Baumuller BUM 62 Operating Instructions Manual Download Page 4

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Abbreviations

Mono Power Unit BUM 62, 63, 64

5.94005.12

Baumüller Nürnberg GmbH

BBREVIATIONS

Alternating current

Asynchronous motor

a.m.s.l. above mean sea level
BUC

Baumüller Feed/Feed back Unit

BUG

Baumüller Basic Feed Unit

BUM

Baumüller Mono Power Unit

BUS

Baumüller Power Module

Direct current

DIN

Deutsches Institut für Normung e.V.
(German Standardization Authority)

EMC

Electromagnetic compatibility

European standard

Main contactor

PELV

Protective extra-low voltage

SELV

Safe extra-low voltage

MSL

Main Sea Level

Protective earth

Synchronous motor

DC link

Summary of Contents for BUM 62

Page 1: ...E 5 94005 12 Manual Mono Power Unit BUM 62 63 64 ...

Page 2: ... on by the owner 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 destroyed When the present operating instructions are handed over corresponding sets of operating instructions of a previous version are automatically invalidated Please...

Page 3: ...EMC information 26 5 4 Safety relay 33 5 5 Terminal diagrams 39 5 6 Connector pin assignment 44 5 7 Accessories 49 6 Commissioning 51 6 1 Danger information 51 6 2 Function diagram BUM 62 53 6 3 Function diagram BUM 63 64 54 6 4 Operation 55 6 5 Messages and warnings 56 6 6 Monitoring motor end power unit 58 6 7 Voltage failure 61 7 Maintenance 63 7 1 Maintenance notes 63 7 2 Environmental conditi...

Page 4: ... back Unit BUG Baumüller Basic Feed Unit BUM Baumüller Mono Power Unit BUS Baumüller Power Module DC Direct current DIN Deutsches Institut für Normung e V German Standardization Authority EMC Electromagnetic compatibility EN European standard HS Main contactor PELV Protective extra low voltage SELV Safe extra low voltage MSL Main Sea Level SL Protective earth SM Synchronous motor ZK DC link ...

Page 5: ... 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 considerable damage to material assets It is only permitted to use the units on earth p...

Page 6: ...d 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 you own personal safety and on the other to prevent damage to the described products or to other connected units DANGER This means that death severe perso...

Page 7: ...he unit system for the purposes specified in the operating instructions and in conjunction with the third party equipment and components recommended or authorized 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 ca...

Page 8: ...Safety Notes 8 Mono Power Unit BUM 62 63 64 5 94005 12 Baumüller Nürnberg GmbH ...

Page 9: ...variations from simple frequency converters to highly dynamic and precise vector controllers With the BUM 62 BUM 63 and BUM 64 mono power units both asynchronous and synchronous mo tors with different encoder systems can be driven by the same unit 2 1 1 Function description The BUM 62 63 and 64 units consist of two parts the supply converter and the motor end inverter y BUM 62 The supply converter...

Page 10: ...Technical Data 10 Mono Power Unit BUM 62 63 64 5 94005 12 Baumüller Nürnberg GmbH 2 1 2 Block diagram BUM 62 ...

Page 11: ...Technical Data Mono Power Unit BUM 62 63 64 11 Baumüller Nürnberg GmbH 5 94005 12 2 1 3 Block diagram BUM 63 64 ...

Page 12: ... s without additional DC link capacitors Choke external no 4 uk 4 uk Output voltage AC 0 supply voltage Output power 1 2 52 kVA 104 kVA 208 kVA Typical motor power 1 2 35 kW 70 kW 140 kW Nominal output current Ieff 1 2 at TK 45 C and TB 45 C 75 A 150 A 300 A Peak output current Ieff 2 3 at TK 45 C and TB 45 C 97 5 A 195 A 390 A Connecting voltage fan 5 3x400 VAC 10 50 60 Hz Control voltage 6 24 VD...

Page 13: ...voltage 440 V Ensure the necessary supply voltage e g by an transformer power 110 VA 50Hz or 160 VA 60 Hz 6 with reference to EN61131 2 table 5 Only BUM 62 and BUM 63 The internal fan power is reduced if control voltage 24 V You must reduce the output currents when the control voltage 24 V Characteristic curve 1 Load in dependence on installation height Characteristic curve 2 Current reduction dep...

Page 14: ...Technical Data 14 Mono Power Unit BUM 62 63 64 5 94005 12 Baumüller Nürnberg GmbH 2 3 Type code ...

Page 15: ... the package s and checking that the shipment is complete you can start assembly Fibre board cartridge paper and or wood are used as packaging materials and they can be disposed of in accordance with local regulations Report any damage in transit without delay DANGER If the unit has been damaged in transit do not connect it to the mains until appropriate high voltage testing has been carried out I...

Page 16: ...Transportation Unpacking 16 Mono Power Unit BUM 62 63 64 5 94005 12 Baumüller Nürnberg GmbH ...

Page 17: ... left above and below the units and sufficient cool air and air circulation must be pro vided Sheets of plastic on the devices that cover the equipment connection act as additional guards pre venting accidental contact at commissioning and in the case of casual use of control elements located close to the equipment DIN VDE 0106 Part 100 Accident Prevention Regulation VBG4 Electrical Systems and Eq...

Page 18: ...Assembly 18 Mono Power Unit BUM 62 63 64 5 94005 12 Baumüller Nürnberg GmbH 4 1 Dimensions 4 1 1 Dimensions BUM 62 For the total depth pay attention to the controller s size ...

Page 19: ...Assembly Mono Power Unit BUM 62 63 64 19 Baumüller Nürnberg GmbH 5 94005 12 4 1 2 Dimensions BUM 63 For the total depth pay attention to the controller s size ...

Page 20: ...Assembly 20 Mono Power Unit BUM 62 63 64 5 94005 12 Baumüller Nürnberg GmbH 4 1 3 Dimensions BUM 64 Für die Gesamttiefe ist die Reglergröße zu beachten ...

Page 21: ...mperature 50 mm under the units up to 45 C With higher temperatures up to max 55 C power output of the units must be reduced by 3 per K y Do not locate any additional sources of heat above or below the units y You must avoid degrees of contamination 3 and 4 according to provisional standard EN 50178 1994 Section 5 2 15 2 The devices are suitable for use in enclosed workshops VDE 0558 Part 1a Sec t...

Page 22: ...62 63 64 5 94005 12 Baumüller Nürnberg GmbH 4 3 Fastening Fasten the unit via the back panel in the switching cabinet see dimensions With devices that are mounted next to one another the back panels must be in contact with one another ...

Page 23: ...ant national and local regulations are met with regard to cable ratings and protection grounding disconnectors overcurrent protection etc Relatively high leakage to ground occurs in the converter and the motor i e the drive may be incom patible with current operated e l c b s corresponding to provisional standard EN 50178 1994 Section 5 2 11 2 You may only use variable speed drives in applications...

Page 24: ... a higher level cur rent operated e l c b either more difficult or totally impossible This means that connecting the power converter to the mains using only the current operated e l c b is prohibited preliminary standard EN 50178 VDE 0160 11 94 Sections 5 2 11 and 5 3 2 1 With regard to climatic conditions the equipment conforms to category 3K3 for sheltered locations ac cording to provisional sta...

Page 25: ...onal standard EN 50178 VDE 0160 11 94 Section 5 2 16 1 The rated insulation voltage of the mains circuits for TN and TT systems according to DIN VDE 0100 Part 410 11 83 with a diametric voltage of 3 x 500 V Insulation material IIIa for creepage distances according to provisional standard EN 50178 VDE 0160 11 94 Section 5 2 17 Series BUM 62 63 64 power converters are short circuit proof in the sens...

Page 26: ...nusoidal network loading in particular with line commutated converters 100 Hz 20 kHz German EMC Law EMVG This converter complies with Paragraph 5 Section 5 Sentence 3 of the German EMC Law EMVG dat ed 09 11 92 Devices that are exclusively manufactured or stocked as vendor parts or spare parts for further process ing by industrial companies or craftsmen or by other specialists in the field of elect...

Page 27: ...ower Unit BUM 62 63 64 27 Baumüller Nürnberg GmbH 5 94005 12 Cabling y To suppress radiated noise outside the converter you should screen all the connected cabling Also observe the topics in the section entitled Screening ...

Page 28: ...Installation 28 Mono Power Unit BUM 62 63 64 5 94005 12 Baumüller Nürnberg GmbH ...

Page 29: ...rt y Lines of different EMC categories should only cross at an angle of 90 y In the case of symmetrical signal transfer e g differential amplifier inputs for the speed specified val ue twist the conductors of each pair of wires together and twist the pairs of wires together y The converter to ground plate earth connection should be as short as possible less than 30 cm Use large cross sections more...

Page 30: ...e and a short cable 30 cm y Remove insulating layers such as paint adhesives 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 ...

Page 31: ...rences on the frame ground system However this is very rare if you carry out the measures described in the previous sections entitled Cabling and Grounding You can also make a capacitive RF connection of a screen to frame ground This prevents low fre quency interference due to earth circuits Screened cables that pass through different EMC areas must not be separated at terminals since screen dampi...

Page 32: ... converter With lines that are more than 30 cm long you must screen the mains line between the converter and the filter frame ground on both sides y Physically separate the filter s input and output lines by more than 30 cm y Make a broad connection between the filter housing and frame ground Discharge currents Due to the principle of operation parasitic capacities in the filter the mains unit the...

Page 33: ... 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 generation therefore cannot lead to a starting of the motor as long as the second condition namely the interruption of the amplifying power supply is available a...

Page 34: ...the safety function Also if up to three from one another independent errors arise the safety function is always maintained 5 4 3 The safety relay The function of the safety relay is executed in fail safe technic also named closed circuit principle The safety function safe stop is active as long as no voltage is applied to the input terminals X68 3 4 Consequently the functioning of the safety funct...

Page 35: ...plied 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 performance of the protection of unexpected starting once has been determined then this ...

Page 36: ...3 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 ...

Page 37: ... the 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 e...

Page 38: ...same 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 ...

Page 39: ...Installation Mono Power Unit BUM 62 63 64 39 Baumüller Nürnberg GmbH 5 94005 12 5 5 Terminal diagrams 5 5 1 Terminal diagram BUM 62 ...

Page 40: ...Installation 40 Mono Power Unit BUM 62 63 64 5 94005 12 Baumüller Nürnberg GmbH 5 5 2 Terminal diagram BUM 63 ...

Page 41: ...Installation Mono Power Unit BUM 62 63 64 41 Baumüller Nürnberg GmbH 5 94005 12 5 5 3 Terminal diagram BUM 64 ...

Page 42: ...ction of mains connection according EN 60204 1 1992 For cable laying refer to EMC information If UL508C has to be observed Use 60 C 75 C copper conductors only UL508C Nov 27 1996 Tab 39 2 Nominal tightening torque of the terminal screws 4 Nm resp 35 4 pound inches BUM 62 U V W PE BUM 63 64 1U2 1V2 1W2 Cross section of motor connection according EN 60204 1 1992 For cable laying refer to EMC informa...

Page 43: ...al tightening torque of the terminal screws 6 Nm resp 53 1 pound inches BUM 64 Fan 2U1 2V1 2W1 Circuit protection according to VDE 0100 BUM 62 63 fan power supply internal BUM 64 3 x 400 V 50 Hz 0 23 A 3 x 400 V 60 Hz 0 27 A Netzteil 24 V 24 V power supply with secure isolation PELV according DIN 19240 for supplying the electronic parts Current consumption BUM 62 3 A BUM 63 3 5 A BUM 64 2 5 A NOTE...

Page 44: ...al screws 4 Nm resp 35 4 pound inches y ZK ZK Connections for further units e g ballast M6 terminals If UL508C has to be observed Nominal tightening torque of the terminal screws 4 Nm resp 35 4 pound inches 5 6 2 Power terminals BUM 63 64 y 1U1 1U2 1U3 1U1 1U2 1U3 Unit input voltage 400 VAC 460 VAC Control cabinet ground BUM 63 M 8 terminals BUM 64 M 10 terminals If UL508C has to be observed Use 6...

Page 45: ...ical Data input rectifier If UL508C has to be observed Nominal tightening torque of the terminal screws 4 Nm resp 35 4 pound inches y 1C1 1D1 DC link of further units e g ballast If UL508C has to be observed Use 60 C 75 C copper conductors only UL508C Nov 27 1996 Tab 39 2 Nominal tightening torque of the terminal screws 6 Nm resp 53 1 pound inches BUM 63 M 8 terminals BUM 64 M 10 terminals ...

Page 46: ...from outside must be PELV or SELV Terminal no Assignment 1 2 24 V PELV Terminal for power supply to the units both terminals internally connected 2nd terminal with power supply current 10 A 3 4 Ground 24 V PELV Terminal for power supply to the units both terminals internally connected 2nd terminal with power supply current 10 A 5 BB int PELV Ready for use signal form the supply converter to all un...

Page 47: ...ments there must be several separate current feeds Terminal No Assignment 1 2 BB ext PELV Relay output Ready for use of supply converter 24 V 0 5 A max 3 4 Alert PELV Relay output Alert of supply converter 24 V 0 5 A max 5 Reset with 24 V signal PELV Input for resetting error messages of the supply converter potential free optocoupler input 10 25 mA 6 Ground reset PELV Reference point for resettin...

Page 48: ...nnection 3 x 400 V 0 23 A 0 27 A 50 60 Hz a pre transformer must be used for other voltages y X60 64 pin plug In order to connect the controller cassette to the motor end converter internal connection plug X 60 in the cassette recess must be used For information on the controller cassette external connections see the controller description Terminal No Assignment 1 2 Message contact 1 and 2 Relay o...

Page 49: ...tor fuses part no 100 A 1000 V 19008526 250 A 1000 V 19008626 350 A 1000 V 19008621 Needed amount per unit Size according DIN 43620 0 1 1 Line protection fuses only with reduced cross section BUM 62 BUM 63 BUM 64 Line reactor no DR3 50 4 0200 part no 19007487 DR3 40 4 0200 part no 19007474 DR3 50 4 0400 part no 19007489 DR3 40 4 0400 part no 19007476 ...

Page 50: ...able EMC filter shielded cable connection parts Line reactor DR3 40 4l Type DC current A a mm b mm c mm d mm e mm f x g mm Flat termination mm x mm Weight kg Losses W Part no 1900 0 200 200 310 170 255 280 106 11 x 18 40 x 4 14 28 0 160 7474 0 400 400 310 220 260 280 131 11 x 18 40 x 4 14 45 0 180 7476 Line reactor DR3 40 4l Type DC current A a mm b mm c mm d mm e mm f x g mm Flat termination mm x...

Page 51: ...utating reactor or the motor personal injuries are inevitable since the surfaces may carry dangerously high voltages During operation the principles on which the power converter and the motor work lead to leakage cur rents to earth that are dissipated via the specified protective earths and may result in a current oper ated e l c b on the input side blowing prematurely In the case of a short circu...

Page 52: ...ed close to the equipment DIN VDE 0106 Part 100 Unfallverhütungsvorschrift Elektrische Anlagen und Betriebsmittel VBG4 Switching cabinets must have an emergency off facility to switch off any voltages that could be dan gerous This does not include equipment which if switched off would cause an even more dangerous situation The emergency off releasing element must be arranged in such a way that it ...

Page 53: ...Commissioning Mono Power Unit BUM 62 63 64 53 Baumüller Nürnberg GmbH 5 94005 12 6 2 Function diagram BUM 62 NOTE The LEDs cannot be seen from outside ...

Page 54: ...Commissioning 54 Mono Power Unit BUM 62 63 64 5 94005 12 Baumüller Nürnberg GmbH 6 3 Function diagram BUM 63 64 ...

Page 55: ...f the motor end power unit can be resetted by the controller Reset of operational faults reported by the supply unit y Set the reset input at plug X99AB y Switch off the 24 V power supply The reset signal effects on the supply unit only the stored faults in the motor end power unit are not in fluenced Settings do not have to be made for the units BUM 62 63 64 ...

Page 56: ...nitoring BUM 62 The phase failure monitoring function recognizes that a phase is missing in the supply voltage and give a warning message After 10 seconds the error is stored and an internal and external ready for use message is prevented y Phase monitoring BUM 63 64 This prevents an internal and external ready for use message y Temperature monitoring The temperature of the cooling element is moni...

Page 57: ...or use closes the message contact X99AB if none of the phase failure mains failure or temperature monitoring functions generates a warning Reset The error message memory of the supply unit is erased by operating the reset input supply 24 V at X99AB optocoupler input without having to switch off the 24V auxiliary voltage supply function erase error message memory Only BUM 62 Error saving can be can...

Page 58: ...ted if the fault current exceeds 20 BUM 62 or 10 BUM 63 64 of the power unit s peak current Earth fault monitoring can be reset by a controller reset For display and message resetting see controller description y DC link monitoring The amount of the DC link voltage is monitored in the power unit If it reaches 800 V an error mes sage is generated DC link monitoring can be reset by a controller rese...

Page 59: ...rred free of potential to the controller cassette where it is processed see controller description y Cooling element temperature monitoring The power unit has no temperature monitoring feature of its own as the cooling element temperature is not greatly time critical The cooling element has a linear temperature sensor which passes measurements on to the con troller Temperature monitoring is thus t...

Page 60: ...diate circuit voltage Only in this case a continuation is possible immediately and without time loss Switching states of the safety relay The transition secure state normal run only occurs via a RESET caused by controlling It is recommended to avoid mistakes in recognizing the secure state combine the output states test the output states once again after 10 ms Relay Feed back contact Internal cont...

Page 61: ... corresponds to reset error memory In the case of voltage failure intermediate circuit voltage lower than 300 V the mono unit generates the message voltage failure power error H2 The unit s ready for use signal is taken away The message voltage failure is deleted automatically if the mains voltage returns The unit s status is now ready for use y BUM 63 64 In the case of voltage failure the ready f...

Page 62: ...Commissioning 62 Mono Power Unit BUM 62 63 64 5 94005 12 Baumüller Nürnberg GmbH ...

Page 63: ...on the equipment may only be carried out in a voltage free state Work on the DC link may only be started when it is ascertained that there is neither potential nor volt age remanent voltage present On dismantling safety equipment during commissioning repair and maintenance the machine is to be shut down exactly according to instructions After completion of commissioning repair and main tenance wor...

Page 64: ... 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 capacito...

Page 65: ...g on various power semi conductor beryllium oxide has been used The beryllium dust caused by opening represents a health hazard The disposal of the units should conform to the recycling regulations of the country and region in which they are disposed Components Material Housing Sheet steel aluminium Various distance bolts current converter hausing and fan housing etc Plastic Conductor plates accom...

Page 66: ...Maintenance 66 Mono Power Unit BUM 62 63 64 5 94005 12 Baumüller Nürnberg GmbH ...

Page 67: ...ie 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 built in complies with the regulations of the EC machine ...

Page 68: ...ngs Einheit BUM 62 75 97 5 54 BUM 63 150 195 54 BUM 64 300 390 54 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 Betriebsmitteln EN 50...

Page 69: ...or sale and delivery items are packaged and trans port 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 with out delay free of freight charges and expenses 6 Dispatch and Passing of Risk Deliveries shall be made ex works The dispatch shall be effected at a cost to and at the risk of the recipient ...

Page 70: ...ed goods or to the assigned claims The purchaser shall bear the costs incurred by this d The authorisation on the behalf of the purchaser to dis pose of the reserved goods and to collect assigned claims expires in the event that the terms of payment are not complied with in particular also in the case of bill and cheque protests In this case Baumüller is entitled to take possession of the reserved...

Page 71: ...en put into oper ation by the purchaser himself herself or upon his her instructions by third parties beyond the functional test re quired 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 parties shall take part in the acceptance inspection The result of the functiona...

Page 72: ...22 Filter assembly 32 Filtering 32 G General conditions of sale and delivery 69 I Installation 23 Installation height 12 L L1 L2 L3 PE 44 M Maintenance 63 Maintenance notes 63 Manufacturer Declaration 67 Monitoring Input rectifier 56 Phase failure 56 Temperature 56 Voltage failure 56 Motor connection 42 O Output power 12 P Pollution degree 17 Power loss 12 R Ready for use 57 59 Recommissioning 64 ...

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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