Baumuller BUM64A Manual Download Page 5

Page: 5 / 120

Manual Single Power Unit BUM64S/A/F

Document no.: 5.01056.03

of 118

Table of contents

12.2

Demands on the personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

12.3

Disposal instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

12.3.1

Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

12.4

Recycling plants / offices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Appendix A - Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Appendix B - Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

B.1

Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

B.2

Water cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

B.3

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

B.3.1

Extreme range fuse gR (appliance and cable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

B.3.2

Semiconductor fuse aR (appliance) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

B.4

Line reactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

B.5

EMC accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Appendix C -

Declaration of Conformity /

Decl. by Manufacturer /

UL-cert. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

C.1

What is an EC directive? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

C.2

What the CE symbol indicates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

C.3

Definition of the term Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

C.4

Definition of the term Declaration by Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

C.5

Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

C.6

Declaration by Manufacturer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

C.7

UL-certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Appendix D - Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

D.1

Requirements on the power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

D.2 Required

environmental

conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

D.3

Electrical specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

D.4

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

D.5

BUM64S - non-electrical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

D.6

BUM64A - non-electrical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

D.7

BUM64F - non-electrical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

D.8

Cable from mains supply to appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

D.9

Cable for control voltage supply / signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

D.10

Cable from appliance to motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

D.11

Electrical motor to be connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Appendix E - Safety relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

E.1

Methods to avoid an unexpected starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

E.2

Safety categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

E.3

The safety relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

E.4

Application example for machine of category 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

E.5

Application example for machine of category 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

E.6

Service time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Table of figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Summary of Contents for BUM64A

Page 1: ...E 5 01056 03 Manual Single Power Unit BUM64S A F ...

Page 2: ... 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 notice that sp...

Page 3: ...ication 19 2 5 Education of the personnel 20 2 6 Reconstructing the appliance 20 2 7 Disposal of the appliance 20 2 8 Fire fighting 21 3 Packing and Transport 23 3 1 Transport 23 3 2 Unpacking 23 3 3 Disposal of the packaging 24 3 4 Transportation precautions 24 4 Description of the unit 25 4 1 Variants 26 4 2 Overview of hazardous areas 27 4 3 Characteristics of the unit type key 28 4 4 Block swi...

Page 4: ...according to UL 60 7 Commissioning 61 7 1 Requirements the executing personnel must meet 61 7 2 Checking the mounting 62 7 3 Checking the installation 62 7 4 Checking the safety devices 63 7 5 Commissioning sequence 63 8 Operation 65 8 1 Safety regulations 65 8 2 Monitoring functions and their messages 65 8 2 1 Monitoring functions of feed module 66 8 2 2 Monitoring functions of motor side power m...

Page 5: ...rm Declaration by Manufacturer 92 C 5 Declaration of Conformity 93 C 6 Declaration by Manufacturer 94 C 7 UL certification 95 Appendix D Technical specifications 97 D 1 Requirements on the power supply 98 D 2 Required environmental conditions 99 D 3 Electrical specifications 101 D 4 Fuses 103 D 5 BUM64S non electrical data 103 D 6 BUM64A non electrical data 103 D 7 BUM64F non electrical data 103 D...

Page 6: ...Manual Single Power Unit BUM64S A F Document no 5 01056 03 Baumüller Nürnberg Electronic GmbH Co KG 6 of 118 Table of contents ...

Page 7: ...nd commissioning 4 hand over this manual to the personnel for mounting installation and commissioning Make sure that particularly the safety information is understood and will be observed 1 2 Terms used In this documentation for the Baumüller product Single Power Unit we will also use the term appliance In the appendix you will find a list of all terms used see ZAppendix A Abbreviations from page ...

Page 8: ...given in this manual m you have used this appliance within a non appropriate application n this appliance you have m unskillfully mounted m unskillfully connected m unskillfully commissioned m unskillfully operated m unskillfully or not maintained m let be mounted connected commissioned operated and or maintained by not or not adequate qualified personnel m overloaded n operated it with m defectiv...

Page 9: ...fully combined the appliance with products of other manufacturers m you have combined the drive system with defective and or incorrectly documented products of other manufacturers The General terms of sale and delivery of Baumüller Nürnberg Electronic GmbH Co KG apply generally Those you have available at least since the contract has been con firmed ...

Page 10: ...Obligation and liability Manual Single Power Unit BUM64S A F Document no 5 01056 03 Baumüller Nürnberg Electronic GmbH Co KG 10 of 118 1 3 ...

Page 11: ...ns All the symbols used in this documentation you will find listed and explained be low How you can protect yourself against every single danger in detail we however cannot state in this chapter Here only information about general safety measures will be given to you The respective safety measures against an occurring hazardous situation you will find in the following chapters always directly wher...

Page 12: ... CAUTION m minor to medium personal injury or m environmental pollution or m property damage may occur A triangle indicates hazard for human beings The shade of grey of the outline reflects the severity of the hazard darker grey means rising hazard The icon within the square illustrates the hazard The outline s shade of grey reflects the severity of the hazard darker grey means rising haz ard Not ...

Page 13: ...on of this hazard class we use in this documentation is listed below HERE STANDS THE SIGNAL WORD WHICH INDICATES THE DEGREE OF THE HAZ ARD Here we tell if one or more of the consequences described lower will occur if this hazard in formation is not observed m here we describe the possible consequences The worst consequence stands on the right side Here we describe the hazard Here we describe what ...

Page 14: ...may occur if you do not observe this warning information m serious personal injury m death The hazard is mechanical influence Here the hazard may be described in detail Here we describe what you can do to avoid the hazard WARNING The following may occur if you do not observe this warning information m serious personal injury m death The hazard is electro conductive liquid together with electricity...

Page 15: ...ocument no 5 01056 03 15 of 118 2 WARNING The following may occur if you do not observe this warning information m serious personal injury m death The hazard is liquid coolant Here the hazard may be described in detail Here we describe what you can do to avoid the hazard ...

Page 16: ... to avoid the hazard CAUTION The following may occur if you do not observe this caution information m minor to medium personal injury The hazard is sharp edges Here the hazard may be described in detail Here we describe what you can do to avoid the hazard CAUTION The following may occur if you do not observe this caution information m minor to medium personal injury The hazard is rotating parts He...

Page 17: ... to avoid the hazard CAUTION The following may occur if you do not observe this caution information m minor to medium personal injury The hazard is hazard of sliding caused by liquid Here the hazard may be described in de tail Here we describe what you can do to avoid the hazard CAUTION The following may occur if you do not observe this danger information m environmental pollution The hazard is un...

Page 18: ...r if you do not observe this caution information m property damage The hazard is electro static discharge Here the hazard may be described in detail Here we describe what you can do to avoid the hazard CAUTION The following may occur if you do not observe this caution information m property damage The hazard is damage of the coolant hose Here the hazard may be described in detail Here we describe ...

Page 19: ...is appliance always in an environment according to the information given in the Technical specifications m operate this appliance always in the regular condition For safety reasons you are not allowed to reconstruct this appliance m observe all respective information given if you want to store this appliance You are using this appliance according to the terms if you observe all notes and informa t...

Page 20: ...killfully m you have unskillfully combined the appliance with products of other manufacturers m you have combined the drive system with defective and or incorrectly documented products of other manufacturers 2 5 Education of the personnel Qualified personnel Qualified personnel are persons who have been authorized by the plant manager to carry out the activities required who are able to recognize ...

Page 21: ...o 5 01056 03 21 of 118 2 2 8 Fire fighting WARNING The following may occur if you do not observe this warning information m serious personal injury m death The hazard is electricity when using a conductive fire extinguishing medium Use this fire extinguishing agent ABC powder CO2 ...

Page 22: ...Fire fighting Manual Single Power Unit BUM64S A F Document no 5 01056 03 Baumüller Nürnberg Electronic GmbH Co KG 22 of 118 2 8 ...

Page 23: ...e visible transportation damages if yes h report this to your deliverer Request a written confirmation of your reclamation and make immediate contact with your local Baumüller Nürnberg Electronic GmbH Co representative if there is no transportation damage visible h open the packaging of the appliance h check the scope of delivery according to the delivery note The scope of delivery is m Produkt m ...

Page 24: ...the appliance has been packaged by the manufacturer If you intend to transport the appliance yourself make sure that the following conditions are kept throughout the whole transport m 2 K 3 environmental class m 30 C to 70 C temperature interval m max 1 g vibration shock continuous shock WARNING The following may occur if you do not observe this warning information m serious personal injury m deat...

Page 25: ...ntrol only Baumüller Nürnberg Electronic GmbH Co KG rack type controllers can be used m BUS 6 V controller m BUS 6 M controller For the controller there is a separate description with the respective features and techni cal specifications available Depending on the controller used you can drive either asynchronous or even synchro nous motors equipped with different encoder systems at the BUM64S A F...

Page 26: ...units are available in 3 variants which differ in power T or in the cooling version S A F m S stands for Switching cabinet variant air ventilation inside the switching cabinet A stands for window mounting variant Air ventilation outside the switching cabinet m F stands for window mounting variant water cooler outside the switching cabinet figure 1 Cooling variants ...

Page 27: ... 01056 03 27 of 118 4 4 2 Overview of hazardous areas The following figure shows the hazardous areas at each respective appliance Use this overview to get informed about the existing hazardous areas when you learn to get famil iar with this appliance figure 2 Hazardous areas ...

Page 28: ...BUM63X XXX X XX XX X X XXX Size BUM63X XXX X XX XX X X XXX Cooling variant S air ventilation with intake and outlet inside the switching cabinet A air ventilation with intake and outlet outside the switching cabinet F water cooled with water cooler outside the switching cabinet BUM63X XXX X XX XX X X XXX Output rated current in ampere at 40 C environmental and cool ant temperature and 4 kHz cycle ...

Page 29: ...Description of the unit Manual Single Power Unit BUM64S A F Document no 5 01056 03 29 of 118 4 4 4 Block switching diagram figure 4 Block switching diagram BUM 64S A F ...

Page 30: ...Block switching diagram Manual Single Power Unit BUM64S A F Document no 5 01056 03 Baumüller Nürnberg Electronic GmbH Co KG 30 of 118 4 4 ...

Page 31: ...uirements of EN 50178 VDE 0160 section 5 2 4 and EN 60204 1 VDE 0113 part 1 section 6 2 2 5 1 Hazardous areas during mounting The following overview shows you the hazardous areas at the appliance which are impor tant for mounting figure 5 Hazardous areas during mounting Use this overview for the mechanical mounting only Hazards which are caused by electricity are not shown here Hazards caused by e...

Page 32: ... Select a switching cabinet BUM64S A F units are build in appliances with respect to EN 50178 VDE 0160 section 5 2 6 They are intended for mounting into ordinary switching cabinets which meet the minimum requirements regarding the protection class stated in EN 50178 VDE 0160 section 5 2 4 IP 2X eventually also IP4X acc to EN 60529 5 1 WARNING The following may occur if you do not observe this warn...

Page 33: ... occur if you do not observe this caution information m property damage The hazard is overheating of the appliance Take care of proper ventilation of the appliances exhaust air Make sure that the coolant in take and outlet is not obstructed Observe the required coolant temperature and amount see ZD 2 Required environmental conditions on page 99 If necessary mount additional ventilators to the swit...

Page 34: ...5 01056 03 Baumüller Nürnberg Electronic GmbH Co KG 34 of 118 5 3 5 3 Producing the drill holes threaded holes and the cut out h produce the drill holes threaded holes variant A F only according to the drilling figures below figure 7 Drilling figure of BUM64S A F all other dimensions see BUM64A screw head ...

Page 35: ...screws in order to secure EMC of the units 5 4 1 BUM64S mounting CAUTION The following may occur if you do not observe this caution information m minor to medium personal injury The hazard is sharp edges Keep the unit s weight in mind the appliance weighs at least 49 kg Lift the appliance only with suitable equipment and or with the help of adequate qualified per sonnel carry safety gloves ...

Page 36: ...t Manual Single Power Unit BUM64S A F Document no 5 01056 03 Baumüller Nürnberg Electronic GmbH Co KG 36 of 118 5 4 screws A 4 x M8 washers B 4 x 8 4 x 17 mounting distance c c 7 mm figure 8 Mounting instruction BUM64S ...

Page 37: ...t and or with the help of adequate qualified per sonnel carry safety gloves WARNING The following may occur if you do not observe this warning information m serious personal injury m death The hazard is electrical conductive liquid in contact with electricity When a water cooled appliance is ejecting coolant water the water can invade through defective sealings into the switching cabinet and make ...

Page 38: ... GmbH Co KG 38 of 118 5 4 5 4 2 1 Coolant The coolant must meet certain requirements The requirements the coolant must have you will find in ZD 2 Required environmental conditions on page 99 screws A 16 x M8 washers 16 x 8 4 x 17 sealing see accessories figure 9 Mounting instruction BUM64 window variant A F ...

Page 39: ...io and test the mixture ratio within the stated maintenance intervals see ZInspection interval from page 73 Observe the security information supplied by the anticorrosive manufacturer and the security data sheets according to EU guideline 91 155 EWG or respective common national guide lines of the country where the appliance is in operation CAUTION The following may occur if you do not observe thi...

Page 40: ...ections 1 supply suitable connectors material brass G1 8 outside thread 2 clean the threaded holes and connectors 3 apply silicone sealant e g Loctite 5331 onto a least one clean thread winding The silicone sealant prevents either corrosion between the different construction ma terials and improves also the security tightness 4 turn the connectors by hand into the threaded holes of the heatsink an...

Page 41: ...otection against danger ous body currents not only comes from the basic insulation Furthermore they are equipped with additional safety precautions This additional protection consists of the housing and other parts being supplied with a protective earth connection So in case the basic insulation fails there is no risk of dangerous voltages The insulation of the appli ances is carried out across th...

Page 42: ...tion additional measures must be taken according to IEC 60536 2 chapter 5 1 1 German accident prevention directive Electrical plants and working funds VBG4 Essential for personal protection are the safety measures and security regulations ac cording to DIN VDE WARNING The following may occur if you do not observe this warning information m serious personal injury m death The hazard is Electricity ...

Page 43: ...eutral point according to IEC 364 4 41 chapter 413 1 3 chapter 413 1 4 they are intended for indus trial networks with non or high impedance earthed neutral point IT supply and for indus trial networks with hard or low impedance earthed corner point earthed star delta supply with a line to line voltage from up to 3 x 480 Veff WARNING The following may occur if you do not observe this warning infor...

Page 44: ...and oth er which must be observed when choosing a cable The BUM64S A F unit meets the UL requirements if you use the respective cables and if you carry out the fastening of the cables accordingly Further information you will find in the appendix under ZCable from mains supply to appliance on page 104 ZCable for control voltage supply signals on page 104 and ZCable from appliance to motor on page 1...

Page 45: ...ion Manual Single Power Unit BUM64S A F Document no 5 01056 03 45 of 118 6 6 5 1 Power terminals The power terminals are located at the bottom side of the unit see Zfigure 10 on page 45 figure 10 Power terminals ...

Page 46: ...ng on the cable lugs used 1V2 2 V phase motor terminal 1W2 3 W phase motor terminal S 4 earth connection 1U1 5 L1 phase mains connection 360 V UAC to 528 V UAC 0 A IAC to 230 A IAC 1V1 6 L2 phase mains connection 1W1 7 L3 phase mains connection S 8 earth connection Ba 9 Ballast resistor connection Ba is connected to the collec tor of the breaking switch Ba is 1C1 between Ba and Ba 0 to 830 V UDC 0...

Page 47: ...formation from page 52 3 4 This message is only related to BUM64S A F see also Z ready for use feed module on page 67 terminal pos 1 description Uinterval Iinterval A2 24 V 1 24 V PELV 3 terminal 1 and 2 are bridged internally 21 6 V UDC to 28 8 V UDC 0 A Ieff to 10 A Ieff 0 2 to 2 5 mm2 AWG 24 to 12 24 V 2 M 24 V 3 ground 24 V PELV terminal 3 and 4 are bridged internally 0 V UDC M 24 V 4 BBint 5 ...

Page 48: ...nnect terminal X99A If you need more screw type connectors please contact Baumüller Nürnberg Electronic GmbH Co KG or the manufacturer of the connectors directly see ZB 1 Connectors on page 87 WARNING The following may occur if you do not observe this warning information m serious personal injury m death The hazard is Electricity Take care to use multiple separate supply if you demand higher curre...

Page 49: ...sage ready for use external PELV Open contact supply unit not ready for use Closed contact supply unit not ready for use 0 V UDC to 24 V UDC 0 A IDC to 0 5 A IDC max 2 5 mm2 2 3 Message Warning PELV Closed contact supply unit no warning Open contact supply unit warning 4 Reset 5 potential free optocoupler input for reset of error messages PELV PHASE ERR POWER ERR and BRAKE OVERL figure 14 potentia...

Page 50: ...us personal injury m death The hazard is mechanical influence because of safety relay failure Take care that contacts 1 and 2 are loaded by a minimum current of 10 mA while in service Operate the safety relay within its specifications Coil side rated voltage 24 V PELV operating voltage 19 V to 37 V at Tu 20 C PELV coil resistance 660 Ω to 905 Ω Contact side switching voltage UAC max 25 VAC PELV sw...

Page 51: ...pendix E Safety relay from page 107 terminal pos 1 description Uinterval Iinterval A2 1 2 Feedback if the safety relay is enabled PELV 0 V UDC or 24 V UDC 0 01 A IDC to 5 A IDC 1 5 mm2 24 V 3 24 V connection to disable the safety relay PELV 0 V UDC to 24 V UDC 0 mA IDC to 35 mA IDC 1 5 mm2 M 24 V 4 reference point to input 24 V PELV 0 V UDC NOTE When operating the motor terminal 3 must be connecte...

Page 52: ...s occur with frequencies of up to approximately 600 MHz m high clock rates and fast logic circuits electromagnetic field 16 MHz up to 1 GHz m system perturbation and harmonics The reason for this are commutation processes and non sinusoidal mains network loads especially with network controlled converters 100 Hz up to 20 kHz 6 7 1 German EMC law EMVG This appliance complies with 6 sect 9 of EMVG d...

Page 53: ... the EMC compatibility inside the switching cabinet is guaranteed this you can assume when you have observed all configuration instructions given in this manual figure 16 Cabling suggestion for BUM64S A F m If you use Baumüller motor cables you can assume that the permissible limit values are not exceeded m The maximum length of the motor cable is limited The length depends on the cross section of...

Page 54: ...l signal transmission form twisted pair cables and twist those against all other twisted pairs e g for differential amplifier inputs used for speed setpoint value h the appliance to ground plate earth connection should be as short as possible 30 cm Use large cross sections 10 mm2 h the PE connection on the load side of the filter to the mounting plate should be carried out low impedant Ideal is a ...

Page 55: ...rt 30 cm cable if it is possible to ground the controller reference potential h remove insulating layers such as paint adhesives etc from the ground connections h if necessary use serrated lock washers DIN 6798 or similar measures to ensure a permanent conductive contact h to prevent corrosion on ground connections use suitable metal combinations in the sense of the electrochemical series of metal...

Page 56: ...length of the line you must always connect the screen at both ends figure 21 Screen contact on both sides of a line Connecting the screen to ground at both ends ensures that the conductor does not leave the system housing Grounding of conductor screens on both sides does not entirely rule out the influence of earth circuits potential differences on the ground system Those are very rare if you car ...

Page 57: ... and filter if the cable length exceeds 30 cm grounding on both sides h input and output cables of the filter should be run separate of each other distance 30 cm h the housing of the filter should be grounded using a wide surface 6 7 2 6 Discharge currents Due to the principle of operation parasitic capacities in the power unit motor cable and motor windings can add to discharge currents of 100 mA...

Page 58: ...ormation m serious personal injury m death The hazard is Electricity Take care that the permissible connected load see ZElectrical specifications from page 101 is never exceeded Reinstall the coverages that came with the appliance and tighten the screws of the coverages after you have finished the power cable connection Make sure that the total power requirement of the motors fed by the power modu...

Page 59: ...Installation Manual Single Power Unit BUM64S A F Document no 5 01056 03 59 of 118 6 figure 22 BUM64S A F connection diagram ...

Page 60: ...e a torque wrench with if you carry out fastening according to UL508C F0 Line protection fuse fuse depends on the cable used DIN VDE0100 430 F1 Semiconductor fuse or extreme range fuse see ZD 4 Fuses on page 103 K1 Line contactor auxiliary contact for control unit release optional not obligatory Mains Filter Mains filter see ZB 5 EMC accessories on page 90 L1 Line reactor see ZB 4 Line reactors on...

Page 61: ...e of the operational con ditions and the respective standards regulations and rules to detect and avoid accidents Examples of the qualifications to work with this appliance are m education training or authorization to commission ground and mark appliances ac cording to safety technology standards m education or training in maintenance and use according of adequate safety equipment to safety techno...

Page 62: ...irmly applied devices The power terminals of the power module hold potential Essential for personal security are the safety measures and safety regulations of the DIN VDE standards If protective conductor connections are missing at the appliance or at the motor you will have to face personal damage because the surfaces may carry dangerous voltages The protective conductor connection is to be carri...

Page 63: ...entilators Switching cabinets must be equipped with emergency stop devices who are able to cut off all voltages which can lead to hazards Not included are appliances that would generate new hazards after being cut off The release for the emergency stop device must be placed in a way that it is fast to reach in case of an emergency If you carry out operations that hold higher hazard levels the pres...

Page 64: ...Commissioning sequence Manual Single Power Unit BUM64S A F Document no 5 01056 03 Baumüller Nürnberg Electronic GmbH Co KG 64 of 118 7 5 ...

Page 65: ...oup is the infeed mod ule monitoring functions see Zfigure 4 on page 29 Second group is the motor side power module monitoring functions This partitioning reflects the appliance s internal construction WARNING The following may occur if you do not observe this warning information m serious personal injury m death Report immediately any situation that might lead to a deterioration of security Befor...

Page 66: ...essed there Further information you will find under ZMonitoring functions from page 69 8 3 Ready for use BB The ready for use message is the most important message When a monitoring function generates a message that erases the ready for use message the drive will be stopped There is not only one single message ready for use If for example there is a V control ler in your BUM 64S A F each drive wil...

Page 67: ...e the message is transmitted to the relay contacts Information about this you will find under ZMonitoring functions on page 69 and ZMessages over relay contacts on page 72 The term ready for use feed module is also called ready for use internal terminal des ignation BB int respectively ready for use external terminal designation BB ext The distinction has its reason only in the construction of the...

Page 68: ...orque free state the power module will produce no more power ready for use controller At the beginning of this section we have mentioned the V controller In the documentation of the controller you are using you will find information about if a ready for use controller message is supplied by your controller and if yes how you can process the ready for use controller message ready for use group Here...

Page 69: ...an switch off the 24V power supply That way all messages of the feed unit will be erased 4 The message must be erased by a reset of the controller Display and erasure of the message is described in the controllers documentation 5 A message only appears when the safety relay is switched off The safety relay is switched off when the 24V supply voltage is not present at the relay Before you are enabl...

Page 70: ...is charged again and the WARNING message is erased If the DC link voltage drops below 300 V after mains network failure or mains voltage dips the ready for use feed module is erased When the mains input voltage returns the wir ing of the X99AB 5 6 input determines the further behavior m if you apply shortly 1 ms 24 V the DC link is re charged the WARNING mes sage will be erased and the ready for u...

Page 71: ...ontroller The message ready for use motor side power module is erased m Monitoring function heatsink overtemperature The peak value of the DC link voltage is monitored A linear temperature sensor is mounted onto the heatsink Its measured value is trans mitted to the controller The controller that way is taking over the temperature monitoring see controller manual This must be adjusted according to...

Page 72: ...better word WARNING Vorw Stör Prew error Contact closed Message WARNING not present Contact open Message WARNING present In which cases this message is generated read under ZMonitoring functions of feed module on page 70 figure 27 X68 With the safety relay you can switch off the supply voltage of the transistor drivers After cut off the motor is torque free but is not galvanic isolated from the po...

Page 73: ... the appliance can block the required heat dissipation Layers of dirt on the ventilation grids are a warning signal which you should keep an eye on h check the devices e g air filters within the switching cabinet which ensure the re quired environmental conditions and be sure to keep the maintenance intervals given by the manufacturers h weekly check the specified environmental conditions The spec...

Page 74: ...Inspection interval Manual Single Power Unit BUM64S A F Document no 5 01056 03 Baumüller Nürnberg Electronic GmbH Co KG 74 of 118 9 1 ...

Page 75: ...n secured that neither po tential nor voltage residual charge is present Before demounting safety devices for commissioning or repair jobs the machine plant is to be put out of operation according exactly to the regulations Right after the commissioning or repair job is done all safety devices must be remounted and it must be made sure that they function correctly NOTE The operator of the machine ...

Page 76: ...Manual Single Power Unit BUM64S A F Document no 5 01056 03 Baumüller Nürnberg Electronic GmbH Co KG 76 of 118 ...

Page 77: ...se of the safety regulations during commissioning must be applied to the set out of operation procedure as well DANGER The following will occur if you do not observe this danger information m serious personal injury m death The hazard is Electricity Make sure that all electrical connections are switched powerless and are secured against un authorized reactivation The modules inside the appliance e...

Page 78: ...ar cranes transportation personnel etc for transport after demounting Disengage all mechanical connections to the switching cabinet only after the appliance has been secured against falling off falling down Keep ready suitable packing material if you intend to store the appliances If in doubt con tact Baumüller Nürnberg Electronic GmbH Co During transport observe that the appli ance is not damaged...

Page 79: ... Demands on the personnel The personnel which you instruct to dispose demount the appliance must have the knowl edge and training to carry out these jobs properly Choose the personnel in a way that it is secured that safety information on the appliance and its parts are understood and ob served CAUTION The following may occur if you do not observe this danger information m environmental pollution ...

Page 80: ...echnical condition 12 3 1 Modules figure 28 Demounting scheme The modules units below given in brackets you will find in the figure above sheet steel A sheet steel must be given to the iron metal recycling aluminium B aluminium must be given to the non iron metal recycling aluminium cop per compound C aluminium copper compound must be given to the non iron metal recycling plastics D the plastic pa...

Page 81: ... demounted further must be recy cled as special waste Observe the respective regulations 12 4 Recycling plants offices Make sure that the disposal is carried out according to your company s regulations and the regulations of the disposal companies and official administration If in doubt contact the local business administration environmental office or other CAUTION The following may occur if you d...

Page 82: ...Recycling plants offices Manual Single Power Unit BUM64S A F Document no 5 01056 03 Baumüller Nürnberg Electronic GmbH Co KG 82 of 118 12 4 ...

Page 83: ... BEDAS Operating data memory BOF Begin of file BS Function module operating system BSA Analog reference potential BSD Digital reference potential BSE External reference for 24 V con troller inputs BUB Ballast unit BUC Baumüller feed feedback unit BUG Baumüller converter basic feed unit BUM Baumüller single power unit BUS Baumüller power module CPU Central processing unit DA Digital analog DAC Digi...

Page 84: ... in DC link KT Function module Coordinate Transformation L Function module Position Control LED Light emitting diode LGE Telegram length LT Function module Power Module LW Low word M Function module Drive Manager M24 Reference potential 24 V MM f Function module Motor Model f Torque detector Prefix for hexadecimal number Mot Function module Field Angle Com puting MR1 Torque direction 1 MR2 Torque ...

Page 85: ...e of motor U Voltage UA Armature voltage UM Submenu USS Function module USS protocol UVS Supply voltage too low USS Siemens trademark universal serial interface UZK DC link voltage intermediate cir cuit voltage V Voltage V Peak voltage VAC Effective value sinus form voltage VBG Verwaltungs Berufsgenossen schaft German management occupation cooperative VDC Effective value direct current voltage VDE...

Page 86: ...Manual Single Power Unit BUM64S A F Document no 5 01056 03 Baumüller Nürnberg Electronic GmbH Co KG 86 of 118 ...

Page 87: ...e Article no Manufacturer order no type Male connector for X99A 00309454 Phoenix Contact MVSTBW 2 5 6 ST Male connector for X99AB 00303455 Phoenix Contact MVSTBR 2 5 6 ST Male connector for X68 00309482 Phoenix Contact MC 1 5 4 STF 3 81 BD 1 4 Article Article no Sealing tape 00350790 Coupling connection accessory BUM64F 00344573 B ...

Page 88: ...00 D1 450A 1250V A1 125E450 D1 500A 1250V A1 125E500 D1 550A 1250V A1 125E550 D1 630A 1250V A1 125E630 D1 2 350A 1250V A2 125E350 D1 400A 1250V A2 125E400 D1 450A 1250V A2 125E450 D1 500A 1250V A2 125E500 D1 550A 1250V A2 125E550 D1 630 A 1250V A2 125E630 D1 700A 1250V A2 125E700 D1 800A 1250V A2 125E800 D1 3 350A 1250V A3 125E350 D1 400A 1250V A3 125E400 D1 450A 1250V A3 125E450 D1 500A 1250V A3 ...

Page 89: ... V mains input voltage TA 55 C max Uk 4 4 8 UN 420 to 500 V 50 60 Hz IP 00 Reactor DR3 40 4 Rated d c current A a mm b mm c mm d mm e mm f x g mm Flat terminal mm x mm Weight kg Power con sumption W Article number 0 400 400 310 220 260 280 131 11 x 18 40 x 4 14 45 0 180 00101921 Reactor DR3 50 4 Rated d c current A a mm b mm c mm d mm e mm f x g mm Flat terminal mm x mm Weight kg Power con sumptio...

Page 90: ...ion Choose mains net filter in such a way that the occurring mains input current is lower than the rated mains input current of the mains net filter mains net filter rated mains input current 1 BFN 3 1 270 270 A for BUM64 with a output power of 132 kW BFN 3 1 250 250 A for BUM 63T at rated operation BFN 3 1 180 001 180 A for BUM 63 at rated operation BFN 3 1 130 001 130 A ...

Page 91: ...m requirements You will find detailed re quirements in standards to which references are made in the directive C 2 What the CE symbol indicates a The CE marking symbolizes conformity to all the obligations incumbent on manufac turers for the product by virtue of the Community directives providing for its affixing b The CE marking affixed to industrial products symbolizes the fact that the natural ...

Page 92: ...l equipment brought into circulation conforms to all the relevant fundamental safety and health requirements By issuing the Declaration of Conformity in this section the Baumüller Nürnberg Electronic GmbH Co KG declares that the equipment conforms to the relevant fundamental safety and health requirements resulting from the directives and standards which are listed in the Declaration of Conformity...

Page 93: ...n accordance with the above mentioned directive and the standards mentioned below under liability of Baumüller Nürnberg Electronic GmbH Co KG Ostendstr 80 90 D 90482 Nürnberg Berücksichtigte Normen standards complied with Nürnberg 17 12 2003 _________________________ _________________________ Dr Peter Kreisfeld Dr Heidrich Geschäftsführer Entwicklungsleiter Head Division Head of development Seite ...

Page 94: ...der obengenannten Richtlinie erklärt ist The machinery into which this unit is to be incorporated must not be put into service until the machinery has been declared in conformity with the provisions of the directive mentioned above Bei der Entwicklung und Konstruktion des Geräts wurden folgende Normen beachtet The development and construction of the unit is complied with following standards Baumül...

Page 95: ...ecorded under file no E179860 Only if all necessary tests have been completely carried out the c mark may be attached to the equip ments or components If single tests have not already taken place at the manufacturer s but are carried out not until at the user s then only the u mark may be attached With products of the Baumüller Nürnberg Electronic GmbH Co KG all tests are already completed at the ...

Page 96: ...UL certification Manual Single Power Unit BUM64S A F Document no 5 01056 03 Baumüller Nürnberg Electronic GmbH Co KG 96 of 118 C 7 ...

Page 97: ...M64S A F Document no 5 01056 03 APPENDIX D TECHNICAL SPECIFICATIONS In this chapter you will find an overview of the technical specifications Some of these data we have been using before in the previous chapters at the respective places D ...

Page 98: ... or TT mains Industrial system with none or high impedant grounded neutral system IT mains Industrial system with solid or low impedant grounded corner grounded mains Total inductance at the unit connection sum of mains inductance and line reactor inductance min Uk 4 max Uk 6 Mains input voltage frequency 1 2 unit UAC ventilator 8 UAC min 3 x 360 V 0 48 to 62 Hz max 3 x 528 V 0 48 to 62 Hz min 207...

Page 99: ...30 C to 70 C Storage climatic class 1 K 4 1 Operational surrounding outside populated areas 2 Operation temperature range min 0 C up to max 55 C 2 Operation climatic class 3 K 3 1 Mounting height 4 up to 2000 m above sea level rated service at 1000 m above sea level Relative humidity operation 5 to 85 no condensation1 Ionizing and non ionizing radiation no limits Vibration shock and continuous sho...

Page 100: ...50178 chapter 9 4 3 2 6 EN 50178 table 2 7 As coolant use clear suspended matter and dirt free desalinated and demineralized water The water may hold a maximum of 100 ppm 0 01 natrium chloride salinity Mix in an anticorrosive The total water hardness must be between 8 and 14 dH 1 dH 0 179 mmol Ca2 l A pH value between 6 5 and 7 5 must be kept Use a closed loop coolant circulation 8 Air inside and ...

Page 101: ...ax 20 mF Input current typical at 4 kHz Ieff 1 290 A Input current maximum at 4 kHz 8 Ieff 1 380 A Output voltage 2 UAC 3 x 0 V to 3 x input voltage 30 V Output frequency 3 0 Hz to 300 Hz Output power 1 at 4 kHz 4 192 kVA Output power 1 at 8 kHz 4 148 kVA Peak output power 8 at 4 kHz 4 250 kVA Peak output power 8 at 8 kHz 4 192 kVA Motor power typical 1 at 4 kHz 4 160 kW Motor power typical 1 at 8...

Page 102: ...40 C and 55 C the output power DC link peak load must be reduced The permissible output current I0 is calculated with the following formula There may be 2 temperature values cooling air that flows inside the appliance cooling air that flows through the heatsink Put in the higher value Example Output rated current 150 A environmental temperature 46 C The output current must be then reduced to 246 A...

Page 103: ...irst value is the depth inside the switching cabinet The second value is the depth outside the switching cabinet NOTE Use semiconductor or extreme range fuses if you intend to regard UL 508C Even if you do not regard UL 508C we recommend to use semiconductor or extreme range fuses Overcurrent protection devices for mains cable 1 according to EN 60204 1 Overcurrent protection devices for device 1 I...

Page 104: ...able lugs that have a maximum width of 25 mm Keep in mind that the M10 screw is used for attachment D 9 Cable for control voltage supply signals Cross section 1 depending on mains current Maximum length mains to mains filter user defined Maximum length mains filter to mains reactor max 0 3 m unscreened max 5 m screened Maximum length mains reactor to unit max 0 3 m unscreened max 5 m screened Cabl...

Page 105: ... n 4 Mount max 2 cable lugs per power rail Do not mount cable lugs onto each other mount one on each side of the power rail Use cable lugs that have a maximum width of 25 mm Keep in mind that the M10 screw is used for attachment D 11 Electrical motor to be connected 1 depends on the controller Cross section1 depending on connection Type of cable screened shield s degree of coverage 85 Maximum leng...

Page 106: ...Electrical motor to be connected Manual Single Power Unit BUM64S A F Document no 5 01056 03 Baumüller Nürnberg Electronic GmbH Co KG 106 of 118 D 11 ...

Page 107: ...safe in its off position when having opened electrical interlocked safety devices The motor may not have torque and thus cannot generate a dangerous movement The prevention of an unexpected starting of the machine can be reached by electrical separated safety devices e g contactors By some machine types it has to be done without the isolation of the electrical connection of the drive to the mains ...

Page 108: ...inist must carry out a safety evaluation for the residual movement The function of the safety relay is limited to the prevention of an unexpected starting The switch ing of the safety relay while the inductor of the motor is rotating causes an uncontrolled coast ing of the machine a braking with help of the converter is not possible anymore Turning off the safety relay has no isolation from the su...

Page 109: ...y the functioning of the safety function is guaranteed if power failure takes place In order to deactivate safe stop a voltage of 24 V has to be applied to the terminals which are intended for this use X68 3 4 For the external error monitoring of the safety relay the instantaneous control state can be in terrogated at its positively driven status signal contact X68 1 2 In case there is no voltage ...

Page 110: ...evant us ing protection against 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 safety 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 ...

Page 111: ...ed to the impulse release 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 and therewith a safe condition voltage is applied to the safety relay input X68 3 and therewith allows a torque generation at the shaft of the motor The NO contact of S1 is connected with the monitoring circuit n The monitoring circuit a fail...

Page 112: ...d must unavoidable have actuated and mechanical con nected contacts as well as a dual port connection NC contact NO contact The mechanical operating at the safety device must take place unavoidable that means tamper resistant The connection cables between the safety relay input X68 3 4 and the control as well as be tween the impulse release input at the converter X3 5 and the controller must not b...

Page 113: ...us signal contact of K1 NO contact to the monitoring circuit is constructed with mechanical with the NC contacts connected contacts The selection of the contactor takes place after its limiting short time current load capability 10 ms This must be bigger than the nominal current of the used semiconductor fuses at the mains input of the converter n S1 NC contact has hardware effects on the safety r...

Page 114: ...is not possible until the error has been repaired n The position switches which are used must unavoidable have actuated and mechanical con nected contacts as well as a dual port connection NC contact NO contact The mechanical operating at the safety device must take place unavoidable that means tamper resistant The connection cables between the contactor K1 and the control circuit as well as betwe...

Page 115: ...terminal X99A 49 potential free optocoupler input 49 Safety relay X68 51 Cabling suggestion for BUM64S A F 53 Reducing effective antenna height 54 Reducing loop area 54 contacting cable screens when routing through cabinet panels 55 Screening of cables at switching cabinet exit 56 Screen contact on both sides of a line 56 BUM64S A F connection diagram 59 Position of relay contacts 66 ready for use...

Page 116: ...Manual Single Power Unit BUM64S A F Document no 5 01056 03 Baumüller Nürnberg Electronic GmbH Co KG 116 of 118 Table of figures ...

Page 117: ... steps 7 Fuses 103 G Grounding 55 Guarantee 8 I Introduction 7 L Low Voltage Directive 92 low voltage power supply 98 M mains input voltage 98 mains network failure monitoring 70 max DC link voltage 46 maximum temperature 71 Monitoring 71 Mounting height 99 O Obligation and liability 7 output power 101 overtemperature 71 P packaging 24 personnel 7 20 61 phase failure monitoring 70 power dissipatio...

Page 118: ... Single Power Unit BUM64S A F Document no 5 01056 03 Baumüller Nürnberg Electronic GmbH Co KG 118 of 118 Index U UL 508 C 44 demands 44 fastening 60 UL certification 91 95 unexpected ramp up 107 V Variants 26 ...

Page 119: ......

Page 120: ...ly using 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...

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