction Troubleshooting 128 Communication error encoder 2 IS See ZError encoder 1 serial interface Error encoder 2 serial interface on page 251 129 reserved 130 Error at overwriting of encoder posit...

Page 246: ...gering not possible no incremental encoder IS Use for this option an incremental encoder 151 Digital I O module not available IS Install the digital I O module 152 Incremental encoder emulation is require but not available IS Install the incremental encoder emulation module 153 Encoder module 1 is required for incremental encoder emulation but not available IS Install the encoder module on slot A ...

Page 247: ...e 171 Error initialize holding brake IS Check if there is a DIO module if it is in the correct slot and if it is correctly parameterized also see P0883 172 Error holding brake holding torque not reached IS Ensure that the torque limits are not set too small P1402 Min P1036 P1037 P1038 173 to 175 reserved not assigned 0 Error No Meaning Reaction Troubleshooting 176 EEPROM copy error adjustable Copy...

Page 248: ... trigger adjustable Used encoder without trigger signal zero pulse or incorrect adjustment in P1425 spindle positioning mode 204 Spindle positioning Timeout at trigger signal adjustable Check encoder for zero pulse check encoder connec tor check zero pulse signal by means of the toggle bit encoder 1 2 status bit 8 205 Error while executing homing adjustable Check the function of the reference swit...

Page 249: ... 224 to 234 not assigned 0 adjustable 235 Torque coupling General error in the master adjustable 236 Torque coupling Operating mode in the slave is not speed control IS 237 Configuration error reaction return motion is invalid IS 238 Return motion target position was not reached adjustable 239 Application error enabled by P0302 bit 1 adjustable Error No Meaning Reaction Troubleshooting 240 to 255 ...

Page 250: ... 64 Drive moved more than 4 times delta angle 3rd level Error code Meaning Troubleshooting 6 Data overflow Error indicates high EMC problems please reduce these Contact Baumüller Nürnberg GmbH 7 Bit frame error 8 Invalid command state Contact Baumüller Nürnberg GmbH 9 Parity error Restart b maXX 4000 10 Checksum error Error indicates high EMC problems please reduce these Contact Baumüller Nürnberg...

Page 251: ...Word address outside of data field 18 Data field is available 19 to 27 reserved 28 Absolute monitoring of the analog signals Check the encoder cable and the encoder connection 29 Transmission current critical 30 Encoder temperature critical Check motor temperature 31 Speed too high no position generation possible Check the encoder cable and the encoder connection 32 Position singleturn unreliable ...

Page 252: ...nsation is switched off Exchange module standard controller or exchange controller ES controller 94 EnDat 2 2 Encoder type does not support EnDat2 2 command set power supply clock frequency Use suitable encoder type 95 EnDat 2 2 RM bit is not set reference of encoder absolute position is not available 96 Error lightning Exchange encoder 97 Error signal amplitude 98 Error position value 99 Error ov...

Page 253: ...ting 1 0 Power supply monitor has detected power fail ure adjustable Correct fault in power supply 2 1 Power supply monitor phase failure adjustable 4 2 Power supply monitor has detected undervolt age power supply adjustable 8 3 Power supply monitor has detected overvoltage power supply adjustable 16 4 Power supply monitor has detected power sup ply frequency below equal than lower frequency limit...

Page 254: ...n method 2 m Increase gain of the following controller P2124 preferred or and increase amplitude of voltage P2122 or P2148 If P2122 or P2148 is at maximum already then reduce the frequency of the current P2120 8 Plausibility step 2 m Find notch position method 2 The measured part of the 2nd harmonic P2147 from FW 3 10 is less than the mini mal level P2125 m Find notch position method 3 Drive shaft...

Page 255: ...tal input no reaction Check the parameterization of the input channel 5 Direct PLC I O access for this module not per mitted no reaction Don t select the module 6 Required module is missing only for BM4100 active mains rectifier unit IS Connect the required module for active mains rectifier unit operation see Operation Manual b maXX BM4100 Active Mains Rectifier Unit 7 Module must not be used for ...

Page 256: ...r 3 adjustable 4115 Wrong parameter No at actual value parameter 4 adjustable 4116 Wrong parameter No at actual value parameter 5 adjustable 4117 Wrong parameter No at actual value parameter 6 adjustable 4118 Wrong parameter No at actual value parameter 7 adjustable 4119 Wrong parameter No at actual value parameter 8 adjustable 4120 Wrong parameter No at actual value parameter 9 adjustable 4121 Wr...

Page 257: ...ed parameter 4156 Error cyclic communication Alive counter conflict adjustable Check if option module and controller are synchro nous 4157 Cmd interface Channel number wrong 0 or 6 adjustable Contact Baumüller Nürnberg GmbH 4158 Cmd interface Selected channel not available adjustable 4159 Cmd interface Internal error wrong pointer adjustable 4160 Cmd interface Internal error wrong state adjustable...

Page 258: ... assigned 0 Warning No Meaning Troubleshooting 16 Internal temperature of device Establish the specified environmental conditions assure correct ventilation conditions 17 Heat sink temperature Reduce the power output check the fans of the device 18 Timeout charge process DC link Check the correct order of mains phases clockwise rotating field and avoid that the DC link supplies energy while chargi...

Page 259: ...wer supply monitor has detected a lower volt age than warning threshold undervoltage power supply P2058 Power supply monitor has detected a lower voltage than warning threshold undervoltage power supply P2058 67 Power supply monitor has detected a higher volt age than warning threshold overvoltage power supply P2059 Power supply monitor has detected a higher voltage than warning threshold overvolt...

Page 260: ...Error handling Instruction handbook b maXX BM4400 BM4600 BM4700 Document No 5 12008 07 Baumüller Nürnberg GmbH 260 of 358 9 4 ...

Page 261: ...rical 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 stallation m Pay heed to areas on the device that could still be electrically energized after op eration Figure 104 Hazard areas during electrical installation ...

Page 262: ...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 motor overheat du...

Page 263: ...harge time of the system discharge time of the device with the longest DC link discharge time in the DC link connection Refer to ZElectrical data basic units from page 63 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 DC link the DC link ...

Page 264: ...age of the power supply system and the control circuits Measurement and comparison with standard values O m Mechanical parts Check points Methods and criteria Inspection intervals Daily Semi annu ally Annu ally Are there any abnormal noises or vibrations Visual and audio check O Are there any loose screws Tighten the screws O Are there any bent or damaged parts Visual inspection O Have there been ...

Page 265: ...s or noticeable odors Visual inspection audio check and odor check O m Solenoid switch and relay in the power supply circuit Check points Methods and criteria Inspection intervals Daily Semi annu ally Annu ally Are there any loose screws Visual and audio check Tighten screws if necessary O Do the switches function correctly Visual inspection O m Plug connectors in the power supply circuit Check po...

Page 266: ...eck O Are there any loose screws Tighten the screws O m Cooling system ventilation duct Check points Methods and criteria Inspection intervals Daily Semi annu ally Annu ally Are there any obstructions in the heat sink air supply or air outlet Visual inspection O 10 4 Repairs In case of device damage please inform your sales office or Baumüller Nürnberg GmbH Ostendstr 80 90 90482 Nuremberg Germany ...

Page 267: ...M4400 BM4600 BM4700 Document No 5 12008 07 11ACCESSORIES AND SPARE PARTS Accessories spare parts for devices of the b maXX series are listed in this appendix Product management is happy to handle any queries and suggestions on accessory parts ...

Page 268: ...tions up to 10 mm2 therefore at the BM4435 pin cable lugs according to DIN 46230 must be used BM4632 4 x 25 mm2 63 A fuses must be provided for the cable protection and a cable with 25 mm2 cross sec tion must be used flexible cable with wire end ferrule screw terminal BM444X BM464X 4 x 16 to 50 mm2 AWG 6 0 flexible cable with wire end ferrule screw terminal BM445X BM465X BM475X 4 x 25 to ca 185 mm...

Page 269: ... ZFigure 87 on page 186 Screw maximum two cable lugs to the current bar one on the front side one on the reverse side of the bar 7 Connection lugs current bars Position see ZFigure 90 on page 189 At connection cross section 95 mm2 Cable lug width max 25 mm Screw maximum two cable lugs to the current bar one on the front side one on the reverse side of the bar At connection cross section 185 mm2 Ca...

Page 270: ...BM446X BM466X BM476X cable lug max width 35 mm current bar 5 BM447X BM477X max 4 cables each with 4 x 95 mm2 max 4 cables each with 2 x 185 mm2 at 95 mm 15 m at 185 mm 30 m cable lug max width 25 mm or 35 mm current bar 6 1 Possible cross section Use a screened circuit Baumüller line optical shield coverage 85 Do not use single conductors For UL conform machines installations you must use UL certi...

Page 271: ...e lug width max 25 mm Screw maximum two cable lugs to the current bar one on the front side one on the reverse side of the bar At a connection cross section of 185 mm2 cable lug width max 35 mm Screw two cable lugs to the current bar at maximum one on the front side one on the reverse side of the bar 11 1 3 Cable control voltage supply signals Cross section 1 1 5 mm2 Maximum length 2 user defined ...

Page 272: ...bled cable is available as a spare part see ZCable RS232 on page 304 1 Use the following materials m Cable LIYCY 6x2x0 14 mm2 m D sub connectors 9 pin female cabinet plastics metalized m D sub connector 9 pin male cabinet plastics metalized 2 Connect the cable shield with the cabinet and with the shield of the D sub connector Figure 105 Interface cable RS 232 ...

Page 273: ...t of fire However they cannot prevent a device from being extensively destroyed in case of a short circuit or ground fault in the DC link Carry out the fusing in accordance with EN 60204 1 Electrical Equipment of Machines Dimension the cable fuse based on the cross section of the power supply cable used and in accordance with the respective applicable national standards and local regulations The c...

Page 274: ... in order that it is possible to repair the device Dimension suitable device protection fuses depending on peak current and the maximum load integral i2toff 1 Use fuses that fall below the specified cutoff integral i2 taus in the operating point Device Maximum load integral 1 BM4412 310 A2s BM4413 310 A2s BM4414 325 A2s BM4422 400 A2s BM4423 450 A2s BM4424 800 A2s BM4425 800 A2s BM4426 800 A2s BM4...

Page 275: ...t trip delay are approved Circuit breakers with only a thermal tripping characteristic are not tested and thus not approved A particular point to consider is that in case of an error the device is not protected against destruction instead only the system is protected against the risk of fire The suitability of circuit breakers depends on the cross section of the power supply cable used and the dim...

Page 276: ...032 0 32A 690V 6 9 URD 0 PV 032 40A 690V 6 9 URD 0 PV 040 Size m Full range fuses gR device and cable BM4414 design type NH Bussmann 000 25A 690V 170M1561 32A 690V 170M1562 Ferraz Shawmut 000 16A 690V 6 9 GGR 000 PV 016 20A 690V 6 9 GGR 000 PV 020 00 16A 690V 6 9 GGR 00 PV 016 SIBA 000 16A 690V 2047734 16A 20A 690V 2047734 20A 00 35A 690V 2047720 35A 0 16A 1000V 2038404 16A 25A 1000V 2038404 25A 3...

Page 277: ...040 00 25A 690V 6 9 URD 00 PV 025 32A 690V 6 9 URD 00 PV 032 40A 690V 6 9 URD 00 PV 040 0 32A 690V 6 9 URD 0 PV 032 40A 690V 6 9 URD 0 PV 040 Size 11 2 2 Fuses BM442X m Full range fuses gR device and cable BM4422 design type NH Bussmann 000 16A 660V 170M1559 u 20A 660V 170M1560 u 25A 660V 170M1561 u 32A 660V 170M1562 u 00 16A 690V 170M2692 20A 690V 170M2693 25A 690V 170M2694 32A 690V 170M2695 SIBA...

Page 278: ...60V 170M1560 u 25A 660V 170M1561 u 32A 660V 170M1562 u 00 20A 690V 170M2693 25A 690V 170M2694 32A 690V 170M2695 Ferraz Shawmut 000 20A 690V 6 9 GGR 000 PV 020 00 20A 690V 6 9 GGR 00 PV 020 SIBA 000 20A 690V 2047734 20A U 00 20A 690V 2047720 20A 25A 690V 2047720 25A Siemens 00 20A 660V 3NE8 714 20A 690V 3NE1 814 0 U 25A 660V 3NE8 715 25A 660V 3NE8 015 32A 660V 3NE8 701 0 32A 1000V 3NE4 101 U Size m...

Page 279: ...9 GGR 00 PV 025 SIBA 000 25A 690V 2047734 25A U 00 25A 690V 2047720 25A Siemens 00 25A 660V 3NE8 715 25A 660V 3NE8 015 25A 690V 3NE1 815 0 U 32A 660V 3NE8 701 0 32A 1000V 3NE4 101 U Size m Semiconductor fuses aR device BM4424 BM4425 and BM4426 design type NH Bussmann 00 25A 1000V 170M2674 32A 1000V 170M2675 40A 1000V 170M2676 1 40A 660V 170M3808 50A 660V 170M3809 63A 660V 170M3810 Ferraz Shawmut 0...

Page 280: ... Bussmann 00 50A 1000V 170M2678 63A 1000V 170M2679 1 63A 690V 170M3810 80A 690V 170M3811 SIBA 0 63A 1000V 2038404 63A 80A 1000V 2038404 80A Siemens 00 50A 660V 3NE8 717 63A 660V 3NE8 718 0 63A 1000V 3NE4 118 U Size m Full range fuses gR device and cable BM443X generation 2 and BM4632 design type NH SIBA 1 80A 690V 2021134 80 U Siemens 000 80A 690V 3NE1820 0 U 00 100A 690V 3NE1021 2 U Size NOTE Ple...

Page 281: ...d cable BM444X design type NH Bussmann 00 80A 690V 170M2699 100A 690V 170M2700 125A 690V 170M2701 1 1 80A 690V 170M4178 100A 690V 170M4179 125A 690V 170M4180 160A 690V 170M4181 Ferraz Shawmut 000 80A 690V 6 9 GGR 000 PV 080 6 9 GGR 000 D08L 080 00 80A 690V 6 9 GGR 00 PV 080 6 9 GGR 00 D08L 080 SIBA 1 80A 690V 2021120 80A 100A 690V 2021120 100A 80A 690V 2021134 80A U 100A 690V 2021134 100A U1 Sieme...

Page 282: ...0 1 U 100A 690V 3NE8 721 1 U 125A 690V 3NE8 722 1 U 160A 690V 3NE8 724 1 U 00 80A 690V 3NE8 020 1 U 100A 690V 3NE8 021 1 U 125A 690V 3NE8 022 1 U 160A 690V 3NE8 024 1 U 0 80A 1000V 3NE4 120 U 100A 1000V 3NE4 121 U 125A 1000V 3NE4 122 U 1 100A 1000V 3NE3 221 U 125A 1000V 3NE3 222 U 160A 1000V 3NE3 224 U Size 1 For the connection of an additional DC link capacity or the parallel operation of up to f...

Page 283: ...0A 690V NH00GS69V16PV SIBA 00C 80 160A 690V 2028220 160 U Siemens 00 125A 690V 3NE8022 1 U Size m Full range fuses gR device and cable BM4642 design type NH Siemens 00 125A 690V 3NE1022 2 U Size m Semiconductor fuses aR device BM4642 design type NH Bussmann 000 200A 690V 170M1570D U Ferraz Shawmut 00 160A 690V NH00GS69V16PV SIBA 00C 80 200A 690V 2028220 200 U 1 250A 690V 2021120 250 U Siemens 00 1...

Page 284: ...9 GGR 000 PV 100 00 100A 690V 6 9 GGR 00 PV 100 125A 690V 6 9 GGR 00 PV 125 1 160A 690V 6 9 GGR 00 PV 160 1 SIBA 00 100A 690V 2020934 100AU 125A 690V 2020934 125AU1 1 100A 690V 2021134 100AU 125A 690V 2021134 125AU1 160A 690V 2021134 160AU1 200A 690V 2021134 200AU1 2 160A 690V 2021234 160AU1 200A 690V 2021234 200AU1 Siemens 00 100A 690V 3NE1 021 0 U 125A 690V 3NE1 022 0 U1 1 160A 690V 3NE1 224 0 U...

Page 285: ... 9 URD 000 PV 0125 160A 690V 6 9 URD 000 PV 0160 200A 690V 6 9 URD 000 PV 0200 250A 690V 6 9 URD 000 PV 0250 1 315A 690V 6 9 URD 000 PV 0315 1 Siemens 00 125A 660V 3NE8 022 U 125A 660V 3NE8 722 160A 660V 3NE8 024 160A 660V 3NE8 724 200A 660V 3NE8 725 250A 660V 3NE8 727 1 315A 660V 3NE8 731 1 0 100A 1000V 3NE4 121 U 125A 1000V 3NE4 122 U 160A 1000V 3NE4 124 U 1 125A 1000V 3NE3 222 U 160A 1000V 3NE3...

Page 286: ... type NH Bussmann 00 315A 690V 170M1572D U Ferraz Shawmut 1 250A 690V NH1GS69V250PV SIBA 00C 80 315A 690V 2028220 315 U Siemens 1 110 200A 1000V 3NE3225 U Size m Full range fuses gR device and cable BM4651 design type NH SIBA 1 200A 690V 2021134 200 U Siemens 1 250A 690V 3NE1227 2 U Size m Semiconductor fuses aR device BM4651 design type NH Bussmann 00 315A 690V 170M1572D U Ferraz Shawmut 1 250A 6...

Page 287: ...A 690V 2018920 400 U Siemens 1 110 315A 1000V 3NE3230 0B U 450A 1000V 3NE3233 U Size m Semiconductor fuses aR device BM4755 design type NH Bussmann 1 350A 660V 170M3818 U 2 400A 660V 170M5808 U 450A 660V 170M5809 U 3 500A 660V 170M6808 U SIBA 00 350A 690V 2018920 350 U Siemens 00 315A 1000V 3NE8731 1 U 1 315A 1000V 3NE3230 0B U 350A 1000V 3NE3231 U Size NOTE The semiconductor fuses can be used for...

Page 288: ...690V 2021234 350AU1 3 315A 690V 2021334 315A1 350A 690V 2021334 350A1 Siemens 1 250A 690V 3NE1 227 0 U1 315A 690V 3NE1 230 0 U1 Size 1 For the connection of an additional DC link capacity or the parallel operation of up to five devices suitable that means the DC link of several devices is connected with at the same time existent power supply connec tion of every device m Semiconductor fuses aR dev...

Page 289: ...V 0315 350A 690V 6 9 URD 1 PV 0350 400A 690V 6 9 URD 1 PV 0400 1 2 250A 690V 6 9 URD 2 PV 0250 315A 690V 6 9 URD 2 PV 0315 350A 690V 6 9 URD 2 PV 0350 400A 690V 6 9 URD 2 PV 0400 450A 690V 6 9 URD 2 PV 0450 1 500A 690V 6 9 URD 2 PV 0500 1 560A 690V 6 9 URD 2 PV 0560 1 630A 690V 6 9 URD 2 PV 0630 1 3 315A 690V 6 9 URD 3 PV 0315 350A 690V 6 9 URD 3 PV 0350 400A 690V 6 9 URD 3 PV 0400 450A 690V 6 9 U...

Page 290: ...type NH SIBA 1 315A 690V 2021134 315 U Siemens 1 315A 690V 3NE1230 2 U Size Bussmann 1 500A 690V 170M4864D U 550A 690V 170M5811D U Ferraz Shawmut 2 350A 690V NH2GS69V350PV SIBA 1 110 500A 690V 2061331 500 U Siemens 1 110 400A 1000V 3NE3232 0B U Size SIBA 1 315A 690V 2021134 315 U 2 350A 690V 2021134 350 U Siemens 2 400A 690V 3NE1332 2 U 500A 690V 3NE1334 2 U Size Bussmann 2 550A 690V 170M5811D U F...

Page 291: ... for the device BM4766 provided that m The total DC link capacity of all connected devices is lower than 20 mF m The used mains filter and power choke fulfill the Baumüller specifications Bussmann 2 500A 660V 170M5810 U 3 550A 660V 170M6809 U Ferraz Shawmut 2 500A 690V 6 9URD2PV0500 3 560A 690V 6 9URD2PV0560 SIBA 1 110 mm 500A 690V 2061331 500 U Siemens 1 110 mm 450A 1000V 3NE3233 U 2 450A 1000V 3...

Page 292: ...y at the power supply connection of BM447X devices Semiconductor fuses are required in the connection between brake resistor and device except the user assures the short circuit protection of re sistor and cable Siemens 2 500A 1000V 3NE3 334 0B u 560A 1000V 3NE3 335 u 710A 900V 3NE3 337 8 u Size NOTE The 710 A fuse is recommended if the BM4472 is operated constantly at rated power and or peak powe...

Page 293: ... 508 C Assure that all marked e l v connections 24 V at the device have a maximum voltage of 30 VDC Additionally these connections must be protected with fuses which are in ac cordance with UL 248 with a triggering current of maximum 4 A Siemens 160A 700V 3NE8 724 1 u Siemens 250A 700V 3NE8 727 1 u Siemens 1 350A 1000V 3NE3 231 u Size HINWEIS If the current consumption is lower than 4 A several co...

Page 294: ...of environment Further information see Instruction handbook Mains Filter BFN 5 09010 11 3 1 Block diagram of filter for mains applications simplified 11 3 2 Baumüller mains filter type code Figure 106 Mains filter type code 11 3 3 Required mains filter environmental conditions Transport temperature range 25 C to 85 C Storage temperature range 25 C to 85 C Operating environment Outside of residenti...

Page 295: ...125 VDC 2 s Connection L1 L2 L3 safe to touch screw terminals PE connection bolt M5 M6 M10 Maximum connection cross section 4 mm2 4 mm2 10 mm2 10 mm2 16 mm2 25 mm2 50 mm2 50 mm2 50 mm2 Power loss typical 4 W 8 W 12 W 15 W 18 W 24 W 24 W 30 W 35 W Protection class IP 20 EPCOS B84143A0150R410 Max input supply voltage 3 x 480 VAC 10 50 60 Hz Rated current at TB 50 C 150 A Peak current at TB 50 C 1 5 ...

Page 296: ...ne 2150 VDC 2 s line housing 2700 VDC 2 s Connection bolt M10 bar with hole 11mm PE bolt M12 Power loss typical 60 W 40 W 50 W 65 W Protection class IP 00 BFN 3 1 101 0320 0400 0600 1000 Max input supply voltage 3 x 480 VAC 10 50 60 Hz Rated current at TB 50 C 320 A 400 A 600 A 1000 A Peak current at TB 50 C 1 5 x IN for 3 min per hour or 2 5 x IN for 30 s per hour Test voltage line line 2280 VDC ...

Page 297: ... PE bolt M12 bar with hole 11mm PE bolt M12 Power loss typical 30 W 60 W 40 W 50 W 65 W Protection class IP 00 BFN 3 1 102 0320 0400 0600 1000 Max input supply voltage 3 x 480 VAC 10 50 60 Hz Rated current at TB 50 C 320 A 400 A 600 A 1000 A Peak current at TB 50 C 1 5 x IN for 3 min per hour or 2 5 x IN for 30 s per hour Test voltage line line 2280 VDC 2 s line housing 2690 VDC 2 s Connection bar...

Page 298: ...f the drive During short time operation S3 the RMS value is calculated as follows Irms 1 T i 2 0 T dt Irated AC 1 Typ Part No 7 A BFN 3 1 0007 001 314277 16 A BFN 3 1 0016 001 314278 30 A BFN 3 1 0030 001 314279 42 A BFN 3 1 0042 001 314280 56 A BFN 3 1 0056 001 314281 75 A BFN 3 1 0075 001 314282 100 A BFN 3 1 0100 001 314283 130 A BFN 3 1 0130 001 314284 150 A EPCOS B84143A0150R410 437618 180 A ...

Page 299: ...ment No 5 12008 07 299 of 358 11 IT system 1 Rated temperature 50 C Irated AC 1 Typ Part No 150 A BFN 3 1 0150 002 433177 250 A BFN 3 1 250 002 373620 320 A BFN 3 1 320 002 373894 BFN 3 1 320 102 439387 400 A BFN 3 1 400 002 373898 600 A BFN 3 1 600 002 373902 BFN 3 1 600 102 439388 ...

Page 300: ... than there is at 50 Hz according to the formula uk L IN 3 UN with 2 f the short circuit voltage that would result at another power supply frequency can be calculated NOTE The rated inductance is constant up to 1 1 times of rated current You can expect that the inductance is reduced if the current flow through the commutation choke is higher than this value If it is important for the application t...

Page 301: ...choke Rated AC current Ieff Development status design 001 Connection copper bar overload factor 1 1 002 Connection terminal overload factor 1 1 101 Connection copper bar overload factor 2 102 Connection terminal overload factor 2 DC set value Single phase choke 1 0 x Ieff Three phase choke 1 22 x Ieff Irated AC Induc tance Type code Part No type 101 connection copper bar Part No type 102 connectio...

Page 302: ...065 0080 368379 399138 BM4434 BM4435 BM4435 80 A 0 36 mH BK3 0080 0100 368380 399139 BM4443 115 A 0 26 mH BK3 0115 0140 368381 399140 BM4443 BM4444 BM4444 BM4445 BM4452 165 A 0 18 mH BK3 0165 0200 368382 399141 BM4445 BM4452 BM4446 BM4453 195 A 0 15 mH BK3 0195 0240 368383 BM4446 BM4453 BM4755 275 A 105 µH BK3 0275 0340 368384 BM4454 BM4454 BM4462 365 A 80 µH BK3 0365 0450 368385 BM4462 BM4463 BM4...

Page 303: ...90 0232 101 456725 190 232 300 220 285 240 135 11x25 42 25 4 for M10 0195 0240 001 368383 197 240 265 195 230 215 126 11 15 28 25 3 for M10 0240 0294 101 456728 240 294 360 225 330 310 125 11 30 52 40 5 for M12 0275 0340 001 368384 297 340 300 225 271 240 145 11x15 38 30 5 for M10 0285 0350 101 456729 285 350 360 255 330 310 155 11x30 69 40 5 for M12 0365 0450 001 368385 369 450 360 220 320 310 12...

Page 304: ...le diameter 7 mm to 16 mm 00397366 Width 27 mm for cable diameter 6 mm to 24 mm 00397375 Width 43 mm for cable diameter 22 mm to 40 mm 00397376 NOTE In case you don t use an optically decoupled interface cable the cable shield has only to be connected to the connector housing at the controller connector The company Baumüller Nürnberg GmbH recommends the usage of optically decou pled transmitters e...

Page 305: ...uest Crossover package consisting of cross connector part No 365463 and Cat5 cable 0 5 m part No 325160 Modular connector RJ45 female RJ45 female crossover Cat5 shielded Type Length m Part No 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 Type Part No K ETH CROSS ADAPTER 365464 Typ...

Page 306: ...pe Model Length m Part No BM4 CAN K 31 01 RJ45 plug male sub D con nector 1 346568 BM4 CAN K 31 02 2 on request BM4 CAN K 31 03 3 346571 BM4 CAN K 31 05 10 5 10 on request BM4 CAN K 32 01 RJ45 plug 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 plug RJ45 plug 1 346577 BM4 CAN K 33 02 2 on request BM4 CAN K 33 03 3 on...

Page 307: ...e Part no Encoder plug 12 pin 245147 12 pin SpeedTec 448729 17 pin 362601 17 pin SpeedTec 448730 Length not trailing cable Part no trailing cable Part no SpeedTec trailing cable Part no 1 m 243601 448941 2 m 211338 448943 3 m 219333 246658 448944 4 m 231166 243379 448945 5 m 209879 239540 448948 6 m 220197 242954 448946 7 m 216455 448947 8 m 220429 239541 448949 10 m 210052 239542 448956 15 m 2157...

Page 308: ...east 85 opt overlap m D sub connector 15 pin male m Circular connector 12 pin female e g Interconnectron 2 Connect the cable shield with the cabinet of the circular connector and with the shield of the D sub connector Figure 109 Cable connectors 12 wire NOTE The cable connector must be produced according to the illustration which is shown above In case there is another assignment of the pins the c...

Page 309: ...ling cable Part no SpeedTec trailing cable Part no 2 m 383152 393889 448816 3 m 383923 369864 448817 5 m 393885 394014 448818 7 m 389445 389807 448819 8 m 380138 393890 448820 9 m 389446 389808 448821 10 m 393886 393891 448822 15 m 388505 393892 448823 17 m 371494 448824 20 m 388418 393893 448825 25 m 393887 393894 448826 30 m 393888 380358 448827 35 m 387958 391216 448828 40 m 382006 382005 44883...

Page 310: ... Cu transfer Cu braiding with at least 85 opt overlap m D sub connector 15 pin male m Circular connector 17 pin female e g Interconnectron 2 connect the cable shield laminar with the shield of the D sub connector Figure 110 Cable connector for sine cosine encoder with EnDat interface NOTE The cable connector must be produced according to the illustration which is shown above In case there is anoth...

Page 311: ... No 5 12008 07 311 of 358 11 m EnDat 2 2 encoder cable without incremental signals original encoder cable of Fa Heidenhain lengths on request Cable with M12 connector 8 pin completely assembled with female connector plug and male D sub connector Item no Fa Heidenhain 524599 xx xx length ...

Page 312: ... X X X X 351210 Connector Motor Phoenix GIC 2 5 4 ST 7 62 1828825 X X X X 354746 Connector 1C1 1D1 or 1C1 1D1 Ba Phoenix GIC 2 5 4 ST 7 62 1828825 X X X X 354746 Connector Ba Ba Phoenix GIC 2 5 2 ST 7 62 X X 381872 Connector Power supply Phoenix GMSTB 2 5 4 ST 1766903 Wieland 8313B 4 OBGN 25 360 3453 7 X X X X 309377 Connector X3 Phoenix FK MCP 1 5 6 ST 3 81 1851083 X X X X X X X X X X 354874 Conn...

Page 313: ...ouch electrically 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 additiona...

Page 314: ...nnections earliest 10 minutes after switching off 3 demount the connections and protect the connections according to the safety instruc tions 4 document the shut down setting 12 4 Demounting The demounting assumes a completed documented setting out of operation 1 secure the device against falling off out 2 loosen all mechanical connections 3 lift the device out of the control cabinet 4 store the d...

Page 315: ...ions Incorrect storage can damage destroy the device Therefore Assure that the environmental conditions are kept during the entire period of storage m Climatic category 1K4 m Temperature range 25 C to 55 C CAUTION Recommissioning without forming of the capacitors From six months storage period on the capacitors are destroyed during commission ing if they are not formed beforehand m Reform the DC l...

Page 316: ...m six months storage period on the capacitors are destroyed during commission ing if they are not formed beforehand 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 reactor for this forming...

Page 317: ...ime of the device with the longest DC link discharge time in the DC link connection Refer to ZElectrical data basic units from page 63 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 DC link the DC link discharge can take a much longer tim...

Page 318: ...rsonnel 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 ...

Page 319: ...l as with 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 b...

Page 320: ...Disposal facilities authorities Instruction handbook b maXX BM4400 BM4600 BM4700 Document No 5 12008 07 Baumüller Nürnberg GmbH 320 of 358 13 2 ...

Page 321: ... value alternating current IF Pulse enable IF Field current ID No Identification number Ink PPR count of incremental encoder IS Impulse inhibit ISO International Organization for Standardization Iset Current set value LT Power unit M24 Reference potential 24 V MR1 Torque direction 1 MR2 Torque direction 2 n 0 Speed 0 nist Speed actual value nmax Maximum speed nmin Minimum speed NN Altitude over se...

Page 322: ...Instruction handbook b maXX BM4400 BM4600 BM4700 Document No 5 12008 07 Baumüller Nürnberg GmbH 322 of 358 A ...

Page 323: ...323 of 358 Instruction handbook b maXX BM4400 BM4600 BM4700 Document No 5 12008 07 APPENDIX B DECLARATION OF CONFORMITY B 1 Declaration of conformity ...

Page 324: ...pe BM4XXX XXX XX4XX BM4XXX XXX XX5XX manufactured since 03 05 2013 are developed designed and manufactured in accordance with the EMC Directive 2014 30 EU and the Low Voltage Directive 2014 35 EU Applied harmonized standards Attention should be paid to the safety instructions in the manual Nuremberg 14 Jun 2016 Location Date Standard Title DIN EN 62061 2010 05 Safety of machinery Functional safety...

Page 325: ...egistration numbers 01 205 5327 13 BM441X 442X 01 205 5326 13 BM443X 447X 01 205 5324 13 BM463X BM466X 01 205 5325 13 BM475X BM477X Attention should be paid to the safety instructions in the manual 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 2006 42 EC Nur...

Page 326: ...Declaration of conformity Instruction handbook b maXX BM4400 BM4600 BM4700 Document No 5 12008 07 Baumüller Nürnberg GmbH 326 of 358 B 1 ...

Page 327: ...e the danger area or to remove his hand from the danger area Therefore the drive must be kept safe off position with opened and electrical interlocked safety devices The motor must be in torqueless state Thus the motor cannot generate a dan gerous movement The prevention of an unexpected starting of the machine is reached with electrical separated safety devices e g contactors This is not state of...

Page 328: ... versa The protection against unexpected starting is reached by an electromechanical method which is superior to the electronics This is reached by a safe isolation which is not executed in the load circuit Energy supply of the motor windings at a stop is reached by inhibiting the power semiconduc tors Semiconductors can fail or can be started accidentally due to electromagnetic interferenc es The...

Page 329: ...a machine with a synchronous motor is developed NOTE The function is limited to the prevention of an unexpected starting The switching of the safety relay while the rotor of the motor is rotating causes an uncontrolled coasting of the machine Braking with the converter is not possible DANGER Danger to life by electrical current Power supply voltage can be present at the motor and at the device if ...

Page 330: ...p category 0 according EN 60204 1 The drive stops after coasting if there is no force at the drive shaft If STO function is selected no danger will occur from the drive A starting of the drive without a disabling of the STO function is not possible NOTE If the safety relay is switched off it is not possible to use a ballast switch at BM441X and BM442X NOTE A device with safety relay is not a safe ...

Page 331: ...ays Size 3 7 m PL e according to EN ISO 13849 1 with the following parameters m Structure cat 4 n MTTFd high n DC high m SIL 3 according to EN 62061 and 61508 with PFHDssD 2 4 x 10 10 Additional instructions for the STO function EN 61800 part 5 2 For further information contact Baumüller Application department m The classification of the safety category applies only to the STO function m The follo...

Page 332: ...tes the drive from its torque but not from its voltage For the safe isolation of the supply other measures must be executed for example the use of a main switch m A temporal excitation occurs if the internal driver IGBT or a control element also in STO state fails The motor can generate a magnetic field for a moment if the DC link is short circuited via a motor winding If an asynchronous motor is ...

Page 333: ... circuit size 1 7 2 Applications for a minimizing risk according to performance level e EN ISO 13849 1 or SIL 3 EN62061 therefore need 2 independent shutdown paths too The difference to 1 is that the two channel shutdown must be implemented via two safety relays in order to achieve a minimizing risk The Baumüller inverters of the b maXX of the device model BM4XXX XXY XXXXX Ryy S01 XX in combinatio...

Page 334: ...o voltage at the safety relay STO is active Also cable break is recognized as error If the voltage at the input terminals of the relay X102 3 4 X103 3 4 is switched off the inverter generates the message Power unit warning 20 undervoltage safety relay or the message Power unit error 87 error safety relay At an inhibited pulse enable the warning message warning is not saved is generated At pulse en...

Page 335: ...inals X3 3 5 to deactivate the safety function C 2 2 2 Sequence diagram The starting and the shutdown sequence of the release signals and of the safety relay must be considered in order to assure a faultless operation of the drive Figure 111 Sequence diagram of 1 or 2 safety relays NOTE The safety function must be checked before commissioning the machine in which the BM4000 with the safety functio...

Page 336: ...ram Recommended starting shutdown sequence Different starting shutdown sequences possible See table ZDifferent starting shutdown op tions BM4X1X to BM4X7X on page 337 1 TBoot_controller dependent on the used option module from firmware version 03 05 approx 5 s 2 Tcharge DC link 1 5 s exception BM4X3X 6 s 3 TSR pulse enable 20 ms exception BM4X2X 200 ms ...

Page 337: ...es yes yes yes Auxiliary supply 24 V and safety relay 1 2 simultaneously ON yes yes yes yes yes yes yes Power supply OFF power supply ON at pulse inhibit yes yes yes yes yes yes yes Pulse enable ON at an activated safety relay yes yes yes yes yes yes yes Pulse enable and safety relay 1 2 simultaneously ON no no no no no no no Pulse enable and safety relay 1 2 simultaneously OFF no no no no no no n...

Page 338: ...00 with one safety relay first safe shutdown path and pulse enable at the controller LC3 sizes 1 7 second safe shutdown path Figure 113 Shutdown paths with a safety relay and pulse enable at the controller m Device models BM4000 with two safety relays safe shutdown paths and pulse enable at the controller functional Figure 114 Shutdown paths with two safety relays BM4000 BM4000 ...

Page 339: ...only control inputs X102 3 4 X103 3 4 The state of the relay contacts can be obtained via the positively driven NC contacts signal out puts X102 1 2 X103 1 2 At the device model BM4000 with a safety relay the second shutdown path is obtained by pulse enable of the device at BM4000 controller LC3 The safety function pulse enable is active if no voltage is connected to the input terminals X3 3 5 The...

Page 340: ...e level the single error certainty to recognize errors partially The safety related components may not lead to a loss of safety function if one single error occurs The errors are not all detected by the system however The accumulation of undetected errors can lead to a loss of the safety function Category 4 complies with level Self monitoring This component detects possible errors These errors are...

Page 341: ...fe stop The feedback contacts are closed NC contact Cable break is also detected as an error The converter generates Power unit warning 20 undervoltage safety relay or Power unit error 87 error safety relay if the voltage at the input terminals of the relay X102 3 4 X103 3 4 is switched off At inhibited pulse enable the warning warning is not saved is generated and at pulse enable the error messag...

Page 342: ...age is applied to the pulse enable input of the converter n S1 NC contact has hardware effects on the safety relay of the converter Only if S1 displays a closed cover safe state voltage is applied at the safety relay input X102 3 A torque now can be generated at the motor shaft The NO contact of S1 is connected with the monitoring circuit n The monitoring circuit is a fail safe monitoring control ...

Page 343: ...e safety relay X102 1 2 can be evaluated by the mon itoring circuit not imperative n The position switches which are used must provide positively operated and mechanical con tacts The position switches must provide a dual protected connection a combination of NC contacts and of NO contacts The mechanical operation at the safety device must be tamper resistant The connection cables between the safe...

Page 344: ...f S1 is connected with the monitoring circuit n S2 NC contact and S3 NO contact effect the other safety relay of the converter Only if S2 and S3 display a closed cover safe state voltage is applied to the safety relay input X103 3 A torque now can be generated at the motor shaft n S3 NC contact has hardware effects on the pulse enable input of the converter X3 5 Only if S3 displays a closed cover ...

Page 345: ...C contacts and of NO contacts The mechanical operation at the safety device must be tamper resistant The connection cables between the safety relay inputs X102 3 4 X103 3 4 as well as between the pulse enable input X3 5 and the control circuit may not be installed in a common cable channel outside the control cabinet All information given in the instruction handbook of the converter especially the...

Page 346: ...tegory 4 In the following application examples are viewed at which only two of the three switch off chan nels are used m Application example 1 Application example for machine of category 3 with hardwired pulse enable input and process data communication via a field bus Switching off occurs by means of safety relay 1 and safety relay 2 Figure 117 Version with two safety relays BM4XXX XX2 Herd the h...

Page 347: ...off channels Pulse enable and a second common switch off channel for safety relay 1 and safety relay 2 Figure 118 Version with two safety relays BM4XXX XX2 Here the safety relays 1 and 2 are triggered by a position switch and together generate the first channel The second channel is generated by the hardware pulse enable input which is inde pendently triggered by the safety relay ...

Page 348: ...on with a safety relay BM4XXX XX1 This b maXX 4000 converter is equipped with one safety relay only The hardware is identical with the other converters of this series the second relay is not assembled The internal relay switch off paths are combined and commonly generate the first channel The second channel generates a hardware pulse enable input which is independently triggered by the safety rela...

Page 349: ...not affected The pulse enable inputs X3 5 and the safety relays X102 3 4 X103 3 4 of b maXX 4000 are provided for the use of an OSSD test pulse The test pulses have the following limit values OSSD test pulse Figure 120 OSSD test pulse Thresholds for the inputs X3 5 and X102 3 4 X103 3 4 Value Description tTPLmax 3 ms maximum low time of the test pulse tTPmin 100 ms minimum period of the test pulse...

Page 350: ...2 1 and X102 2 accordingly X103 1 and X103 2 may not fall below the specified values Operate the safety relay within the specification NOTE A device with safety relay is not a safe device The device with safety relay does not comply with the PL level according to ISO 13849 and SIL according to EN 61800 if the part number does not start with 06 This device is not certified for safety functions NOTE...

Page 351: ...Switch on frequency max 6 min max 10 s max 12 s Activation delay time at rated voltage UDC max 25 ms max 15 ms max 15 ms Deactivation delay time max 15 ms max 12 ms max 12 ms Electrical endurance at least 105 operating cycles at least 105 operating cycles at least 105 operating cycles Mechanical service life at least 1 x 107 switching cycles at least 5 x 107 switching cycles at least 1 x 107 switc...

Page 352: ...ürnberg GmbH 352 of 358 C 5 m Installation of the feedback contact with a permanent load Figure 121 Installation of the feedback contact with permanent load Continuous load e g Housing Phoenix Contact EMG12 B2 Part No 2948306 Transparent cover Phoenix Contact BMG12 H 7 5 mm Part No 2947116 Resistor 1 2 k 1 W at TU 70 C ...

Page 353: ...r requirement 61 Derating of output current BM441X universal units 64 Maximum external DC link capacity BM441X 65 Derating the output current BM442X universal units 68 Maximum external DC link capacity BM442X 69 Derating the output current BM443X universal units 71 Derating the output current BM444X universal units 74 Reducing of output current BM445X universal units 77 Reducing of output current ...

Page 354: ...otor for BM442X 183 Electrical connections for power supply motor for BM443X BM463X 184 Electrical connections for power supply motor for BM444X BM464X 185 Electrical connections for power supply motor for BM445X BM465X BM446X BM466X 186 Electrical connections for power supply motor for BM466X and BM476X 187 Electrical connections for power supply motor for BM4755 188 Electrical connections for po...

Page 355: ...ive management 237 E Edges sharp 145 314 Electrical current dangers of 21 Enable signals 224 Encoder module 123 Encoder type 123 Encoders connectable 123 EnDat 207 208 209 210 212 214 216 Energy supply requirements 52 Error handling 238 Error messages 240 Error reset 239 EtherCat cable 305 Ethernet 199 F Fault correction 229 Fire fighting 22 Fuses 273 G Guarantee provisions 12 H Hard hat 20 Hardwa...

Page 356: ...le 133 224 Q Quick stop 224 R Rated supply voltage frequency 52 Recommissioning 316 Repairs 266 Required environmental conditions 55 Residual energy danger from 21 165 Resolver 203 S Safe stop 327 Safety categories 340 Safety equipment 23 Safety fuses 273 Safety relay 127 231 334 341 Durability 351 Safety shoes 20 Screws 156 Semiconductor fuses 274 Shielding clamp 304 Shutdown 313 314 Signs 24 Sig...

Page 357: ...pter encoder encoder cables added New version declaration of Conformity according Machinery Directive 5 12008 03 10 Jan 2014 Chapter Troubleshooting and fault correction adapted Correction Technical data 5 12008 04 01 Dec 2014 Error correction 5 12008 05 20 Jul 2015 Calculation for watter cooled brake resistors 5 12008 06 24 Sep 2015 New choke types new device type 5 12008 07 7 Jul 2016 Revision T...

Page 358: ...Instruction handbook b maXX BM4400 BM4600 BM4700 Document No 5 12008 07 Baumüller Nürnberg GmbH 358 of 358 Notes ...

Page 359: ......

Page 360: ... 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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