Baumuller BUM 62 T User Manual Download

Page: 64 / 74

Maintenance

Mono Power Unit BUM 62 T

5.99009.03

Baumüller Nürnberg GmbH

8.2

Environmental conditions

If you keep to the environmental conditions during the entire period of storage, you can assume, that the
device will not be damaged.

8.3

Recommissioning

Carry out commissioning as with a new device.

WARNING

From six months storage period on, the capacitors are destroyed during commissioning, if they are not
reformed beforehand.

Reform the capacitors by supplying the device ready-for use for at least 48 hours with supply voltage,
but no impulse enable.

WARNING

From six months storage period on, the capacitors are destroyed during commissioning, if they are not
reformed beforehand.

Reform the capacitors by supplying the device ready-for use for at least 48 hours with supply voltage,
but no impulse enable.

Summary of Contents for BUM 62 T

Page 1: ...E 5 99009 03 Manual BUM 62 T Mono Power Unit ...

Page 2: ...n by the own er together with the equipment machine After any sale of the equipment machine this original and all copies must be handed over to the buyer After disposal or any other end of use this original and all copies must be de stroyed When the present operating instructions are handed over corresponding sets of operating instructions of a previous version are automatically invalidated Please...

Page 3: ...nexpected starting 33 6 4 2 Safety categories 34 6 4 3 The safety relay 34 6 4 4 Service time 38 6 5 Connection diagram 39 6 6 Terminal strips and plug in terminals 40 6 6 1 Power connections 40 6 6 2 Control connections 42 6 6 3 Controller connection 46 6 6 4 Safety relay as an option 46 6 7 Accessories 47 7 Commissioning 49 7 1 Danger information 49 7 2 Operation 52 7 3 Monitoring functions and ...

Page 4: ... contents 4 Mono Power Unit BUM 62 T 5 99009 03 Baumüller Nürnberg GmbH 9 Appendix 67 9 1 Manufacturer Declaration 67 9 2 Declaration of Conformity 68 9 3 General Conditions of Sale and Delivery 69 9 4 Index 72 ...

Page 5: ...it BUS Baumüller Power Module DC Direct current DIN Deutsches Institut für Normung e V German Standardization Authority EMC Electromagnetic compatibility EN European Standard MC Main contactor IPM Intelligent power module a m s l above mean sea level PELV Protective extra low voltage SELV Safe extra low voltage PE Protective earth SM Synchronous motor ZK DC link ...

Page 6: ...6 Mono Power Unit BUM 62 T 5 99009 03 Baumüller Nürnberg GmbH ...

Page 7: ... contact during commissioning and casual use of control elements located close to the equipment DIN VDE 0106 Part 100 Accident Prevention Regulation VBG4 Electrical Systems and Equipment The protective measures and safety regulations according to DIN VDE are binding for personal security Neglecting to fit PE connections on the equipment or the motor will result in serious personal injury and or co...

Page 8: ...mmission ground and mark circuits and equipment in accordance with recognized safety standards y Trained or instructed in accordance with recognized safety standards in the care and use of appropriate safety equipment One the one hand the information below is for your own personal safety and on the other to prevent damage to the described products or units connected to it DANGER This means that de...

Page 9: ...unit system for the purposes specified in the operating instructions and in conjunction with the third party equipment and components recommended or authorised by BAUMÜLLER NÜRNBERG GmbH For safety reasons you must not change or add components on to the unit The operator must report immediately any changes that occur which adversely affect the safety of the unit system WARNING If you want to carry...

Page 10: ...Safety notes 10 Mono Power Unit BUM 62 T 5 99009 03 Baumüller Nürnberg GmbH ...

Page 11: ...ormance of the supply current controller can be used for the connection of other power modules of the BUS 6 series The total of all motor powers occurring at the same time must not be higher than the typical motor power Starting current load relief If precautions are not taken the DC link capacitors produce inadmissibly large charging current surges from the mains In order to avoid these surges th...

Page 12: ...rresponding sensors The sensors supply measuring signals for the closed loop control and also ensure the self protection of the power electronics The inverter is triggered by the controller used Baumüller rack modules are provided for the control The drives can therefore be adapted to different applications Controller The BUM 62 T only operates in conjunction with an additional controller The cont...

Page 13: ...VA Continuous motor power at 4 kHz 10 max 43 kW Continuous motor power at 8 kHz 10 max 35 kW Rated output current 6 7 8 at 4 kHz 10 100 A Rated output current 6 7 8 at 8 kHz 10 75 A Peak output current 6 7 9 at 4 kHz 10 130 A Peak output current 6 7 9 at 8 kHz 10 97 A Connection power DC link connection 36 kW External chopper current max 73 A Internal chopper resistor External chopper resistor 11 ...

Page 14: ...aximum output current up to the connection voltage When the input voltage exceeds the rated voltage reduce the output currents at constant output power proportionally Characteristic 1 Output currents in relation to the connection voltage 8 The rated output current must be reduced between 40 C and 55 C The rated output current is calculated according to the following formula Example Rated output cu...

Page 15: ...mined as follows 12 Characteristic 2 Values in relation to the installation height at normal air pressure 3 2 Type key y Determine several measuring points covering the entire area as illustrated at a distance of 10 cm y Measure the temperature at these measuring points The highest value is the ambient temperature ...

Page 16: ...Technical data 16 Mono Power Unit BUM 62 T 5 99009 03 Baumüller Nürnberg GmbH 3 3 Block diagram ...

Page 17: ...ts and checking that the shipment is complete and undamaged you can start assembly The packing consists of fibreboard corrugated cardboard and or wood It can be disposed according to the local regulations Report any transport damage without delay DANGER If you detect a transport damage on the unit it must not be connected unless an appropriate voltage test has been carried out Ignoring this inform...

Page 18: ...Transportation Unpacking 18 Mono Power Unit BUM 62 T 5 99009 03 Baumüller Nürnberg GmbH ...

Page 19: ...ventilation must be strictly observed Otherwise the unit may be overheated y Ensure sufficient cooling air and ventilation y Ventilation must be from the bottom to the top ensure a free space above and below the unit see Free space on page 19 y The rated power of the unit is possible only up to a specific ambient temperature The power must be reduced when higher temperatures occur see Table of tec...

Page 20: ...propriate lifting can cause personal injury or damage to material assets Qualified personnel only may lift the unit using suitable equipment y Observe the weight of the unit y use protective gloves NOTE y Always mount the unit vertically at the back panel of the switch cabinet y Arrange several units side by side ...

Page 21: ...Assembly Mono Power Unit BUM 62 T 21 Baumüller Nürnberg GmbH 5 99009 03 Installation Dismantling ...

Page 22: ...Assembly 22 Mono Power Unit BUM 62 T 5 99009 03 Baumüller Nürnberg GmbH ...

Page 23: ...e or the motor personal injury may be caused since the surface may carry hazardous voltage During operation the principles on which the converter and motor work lead to leakage currents to earth which are dissipated via specified protective earth connections and which may result in a current operated e l c b on the input side blowing prematurely A DC component in the fault current may occur in the...

Page 24: ...ction refers to common covers barriers and procedures which ensure that persons are prevented from touching live active parts Switch cabinet must have emergency stop facilities using which all voltages causing dangerous situations can be switched off This does not include equipment which if switched off would cause another dangerous situation The releasing element for the emergency stop facility m...

Page 25: ... commutations and non sinusoidal mains loading particularly for mains commutated controllers 100 Hz 20kHz German EMC Law EMVG This converter corresponds to EMVG 5 Section 5 Sentence 3 of EMVG German EMC Law dated 09 Nov 92 Devices which are exclusively manufactured or stocked as vendor parts or spare parts for further processing by industrial companies or craftsmen or by other specialists in the f...

Page 26: ...Baumüller Nürnberg GmbH Measures for ensuring EMC To ensure EMC you must observe the configuration information below Cabling y To suppress noise emission outside the converter always screen all connected cables Also observe the items in Chapter Screening ...

Page 27: ...gories should only cross at an angle of 90 y For symmetrical signal transmission e g differential amplifier inputs for the speed setpoint twist the conductors of each pair together and twist the pairs of wires together y The connection between converter and ground plate should be as short as possible 50 cm Use large cross sections 10 mm2 y Sources of noise such as fuses transformers chokes and noi...

Page 28: ...sives etc from the ground connections If necessary use serrated lock washers DIN 6798 or similar measures to ensure a permanent conductive contact To prevent corrosion on ground connections use suitable metal combinations electrochemical series of metals and keep conductive electrolytes away from the connection by a protective coating e g grease y Always connect screens at both ends over a large s...

Page 29: ...m cannot be excluded totally However these are very rare if you observe the measures of the above chapters Cabling and Grounding The HF connection of a screen to ground can also be capacitive This prevents low frequent noise caused by earth loops Screen cables passing through different EMC areas must not be separated at the terminals otherwise the screening would be reduced considerably They shoul...

Page 30: ... y Mount the filter next to the converter If the cables are longer than 50 cm screen the mains cable between converter and filter grounding at both ends y Input and output cables of the filter must be separated physically distance 50 cm y Connect the filter housing to ground over a large surface Leakage currents Due to the principle of operation stray capacitances in the filter power stage motor c...

Page 31: ...ctions and which may result in a current operated e l c b on the input side blowing prematurely A DC component in the fault current may occur in the event of a short circuit to frame or earth fault which makes a triggering of the higher level current operated e l c b more difficult or even impossible Universal current sensitive current operated e l c b and current operated e l c b for AC and pulsa...

Page 32: ...ections of the power units are safely separated from the mains and are designed for the connection of PELV SELV circuits y The following criteria were considered for the dimensioning of the air and creepage distances Pollution degree 2 acc to EN 50178 VDE0160 11 94 Section 5 2 15 2 Table 2 line 3 y Normally only non conductive pollution occurs If the units are not in operation a casual short term ...

Page 33: ... current drives usually in the micro processors a complex pulse pattern is generated then the pulses are amplified and are used for the switching of the power semiconductors If either no defined pulse pattern is available or the amplify ing connection is interrupted e g by switching off of the power supply with a relay safety relay no rotary field can be generated An error by the pulse pattern gen...

Page 34: ...tion of unrecognized errors can lead to a loss of the safety function Category 4 accords to the level Self monitoring This component recognizes self contained possible errors and signals these in time of the loss of the safety function Also if up to three from one another independent errors arise the safety function is always maintained 6 4 3 The safety relay The function of the safety relay is ex...

Page 35: ...t unexpected starting if the configuring and installation instructions are complied with Before the commissioning of the machine in which the converter with the safety relay is built in the safe ty function protection against unexpected starting must be checked For that purpose a safety device must be executed for example door contact The motor must now be zero torque If the reliability performanc...

Page 36: ...and therewith allows a torque generation at the shaft of the motor The NO contact of S1 is connected with the monitoring circuit y The monitoring circuit a fail safe monitoring control of the category 3 EN 954 1 checks on its own the directly connected switching contacts of the position switch S1 NO contact S2 NO contact and S3 NC contact If the barrier is not completely closed or a theoretical im...

Page 37: ...he protection against unexpected starting also category 4 for the complete drive A possibility is the usage of a contactor with which the external conductors of the motor cable is short circuited The diagram shows exemplary the usage and cabling of a Baumüller converter of the series BUM 6 BUS 6 or BKH of a machine tool at which the safe taking of work pieces at opened barrier according to cat ego...

Page 38: ...me switch condition or the status signal contact of the safety relay is opened closed although the status signal contact of S1 is closed opened the control circuit re ceives no release signal of the monitoring signal A missing release signal of the monitoring device leads to a direct switching off of the converter by means of the control circuit If the monitoring circuit has recognized an error fo...

Page 39: ...Installation Mono Power Unit BUM 62 T 39 Baumüller Nürnberg GmbH 5 99009 03 6 5 Connection diagram ...

Page 40: ...re safely connected DANGER Danger to life The permissible connection value see Technical data must never be exceeded Termina l Pos 1 Description Urange 2 Irange 3 A4 1U2 1 Motor connection phase U max 570 V max 130 A 10 25 mm2 8 4 AWG 1V2 2 Motor connection phase V 1W2 3 Motor connection phase W PE 4 Earth connection L1 5 Mains connection phase L1 400 V 15 up to 460V 10 max 105A L2 6 Mains connect...

Page 41: ... M6 1 Position 2 Voltage range r m s value 3 Current range r m s value 4 Conducting cross section of the bars DANGER The total power of the motors supplied via the power modules which are connected to the BUM 62 T must not be higher than the power which can be supplied from the supply converter of the BUM 62 T Termina l Pos 1 Description Urange 2 Irange 3 A4 ZK top DC link connection Connection of...

Page 42: ...ller Nürnberg GmbH 6 6 2 Control connections WARNING The permissible maximum current of 10 A per connection point must not be exceeded otherwise the units may be damaged All control voltages applied externally must comply with the regulations for PELV or SELV ...

Page 43: ... the controller see also Ready for operation on page 53 Termina l Pos 1 Description Urange 2 Irange 3 A4 24 V 1 24 VDC PELV 5 Terminals 1 and 2 are bridged internally 24 V 20 24 V 10 max 10 A 0 2 2 5 mm2 24 12 AWG 24 V 2 M 24 V 3 Ground 24 VDC PELV Terminals 1 and 2 are bridged internally 0 V M 24 V 4 BBint 5 Message Internal ready for operation 6 0 V Supply part is not ready 24 V Supply part is r...

Page 44: ... to the BUM 62 T connect terminals 1 to 5 of relay X99B of the added unit to terminals 1 to 5 of relay X99A of the BUM 62 T Connection X99B X99A added unit BUM 62 T for instance BUR 622 NOTE The combination of two plug in terminals and connecting cables see figure above is available as an accessory from Baumüller Nürnberg ...

Page 45: ...the controller see also Messages via relay contacts on page 61 Termina l Pos 1 Description Urange 2 Irange 3 A4 1 Message External ready for operation 5 Open contacts Supply part not ready Closed contacts Supply part ready 24 V 0 5 A max 2 5 mm2 2 3 Message Early warning 5 Closed contacts Supply part no early warning Open contacts Supply part early warning 4 Reset 5 isolated optocoupler input to r...

Page 46: ...n cable with wire crimp 1 Position 2 Voltage range r m s value 3 Current range r m s value 4 Cross section of the conductor WARNING The user must prevent overloading of the relay contacts e g by suitable fuses The load of 10 mA is a minimum load to ensure permanently a trouble free function Termina l Pos 1 Description Urange 2 Irange 3 A4 1 2 Feedback whether the safety relay is supplied with 24 V...

Page 47: ... Nürnberg GmbH 5 99009 03 6 7 Accessories y EMC package EMC filter Screened cables Connection parts NOTE During motor operation 24 V DC must be applied at the terminals 3 and 4 Safety relay OFF is saved as a message and must be reset via the controller ...

Page 48: ...Installation 48 Mono Power Unit BUM 62 T 5 99009 03 Baumüller Nürnberg GmbH ...

Page 49: ...he commutation choke or the motor personal injury may be caused since the surface may carry hazardous voltage The power connections of the converter carry potential The parts of the converter carry hazardous voltage even if the main contactor has released During operation the principles on which the converter and motor work lead to leakage currents to earth which are dissipated via specified prote...

Page 50: ... Protection against direct contact comprises all measures against danger which can result from touching the active parts of electrical equipment The active parts must therefore be protected from direct contact by insulation design position arrangement or firmly installed facilities Protection refers to common covers barriers and procedures which ensure that persons are prevented from touching live...

Page 51: ...ure that the machine is taken out of commission in accordance with applicable regulations Remount and check the safety equipment immediately after completing commissioning repair and maintenance work This list does not claim to be complete for the safe operation of the unit If you should need further information or if special problems arise please contact BAUMÜLLER NÜRNBERG or a sales agency Pleas...

Page 52: ... design of the unit Monitoring functions of the supply part The messages generated by the Monitoring functions of the supply part are indicated via relay contacts and or displayed by LEDs The messages are sent simultaneously to the controller which processes it The position of the relay contacts and the LEDs is illustrated on the following figure For more detailed information on the messages and t...

Page 53: ...n the BUM 62 T Internal ready for operation digital output External ready for operation relay contacts y Supply part ready available in the BUM 62 T and not visible y Controller ready available in the controller y Completely ready available in the controller The message Completely ready depends on the three other Ready messages The message Completely ready is output only when the messages Supply p...

Page 54: ...the power part the message Supply part ready is referred to as External ready Power part on the motor side ready When the Monitoring function of the power part on the motor side does not recognize and errors the monitoring function generates the message Power part on the motor side ready y If the message Power part on the motor side ready is cleared by the monitoring function the BUM 62 T disconne...

Page 55: ... link has discharged UZK 20 V then switch off 24 V supply voltage This clears all messages of the supply part 4 You must clear this message by a controller reset The controller documentation specifies how to display and clear the message 5 A message occurs only if the safety relay is switched off The safety relay is switched off only if the 24V supply voltage for the relay is not applied Switch on...

Page 56: ... and the DC link voltage reduces very fast within a few milliseconds y The message Mains failure is output as soon as the DC link voltage is smaller than 300 V y The message Supply part ready is cleared y The WARNING message is set for a few milliseconds Reason If two or three mains phases fail the procedure Output WARNING message is started This procedure takes a few milliseconds If the DC link v...

Page 57: ...itored If the monitoring function recognizes a short circuit at the connection for the external regenerative circuit the message Short circuit regenerative circuit is generated This message is stored and the message Supply part ready is cleared w WARNING If you enable an automatic start of the drive you cause a severe danger of the operating personnel If a enable an automatic start of the drive yo...

Page 58: ...monitored If the DC link voltage exceeds 800 V a message is generated This message is transmitted to the controller The message Power stage on the motor side ready is cleared y Power transistors monitoring function The collector emitter saturation voltage is monitored If the voltage is too high an overcurrent is applied to the power transistor caused e g by a short circuit of the motor terminals a...

Page 59: ...ternal auxiliary voltage monitoring function The voltage which is used to trigger the power transistors is monitored If there is no internal auxiliary voltage a message is generated This message is transmitted to the controller The message Power part on the motor side ready is cleared y Safety relay option The switching state of the safety relay is monitored For further information on the safety r...

Page 60: ...failure monitoring function page 56 and Mains failure monitoring function page 56 will inform you in which cases the message is activated TEMP Overheat The red LED is always off it has no function in this unit PHASE ERR Phase failure red LED on The message Phase failure is activated Phase failure monitoring function page 56 will inform you in which cases the message is activated POWER ERR Mains fa...

Page 61: ...vated X68 For an immediate production restart it is necessary to stop a drive electronically to achieve the following y no contactors in the motor cables are necessary y DC link voltage does not have to be switched off This requirement is met by using a safety relay Feedback of safety relay safety relay is available as an option Contact closed No 24 V supply for the safety relay The power stage or...

Page 62: ...Commissioning 62 Mono Power Unit BUM 62 T 5 99009 03 Baumüller Nürnberg GmbH ...

Page 63: ...rgized Do not begin work on the DC link of the power unit until you have made sure that neither potential nor voltage residual charge is applied When dismantling safety equipment during commissioning repair and maintenance ensure that the machine is take out of commission in accordance with applicable regulations Remount and check the safety equipment immediately after completing commissioning rep...

Page 64: ...ARNING From six months storage period on the capacitors are destroyed during commissioning if they are not reformed beforehand Reform the capacitors by supplying the device ready for use for at least 48 hours with supply voltage but no impulse enable WARNING From six months storage period on the capacitors are destroyed during commissioning if they are not reformed beforehand Reform the capacitors...

Page 65: ...ion e g in diverse semiconductors The beryllium dust set free when the components are opened is dangerous to your health The units and modules must be recycled at the end of their service life If recycling is not possible dispose the units and modules according to the national regulations and the regional and local ordinances Component Material diverse spacers housing of the current transformer an...

Page 66: ...Maintenance 66 Mono Power Unit BUM 62 T 5 99009 03 Baumüller Nürnberg GmbH ...

Page 67: ...bnahme solange untersagt ist bis festgestellt wurde dass die Maschine in die diese Komponente eingebaut ist den Bestimmungen der EG Maschinenrichtlinie 89 392 EWG Anhang II B entspricht We herewith declare that this delivery includes the following specified machine component and that its putting into operation is prohibited until the declaration is made that the machine in which this compo nent is...

Page 68: ...ung Specification of the machine component Type Einzel Leistungseinheit BUM 62 T Die Übereinstimmung des bezeichneten Produkts mit den Vorschriften der Richtlinie wird nachgewie sen durch die Einhaltung folgender Normen Conformity of the significated product with the guidelines will be proved by following rules EN 50178 1994 VDE 0160 11 94 Ausrüstung von Starkstromanlagen mit elektronischen Betrie...

Page 69: ...no claim to compensation due to non fulfilment or delay of the delivery 5 Packaging Items for sale and delivery items are packaged and transport insurance policies are taken out according to the instructions of and at a cost to the purchaser Upon demand the packaging material has to be returned without delay free of freight charges and expenses 6 Dispatch and Passing of Risk Deliveries shall be ma...

Page 70: ...ebtor c The purchaser shall inform Baumüller without delay of impending and enforced access on the behalf of third parties to the reserved goods or to the assigned claims The purchaser shall bear the costs incurred by this d The authorization on the behalf of the purchaser to dispose of the reserved goods and to collect assigned claims expires in the event that the terms of payment are not complie...

Page 71: ...rvice shall be considered as having been accepted when the item delivered has been put into operation by the purchaser himself herself or upon his her instructions by third parties beyond the functional test required to carry out the acceptance This also applies in the event that the purchaser refuses the functional test the acceptance without sufficient cause e Experts to be designated by both pa...

Page 72: ...embly 30 Filtering 30 Free space 19 G Grounding 28 I Index 72 Installation 23 Installation height 13 Internal ready 54 L Leakage currents 30 Low voltage supply 13 M Mains failure monitoring 56 Maintenance 63 Maintenance information 63 Manufacturer Declaration 67 Maximum temperature 59 Monitoring of the regenerative circuit 57 Monitorings 58 O Output power 13 Overheat 59 P Phase failure monitoring ...

Page 73: ......

Page 74: ... 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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