b maXX BM4400

Basic unit Manual

5.04043.06

Title Product Version Part No. Status Copyright

Manual b maXX BM4400 5.04043.06 384209 13.11.2007 These operating instructions may be copied by the owner in any quantity but only for internal use. For other purposes these operating instructions and extracts thereof must not be copied or reproduced. Use and disclosure of information contained in these operating instructions are not permitted. Designations and company marks contained in these operating instructions may be brand names, the use of which by third parties for their own purposes may violate the rights of the holders. These operating instructions are part of the equipment/machine. These operating instructions must be available to the operator at all times and must be in a legible condition. If the equipment/machine is sold or moved to a different location these operating instructions must be passed 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 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. Baumller Nrnberg GmbH reserves the right, in developing its products further, to change the technical specifications and the handling of the products concerned without prior notice. No liability can be accepted concerning the correctness of the operating instructions unless otherwise specified in the General Conditions of Sale and Delivery.

Obligatory

Manufacturer

Baumller Nrnberg GmbH Ostendstr. 80 - 90 D-90482 Nrnberg Germany Tel. +49 9 11 54 32 - 0 Fax: +49 9 11 54 32 - 1 30 www.baumueller.de

Table of contents

1 1.1 1.2 1.3 1.4 1.5 2

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Validity of this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Survey of the appliance series b maXXBM4400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 First steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Used terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Copyright and trade mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Fundamental safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hazard information and commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hazard information structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Form of the hazard sign (triangular or round) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hazard information on personal injury . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hazard information on property damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Command signs used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Information sign . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Legal instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appropriate use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inappropriate use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Training of the personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety precautions in normal operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dangers due to residual energy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disposal of the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fire fighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Responsibility and liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Observing the safety notes and safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . Dangers when handling this device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warranty and Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . To be considered by transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dispose packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description of the devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controller unit versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Slots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Combination possibilities plug-in module-controller slots . . . . . . . . . . . . . . . . . . . . Interconnect the devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview of dangerous areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Marking of the device - type key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 11 12 13 13 14 19 19 20 20 20 21 22 22 23 23 23 23 24 24 24 24 25 25 25 26 27 28 29 30 31 32 32 34

2.1 2.2 2.2.1 2.2.2 2.2.2.1 2.2.2.2 2.2.2.3 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.13.1 2.13.2 2.13.3 3 3.1 3.2 3.3 4 4.1 4.2 4.2.1 4.2.1.1 4.3 4.4 4.5

Transportation and packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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5 5.1 5.2 5.3 5.4 5.5 5.6 5.7 6

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 General safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Requirements to the executing personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Prepare mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drilling patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mounting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting the water cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Requirements to the executing personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltage check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Requirements to the electrical mains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Requirements to the connecting cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Protection of the device and of the cable respectively . . . . . . . . . . . . . . . . . . . . . . . . . PE connection and RCD compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Requirements on the laying (EMC notes device) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Requirements to the temperature sensor of the motor. . . . . . . . . . . . . . . . . . . . . . . . . Operating sequence of installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connection diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . b maXX 44XX (without power modules) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . b maXX 44XX power modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connection diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connection data of the connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Requirements for the screwing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Requirements to the executing personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Enable signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mains-switch-on frequency/DC-link charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Display elements - LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Freely programmable LED (UH1, UH2)*): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating condition (H1, H2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Current limit (H3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Error (H4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Display (not BM44XX - XXX - XX0XX and BM44XX - XXX - XX1XX) . . . . . . . . . . . . Monitoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Requirements to the executing personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Monitoring functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Monitoring functions - explanations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Error detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Structure of the error list - survey of the error parameter names. . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reset errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Error parameters - error messages (error list) - error reactions. . . . . . . . . . . . . . . . Parameter description warnings (warning bit list) . . . . . . . . . . . . . . . . . . . . . . . . . 37 38 39 39 49 53 61 63 64 64 65 67 67 67 68 68 69 71 71 74 78 89 94 95 96 96 97 97 97 97 98 98 99 99 100 100 101 101 102 104 105 109 109 110 111 134

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11 6.11.1 6.11.2 6.12 6.12.1 6.12.2 7 7.1 7.2 7.3 7.3.1 7.4 7.5 7.5.1 7.5.2 7.5.3 7.5.4 7.5.5 7.6 7.7 8 8.1 8.2 8.3 8.3.1 8.4 8.4.1 8.5 8.5.1 8.5.2 8.5.3

Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Error detection and troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

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9 9.1 9.2 9.3

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Environmental conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection intervals - maintenance notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

137 137 138 139 141 143 143 144 144 144 145 145 147 147 149 149 149 150

10 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Shutdown, storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1 11.2 11.3 11.4 11.5 11.6 12.1 12.2 12.3 12.3.1 12.4 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Requirements to the executing personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Demounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Storage conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Requirements to the executing personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disposal instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recycling plants/offices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix A - Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 Appendix B - Spare parts and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 B.1 B.2 Interface cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dust cover and connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 154

Appendix C Declaration of Conformity/ by Manufacturer, UL - Certification . . . . . . . . . . . . . . . . . . . . . . 155 C.1 C.2 C.3 C.4 C.5 C.6 C.7 D.1 D.2 D.3 D.4 D.5 D.6 D.7 D.8 D.9 D.10 D.11 D.12 D.12.1 What is an EU directive? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . What the CE symbol indicates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Definition of the term Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Definition of the term Manufacturers Declaration. . . . . . . . . . . . . . . . . . . . . . . . . . . . Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Declaration by Manufacturer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UL-certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Requirements on the power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Requirements to the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Required environmental conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Non-electrical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical data - BM441X basic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical data - BM442X basic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical data - BM443X basic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical data - BM444X basic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical data - BM445X basic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical data - BM446X basic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical data - BM447X basic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BM447X, additional information to EMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 155 156 156 157 158 159 162 163 164 165 166 167 171 175 178 180 182 184 185

Appendix D - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

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D.13 D.14 D.15 D.16 D.17 D.18 D.19 D.20 D.20.1 D.20.2 D.20.3 D.20.4 D.20.5 D.20.6 D.20.7 D.20.8 D.20.9 D.20.10 D.20.11 D.20.12 D.20.13 D.20.14 D.20.15 D.20.16 D.20.17 D.20.18 D.20.19 D.20.20 D.20.21 D.20.22 D.20.23 D.21 D.22 D.23 D.24 D.25 D.26 D.27 D.28

Electrical data - BM442X power module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical data - BM443X power module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical data - BM444X power module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical data - BM445X power module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical data - BM446X power module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Additional data BM44XX with water-cooled chopper resistors . . . . . . . . . . . . . . . . . . Output-frequency-dependent current-derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuse protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cable protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Device protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cable protection + device protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Whole range fuses gR (device and cable) BM4412X, BM4413, model NH . . . . . . . Semiconductors aR (device) BM4412, BM4413, model NH . . . . . . . . . . . . . . . . . . . Whole range fuses gR (device and cable) BM4414, model NH . . . . . . . . . . . . . . . . Semiconductors aR (device) BM4414, model NH . . . . . . . . . . . . . . . . . . . . . . . . . . Whole range fuses gR (device and cable) BM4422X, model NH . . . . . . . . . . . . . . . Semiconductors aR (device) BM4422, model NH . . . . . . . . . . . . . . . . . . . . . . . . . . Whole range fuses gR (device and cable) BM4423X, model NH . . . . . . . . . . . . . . . Semiconductors aR (device) BM4423, model NH . . . . . . . . . . . . . . . . . . . . . . . . . . Whole range fuses gR (device and cable) BM4424, BM4425 and BM4426, model NH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Semiconductors aR (device) BM4424, BM4425 and BM4426, model NH . . . . . . . . Whole range fuses gR (device and cable) BM443X model NH . . . . . . . . . . . . . . . . Semiconductors aR (device) BM443X, model NH . . . . . . . . . . . . . . . . . . . . . . . . . . Full-range fuses gR, gRL, gR/gS, gGR (device and cable) BM444X, model NH . . . Semiconductors aR (device) BM444X, model NH . . . . . . . . . . . . . . . . . . . . . . . . . . Whole range fuses gR (device and cable) BM445X model NH . . . . . . . . . . . . . . . . Semiconductors aR (device) BM445X, model NH . . . . . . . . . . . . . . . . . . . . . . . . . . Whole range fuses gR (device and cable) BM446X model NH . . . . . . . . . . . . . . . . Semiconductor fuses aR (device) 446X, model NH . . . . . . . . . . . . . . . . . . . . . . . . . Semiconductor fuses aR (device) 447X, model NH . . . . . . . . . . . . . . . . . . . . . . . . . 24V-extra-low voltage protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cables mains-device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cables device-motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cable control voltage supply/signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Type of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fire fighting appliances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mains filters BM441X to BM447X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mains chokes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temperature sensors of the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

186 188 190 192 194 196 197 198 199 199 200 200 200 201 201 202 202 203 203 204 204 205 205 206 207 208 209 210 210 212 212 213 215 216 217 217 217 218 219

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Appendix E - Safe stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221 E.1 E.2 E.3 E.3.1 E.3.2 E.4 E.5 E.6 E.7 E.8 E.9 E.9.1 Methods to avoid an unexpected starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety categories according to EN 954-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The safety relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Principle sketch safety relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sequence diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Application example for machine of category 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Application example for machine of category 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Application upgrade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technical data safety relay module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Prototype Test Certificate BGIA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Supplement for the test certificate 2005 21349 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Supplement 2 for the test certificate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221 223 224 224 225 228 230 232 235 237 239 239 241 243 247

Table of figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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INTRODUCTION

This manual is an important part of your b maXX BM4400 appliance; Please, therefore completely read this manual, before starting operation, last but not least on behalf of your own security. In this chapter we describe the first steps, which have to be done after you have received the device. Terms are defined, which are continuously used in this manual. We will inform you about duties, which must be considered when using this device.

1.1

Validity of this manual

This manual is valid for b maXX BM4400 devices with the below mentioned type keys and replaces manual 5.01040: BM44XX - xxx - XX0XX[Ryy] - XX (without 7-segment display) BM44XX - xxx - XX1XX[Ryy] - XX (without 7-segment display) BM44XX - xxx - XX2XX[Ryy] - XX (with 7-segment display) BM44XX - xxx - XX3XX[Ryy] - XX (with 7-segment display) b maXX BM4400 power module type codes: BM44XX - XXX - 2XXXX[Ryy] - XX

1.2

Survey of the appliance series b maXXBM4400

An appliance of the series b maXX BM4400 consists of a power unit and a controller cartridge, which are in a common cabinet. The controller part is permanently installed into the controller cartridge. The controller cartridge has slots and can be extended with plugin modules. The appliances are available in graded construction- and capacity sizes. In this manual we will describe the Baumller device series b maXX BM4400, the connection and the commissioning.

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1.3

First steps

WARNING The following may occur, if you disregard these safety notes: m serious personal injury m death All persons, who work on and with devices of the series bmaXX, must have this manual available at their work place and must obey the instructions and notes contained therein - especially the safety instructions.

1.3

First steps
h Check delivery, see ZTransportation and packing from page 25. h Provide for qualified personnel for the mounting, installation and commissioning. h Hand over this manual to the personnel for mounting, installation and commissioning. Assure that especially the safety instructions are understood and obeyed.

1.4

Used terms
In this manual we will also use the term device for the Baumller product b maXX. A list of the abbreviations which are used are to be found in ZAppendix A - Abbreviations from page 151.

1.5

Copyright and trade mark

b maXX HIPERFACE is a registered trade mark of Baumller Nrnberg GmbH is a registered trade mark of SICK/Stegmann

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FUNDAMENTAL SAFETY
INSTRUCTIONS

2.1

General notes
In this chapter dangers are described, arising when working with the Baumller-device. Dangers are pointed up with symbols (icons). All symbols that are used in this manual are listed and explained. How you can protect yourself against the single dangers in the concrete case, we will not explain in this chapter. This chapter contains only general protective measures. The concrete protective measures we will always give directly after the note to the danger. The operation of the described devices is permissible, if the mentioned methods/procedures/measures are obeyed to. Everything else, that means also the operation of devices in installations, which are not shown here, is not permitted and must be checked with the company in each particular case. Any kind of claim to warranty will expire, if the devices are operated other than here described.

WARNING The following may occur, if you do not observe this warning information: m serious personal injury m death The hazard information is showing you the hazards which can lead to injury or even to death. Always observe the hazard information given in this documentation.

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2.2
2.2

Hazard information and commands

Hazard information and commands

Each hazard is classified in one of three different hazard classes. Every hazard class has one of the following characteristic signal words: DANGER m serious property damage m serious personal injury m death - will occur WARNING m serious property damage m serious personal injury m death - may occur CAUTION m minor to medium personal injury or m environmental pollution or m property damage - may occur

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2.2.1

Hazard information structure The following two examples show you how the hazard informations are constructed. The triangle is used when indicating a hazard for human beings. When there is a circle instead of the triangle, the hazard information is only for possible property damage. 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 outlines shade of grey reflects the severity of the hazard - darker grey means rising hazard. (Not every hazard information has a square representing the hazard, so we have shown it as draft here) The icon in the circle represents a command. (Not every hazard information has a circle representing the hazard, so we have shown it as draft here)

The circle indicates hazard for property.

The icon within the square illustrates the hazard. The outlines shade of grey reflects the severity of the hazard - darker grey means rising hazard. (Not every hazard information has a square representing the hazard, so we have shown it as draft here)

The text beneath the icons is constructed as follows: HERE STANDS THE SIGNAL WORD WHICH INDICATES THE DEGREE OF THE HAZARD Here we tell if one or more of the consequences described lower will occur if this hazard information 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 you can do to avoid this hazard.

2.2.2

Form of the hazard sign (triangular or round) If there is a triangle like or or is referring to personal damage. If there is a round hazard signal like is referring to property damage. in front of the signal word, the hazard information in front of the signal word, the hazard information

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2.2

Hazard information and commands

2.2.2.1 Hazard information on personal injury To distinguish each class of hazard information, we use a characteristic outline for both the triangular hazard signs and the square-form icons For the hazard class DANGER the danger sign is used. The hazard information of this hazard class used in this documentation is listed below: DANGER The following will occur, if you do not observe this danger information: m serious personal injury m death The hazard is: electricity. Here the hazard may be described in detail. Here is described what you can do to avoid the hazard.

DANGER The following will occur, if you do not observe this danger information: m serious personal injury m death The hazard is: mechanical influence. Here the hazard may be described in detail. Here is described what you can do to avoid the hazard.

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For the hazard class WARNING the warning sign is used. The following hazard information of this hazard class is used in this documentation. WARNING The following may occur, if you do not observe this warning information: m serious personal injury m death The hazard is: electricity. Here the hazard may be described in detail. Here is described 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: mechanical influence. Here the hazard may be described in detail. Here is described 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. Here the hazard may be described in detail. Here is described 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-magnetic radiation. Here the hazard may be described in detail. Here is described what you can do to avoid the hazard.

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2.2

Hazard information and commands

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 is described what you can do to avoid the hazard.

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For the hazard class CAUTION the caution sign is used when there is hazard for persons or of environmental pollution. The following hazard information of this hazard class is used in this documentation. CAUTION The following may occur, if you do not observe this caution information: m minor to medium personal injury. The hazard is: hot surface. Here the hazard may be described in detail. Here is described 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: sharp edges. Here the hazard may be described in detail. Here is described 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. Here the hazard may be described in detail. Here is described 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: injury of the eye caused by ricochetting particles. Here the hazard may be described in detail. Here is described what you can do to avoid the hazard.

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2.2

Hazard information and commands

CAUTION The following may occur, if you do not observe this caution information: m minor to medium personal injury. The hazard is: noise. Here the hazard may be described in detail. Here is described 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: hazard of sliding caused by liquid. Here the hazard may be described in detail. Here is described 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: unadequate disposal. Here the hazard may be described in detail. Here is described what you can do to avoid the hazard.

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2.2.2.2 Hazard information on property damage If there is a round caution sign to property damage. in front of the signal word, the safety information refers

CAUTION The following may occur, 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 is described 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 is described what you can do to avoid the hazard.

2.2.2.3 Command signs used

wear safety gloves

wear safety shoes

wear eye protection

wear ear protection

Use this fire extinguishing agent: fire extinguishing agent

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2.3
2.3

Information sign

Information sign

NOTE This note is a very important information.

2.4

Legal instructions
This documentation is addressed to technical qualified personnel, who is specifically skilled and who is thoroughly familiar with all warnings and maintenance procedures. The devices are made according to the state-of-the-art technology and are fail-safe. They can be installed safe, can be put into operation and they function without problems, if it is assured, that the instructions of the documentation are followed. The user is responsible for the execution of service and commissioning according to the safety instructions of the prevailing standards and other relevant national and local instructions concerning conductor dimensioning and protection, earthing, disconnector, overcurrent protection and so on. For damages, which result from the mounting or from the connection, the one is liable, who has carried out the mounting or the installation.

2.5

Appropriate use
Always use the device according to the terms. Stated below we have carried a few important notes together. The notes stated below shall give you a feeling for the according to the terms usage of the device. We do not raise any claim for the completion of the notes stated below - follow all instructions given in this operating instruction. m project the application in such a way, that you always operate the device within its specification. m use this device only as converter for three-phase drives. m make sure, that only qualified personnel work with/at this device. m install this device only on an adequate carrying wall. m install this device in the way as it is described in the documentation. m make sure, that the mains/power supply unit always applies to the predetermined specifications. m only operate the device, if it is technical faultlessly. m operate this device only in combination with released components of the company Baumller Nrnberg GmbH. m always operate the device in an area as it is instructed in the "Technical data. m Operate the device in environments of second mode (industrial environment). The device was developed in such a way, that it meets the requirements of the category C3 according to IEC 61800-3:2005. The device is not provided for the connection to the public network. The operation of the device in an environment of the first mode of category C2/C1 (living-, business and industry area without intermediate transformer directly at a public secondary distribution system), in order to reduce the RFI-emission

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(cable-guided and blasted) special measures must be provided for and must be proved by the control cabinet manufacturer, because EMC-interferences can occur, if no additional measures have been taken. If a device, which was described here, reaches the category C2/C1, even with additional measures, can not be ensured. m always operate the device in serialized condition. Due to safety reasons you must not rebuild the device. m consider all instructions referring to this, if you intend to store the device. You are using the device according to the terms, as soon as you regard all notes and information in this operating manual.

2.6

Inappropriate use
Listed below you will find some examples of non-appropriate application. The information below is intended to give you some impression of what non-appropriate application is. However we cannot state all possible non-appropriate applications here. All applications, where the notes and information given in this documentation is disregarded, are non-appropriate and therefore forbidden. Examples: m You disregarded the notes in this manual. m The device has not been specifically applied as a converter in order to control a motor. n The device has been m mounted incorrectly, m connected incorrectly, m commissioned incorrectly, m operated incorrectly, m mounted, connected, commissioned, operated and/or maintained by not qualified or inadequately qualified personnel, m inappropriately maintained or not maintained (also consider the descriptions of the components), m overloaded it, n operated m with defective safety devices, m with incorrectly mounted safety devices or without safety devices, m with incorrectly working safety- and protection devices, m outside the specified environmental conditions. m You have modified the device. m You have insufficiently monitored the parts, which are subject to a wearing. m You have improperly carried out a repair. m You have combined the device with improper products, which are not enabled for devices described in this manual. m You have combined the device with faulty and/or faulty documentated products of other manufacturers. m The device has been operated in an explosive environment.

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2.7
2.7

Safety equipment

Safety equipment
The devices BM441X, BM442X and BM443X comply with the protection class IP 20. The devices BM443X and BM444X comply with the protection class IP20, if the power connections are performed safe-to-touch according to IP20, otherwise IP10. BM445X, BM446X and BM447X comply with the protection class IP 00. The mentioned device types must be built into a suitable control cabinet, in order to comply with the required protection classes in EN61800-5-1, chapter 4.2.3.3 (IP30: only the upper horizontal surfaces; IP20: all the other surfaces). WARNING The following may occur, if you do not observe this warning information: m serious personal injury m death The danger is: electricity. The device cabinet complies with IP 00. Operate the device in a control cabinet, which provides a protection against a direct touching of the devices and fulfills at least the demands of the EN 50178 chapter 5.2.4.

2.8

Training of the personnel

WARNING The following may occur, if you do not observe this warning information: m serious personal injury m death Devices of the company Baumller Nrnberg GmbH may only be assembled, installed, operated and maintained by qualified personnel. Qualified personnel (professionals) is defined below: Qualified personnel Authorized electronic engineers and skilled persons of the customer or third persons, who have learned the installation and commissioning of Baumller drive systems and who are authorized, to put circuits and devices into operation according to the standards of the safety technology, to ground and to label. Qualified personnel has a training or an instruction due to the local valid standards of the safety technique in maintenance and usage of an adequate safety equipment. Requirements to the operating personnel The operating of the drive system must only be executed by persons, who have had a training, who have been instructed and who have been authorized for this. Fault clearance, servicing, cleaning, maintenance and exchange must only be carried out by skilled or instructed personnel. These persons must know the operating manual and must act according to this. The commissioning as well as the instruction must only be carried out by qualified personnel.

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2.9

Safety precautions in normal operation

h at the location of your appliance regard the safety regulations for the plant, into which the appliance has been built in. h if safety regulations require additional monitoring or safety devices supply your appliance with them.

2.10 Dangers due to residual energy

Electrical residual energy After separation of the device from the mains parts under voltage as e. g. power connections may be only then touched if the capacitors in the device are discharged (see discharging time in ZD.6 Electrical data - BM441X basic unit on page 167 to ZD.11 Electrical data - BM446X basic unit on page 182). Also pay regard to the instructions on the device. If you have additional capacitors connected to the DC-link, the DC-link discharging also can last much longer. In this case you must determine the necessary waiting time on yourself or measure wether the device is off-circuit. The mechanical residual energy is dependent upon the application. As we don't know the application, we cannot make any exact statements. Driven parts also rotate/move after disconnection of the mains supply for a certain time. Please, provide adequate safety arrangements.

Mechanical residual energy

2.11 Disposal of the device

The accurate disposal of the device is described in Z12 Disposal on page 147.

2.12 Fire fighting

WARNING The following may occur, if you do not observe this warning information: m serious personal injury m death The danger is: Electricity when using a conductive fire fighting appliance. Use this fire extinguishing agent: ABC powder / CO2

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2.13

Responsibility and liability

2.13 Responsibility and liability

To be able to work as safe as possible with this device, you must know and follow the danger notes as well as the safety instructions. 2.13.1 Observing the safety notes and safety instructions In this manual we use visually unified safety instructions, which are intended to prevent from personal injury or damage to property. WARNING The following may occur, if you do not observe this warning information: m serious personal injury m death All persons, who work with this device, must know and regard the safety notes and the safety instructions in this manual. Apart from this, any and all persons who work on this device must additionally know and regard to all regulations and instructions, that are valid at the location.

2.13.2 Dangers when handling this device The device b maXX was developed and manufactured according to the state-of-theart technology and in compliance with the valid regulations and standards. It is still possible that dangers can arise during use. An overview of possible dangers is to be found in chapter ZFundamental safety instructions from page 11. We warn you against the acute danger at the respective places in this manual. 2.13.3 Warranty and Liability All information in this manual is non-binding customer information; it is subject to ongoing further development and is updated on a continuous basis by our revision service. Warranty- and liability claims against Baumller Nrnberg GmbH are excluded if in particular one or more of the causes listed in ZInappropriate use from page 21 has/have caused the damage.

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TRANSPORTATION AND PACKING

In this chapter we describe, which conditions have to be adhered to at transportation, how you check the device after receipt and what you should have to consider, if you dispose the packing.

3.1

To be considered by transportation
For the first transportation of the device, the device was packed in the manufacturer company. In case you transport the device, assure, that the following conditions are fulfilled during the whole transportation: m 2 K 3 (climatic category) 1) m - 30 C bis + 70 C (temperature range) m max. 1 g (vibration, shock, repetitive shock)
1)

EN 50178, table 7

3.2

Unpacking
After receipt of the device, which is still packed: h Avoid strong transportation vibrations and severe hits, e.g. when setting down. h Check, if transportation damages are visible! If so: h Immediately complain to the deliverer. Let the claim be confirmed in writing and immediately contact the substitution of Baumller Nrnberg GmbH, which is in charge for your company.

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3.3

Dispose packing

WARNING The following may occur, if you disregard these safety notes: m serious personal injury m death The danger is: electricity. Do not operate the device, if you have recognized a transportation damage or if you assume this. In this case immediately contact Baumller Nrnberg GmbH If there is no transportation damage recognizable: h Open the packing of the device. h Check the scope of supply with the help of the delivery note. The minimum scope of supply is: m b maXX BM4400 m This manual inclusively the copy of the declaration of conformity/declaration of manufacturer h Claim at the Baumller substitution, which is in charge, in case the delivery is not complete.

3.3

Dispose packing
The packing is made of cardboard, plastics, metal parts, corrugated cardboard and/or wood. h Regard the local disposal instructions, in case you dispose the packing.

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DESCRIPTION OF THE DEVICES

In this chapter the basic construction of the devices b maXX BM4400 and the slots of the controller cartridge are described and the type key on the devices is explained. NOTE The devices of the b maXX BM4400-series are provided for the operation in the second environment (industrial environment) according to EN 61800-3. At connection to the public mains EMC problems can appear. Also see ZAppropriate use from page 20.

NOTE A correct operation of b maXX BM4400 power modules can only be assured in combination with Baumller power converters or mains inverters.

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4.1

Structure

Structure
The devices of the b maXX-series are servo converters of Baumller Nrnberg GmbH. The devices consist of a power unit with an integrated slot for the controller cartridge (narrow or wide). The controller cartridge itself possess, besides a firmly installed controller (slot F), rows of slots, that can be filled with optional modules. The rated current of the devices reach from 2,5 A to 600 A. The devices differ in size, power, equipment (hard- and software) and cooling types. This data is available in the type key (see ZMarking of the device - type key on page 34).

Figure 1:

Power unit (A) - controller unit (B)

A device of the series b maXX BM4400 consists of the following parts: A: Power unit (con- This part is a power semiconductor converter combination which is build up with power semiconductor components. verter) b maXX BM4400 The present alternating voltage at the three-phase system is converted into direct voltage by the input sided rectifier. The DC link capacitors smooth this DC link direct voltage. The output sided inverter generates a three-phase system from the direct voltage with variable frequency and voltage for the supply of the connected motor. Alternatively you can draw d. c. from the device via the DC link connections. b maXX BM4400 power module The output sided inverter generates via the DC link connection a three-phase system from the direct voltage with variable frequency and voltage for the supply of the connected motor. B: Controller unit The controller unit controls the power unit. You can operate the controller part either with the operating software WinBASS II (PC) or via a PLC or via a field bus and PLC. PLC and field bus interface are available as plug-in module.

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4.2

Controller unit versions

There are three versions of the controller unit:

single row

This version is a 1-row equipped controller unit in a 3-rowed installation space. This controller unit is available for every b maXX BM4400 except for the BM441X-XXX-X0 and the BM441X-XXX-X1.

This version is a 1-row equipped controller unit in a 2-rowed installation space. This controller unit is available only in the BM441XXXX-X0.

2-rowed

This version is a 2-row equipped controller unit in a 3-rowed installation space. This controller unit is available for every b maXX BM4400 except for the BM441X-XXX-X0 and the BM441X-XXX-X1.

This version is a 2-row equipped controller unit in a 2-rowed installation space. This controller unit is available only in the BM441XXXX-X1.

3-rowed

This version is a 3-row equipped controller unit in a 3-rowed installation space. This controller unit is available for every b maXX BM4400. In case you order a b maXX 441X with this controller unit, you will receive the device BM441XXXX-X2.

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4.2.1

Controller unit versions

Slots In slots of the controller unit functional- or optional modules are plugged, which extend the functional range of the controller unit. Every slot is clearly identified by a code letter. A The controller communicates via a functional module bus with plug-in modules in these slots. B Slot D is interrupt-capable. Therewith slot D is particularly is suitable for modules e. C g. measurement sensing. In these slots functional modules can be inserted. D E F
2- and 3-rowed

1-, 2- and 3-rowed

Optional modules can not be inserted into these slots. Controller module, permanently installed.

G The controller communicates via the BACI-bus with plug-in modules in these slots. In these slots option modules can be inserted. H Function modules can not be inserted into these slots.

J
3-rowed

With plug-in modules in these slots the controller communicates via the BACI-bus. In these slots option modules can be inserted. K Function modules can not be inserted into these slots. L M Every plug-in module is delivered with an appropriate manual. In the manual of the module amongst other things the mounting and the installation of the module is described.

CAUTION The following may occur, if you disregard these safety notes: m Property damage The danger is: Plug-in module, which has not been manufactured from Baumller Nrnberg GmbH Modules of other manufacturers can damage/destroy the device. Only use BM4-F-XXX- and BM4-O-XXX-plug-in modules.

Dependable of the existing controller unit version on your device you can retrofit optional plug-in modules (functional modules and optional modules). The slots differ in size and function.

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Description of the devices

4.2.1.1 Combination possibilities plug-in module-controller slots

Function modules BM4-F-ENC-XX (encoder 1 for motor control recommended)

Option modules

BM4-O-IEI-XX* (incremental encoder emulation)

BM4-F-IEE-XX (incremental encoder emulation)

BM4-O-ETH-02* (Ethernet + CANopen master) X o o o o o

BM4-F-SIE-XX (SSI-SSI encoder emulation)

BM4-F-CAN-01 (CANsync slave) in prep.

BM4-O-DNT-XX (DISC-NT slave module)

BM4-O-CAN-04* (CANopen master)

BM4-O-CAN-06* (CANsync master)

BM4-O-CAN-03 (CANopen slave)

A B C D E

X -

X -

o o o X o

o o o X o

X -

o X -

X -

F Controller unit, permanently installed G H J K L M o X o X P P P P o X P P P P o X P P P P o X o X X o o o o o X o o o o o X o o o o o X o o o o o o X P P P P

Figure 2:

X: preferred slot Baumllter Nrnberg GmbH recommends, in order to reach the highest functional range, to insert the plug-in modules into these slots. o: possible slot only if the preffered slot is occupied, we recommend in order to reach the highest functional range, to insert the plug-in modules into this slot. P: only possible, if on slot G or H a PLC module (PLC) is plugged and the PLC (and not the controller) executes the communication to the field bus slave module. -: not possible - card doesnt work in this slot. * Precondition for these cards is an inserted PLC module (PLC). Slot combinations

NOTE In case you insert a BM4X-X-XXX plug-in module into an unsuitable slot, it will not operate. We have made sure, that neither the module nor the device are damaged.

Steckkarten_Rev14_e

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BM4-O-ECT-01 (EtherCAT slave)

BM4-O-CAN-05 (CANsync slave)

BM4-O-PRO-01 (Profibus slave)

BM4-O-SER-XX (Sercos slave)

BM4-F-FIO-XX (fast digital I/O)

BM4-F-AIO-02/03 (analog I/O)

BM4-F-ENC-XX (encoder 2)

BM4-O-ETH-01* (Ethernet)

BM4-F-AIO-01 (analog I/O)

BM4-F-DIO-XX (digital I/O)

BM4-O-PLC-XX (SPS)

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4.3

Interconnect the devices

Interconnect the devices

The device is part of the Baumller series b maXX BM4400 and can be connected together with other Baumller devices.

4.4

Overview of dangerous areas

The following overview shows the existing danger areas on the particular device. Use this survey for an overview of the existing danger areas, if you incorporate into the handling of this device. The explanation of the symbols, which are used you will find in ZHazard information and commands from page 12.

Figure 3:

Danger areas BM441X, BM442X, BM443X and BM444X

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Description of the devices

Figure 4:

Danger areas BM445X, BM446X and BM447X

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4.5

Marking of the device - type key

Marking of the device - type key

On the type plate (label) you will find, besides others, the type key of the device.

Figure 5:

Position of type key label

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Description of the devices

The type key has the form: BM4XXX - XXX - XXXXX[Ryy] - XX. Directly behind the type key is the design code (-XXXX - X - XXX - XXX). In the following table the type key is explained. BM4XXX - XXX - XXXXX[Ryy] - XX Device generation BM4XXX - XXX - XXXXX[Ryy] - XX Controller type
4: Vector controller with and without encoder feedback (closed loop / open loop)

BM4XXX - XXX - XXXXX[Ryy] - XX Size of cabinet

1 to 7 (from cabinet size 1 there are two different wide versions)

BM4XXX - XXX - XXXXX[Ryy] - XX Current grading (output rated current)

2 to 6 (current value is dependent on the cabinet size), see appendix D

BM4XXX - XXX - XXXXX[Ryy] - XX Cooling type

S: air-cooled with air supply and with air outlet in the control cabinet A: air-cooled with air supply and with air outlet outside the control cabinet Z: water-cooled with water cooler in the control cabinet F: water-cooled with water cooler outside the control cabinet C: (cold plate) cooling via mounting wall of the control cabinet

BM4XXX - XXX - XXXXX[Ryy] - XX Mains type

T: TN- or TT-mains I: IT-mains and grounded delta

BM4XXX - XXX - XXXXX[Ryy] - XX Safety relay

0: no module 1: Module with one relay and high power current contacts 2: Module with two relays and high power current contacts 3: Module with one relay and low current contacts 4: Module with two relays and low current contacts

BM4XXX - XXX - XXXXX[Ryy] - XX Hardware type/power unit type

0: Rectifier and inverter with chopper resistor transistor UDC = 540 V 1: Rectifier and inverter with chopper resistor transistor UMains =230 V 10 %, UDC =310 V 2: Power module (only output sided inverter). Operation as power module, UDC = 540 V

BM4XXX - XXX - XXXXX[Ryy] - XX Hardware type/controller unit versions

1: Module in slots A to H pluggable 2: Modules in slots A to M pluggable

BM4XXX - XXX - XXXXX[Ryy] - XX Hardware type (internal information via Baumller Nrnberg GmbH.
0XX: Controller without 7-segment display (RS 485 interface) 1XX: Controller without 7-segment display (RS 485 interface) 2XX :Controller with 7-segment display (RS 485 interface) 3XX :Controller with 7-segment display (Ethernet interface))

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Marking of the device - type key

BM4XXX - XXX - XXXXX[Ryy] - XX Optional chopper resistor

R16: Chopper resistor with 16 R10: Chopper resistor with 10 R05: Chopper resistor with 5 R03: Chopper resistor with 3

BM4XXX - XXX - XXXXX[Ryy] - XX State of software controller (firmware)

01: Series version 1.x 03: Series version 3.x

NOTE This type key is only for the basic device without the plug-in modules. Every plug-in module (except the controller) has its own type key.

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MOUNTING

In this chapter we describe the mechanical mounting of the device into a control cabinet. Data about the installation space is available in this manual (see ZInstallation space from page 39). Mounting consists of the following steps: 1 Prepare mounting (drill holes/cut-out segments) 2 Install device

WARNING The following may occur, if you do not observe this warning information: m serious personal injury m death At execution of any mounting workings it must be assured that no strange substances (e.g. drilling chips, copper wire etc.) get into the device. If possible the drillings should be done before mounting the device and the assembling of the cables should be done outside the control cabinet. If this is not possible, the device must be covered accordingly.

5.1

General safety instructions

CAUTION The following may occur, if you disregard these safety notes: m Property damage The danger is: electrostatic discharge. Connections of the device sometimes are dangerous to ESD. Regard the corresponding notes.

h Please regard to the information in chapter ZFundamental safety instructions from page 11.

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Requirements to the executing personnel

h Pay attention to all areas at the device, which could be dangerous for you while mounting. Use this survey only for the mechanical mounting. Dangers, which, for example, result from electricity are not shown here.

Figure 6:

Danger areas by the mechanical mounting

5.2

Requirements to the executing personnel

CAUTION The following can occur, if you disregard this warning instruction: m minor to medium personal injury. The danger is: sharp edges. In case, while installing, you lift a device with unprotected hands, fingers/palm can be cut. If the device falls off, your feet can be cut up. Make sure, that only qualified personnel, who is familiar with the safety- as well as with mounting instructions, works on this unit.

Wear safety gloves

Wear safety shoes

Qualified personnel are persons, who have been instructed by the responsible person, based on their training, experience, the instructions they were given as well as their knowledge about relevant standards and instructions, knowledge of the accident prevention instructions and of the company, to execute the necessary operations and thereby are able to recognize and avoid the dangers which could happen. The required qualifications for the work with this unit are for example: m Training or instruction due to the standards of the safety engineering in maintenance and use of appropriate safety equipment.

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5.3

Prepare mounting
You can prepare the mounting with the configuring manual for your installation. With the project manual and the drill figures (see ZDrilling patterns from page 49) you can determine the dimensions for the cut-outs and for the fastening drills. CAUTION The following can occur, if you disregard this warning instruction: m minor to medium personal injury. The danger is: Eye injury due to catapulting particles. While executing the drillings and the cut-out metal particles are catapulted.

Wear eye protection

h Execute the drilling and if necessary the cut-outs.

5.4

Installation space
The following drawings show the main dimensions of the devices in mm. Use these drawings, in order to determine the required space in the control cabinet. For the construction of the necessary drilling/cut-outs use the drawings in ZDrilling patterns from page 49.

Figure 7:

Installation space BM441X

*: min. expansion space, also consider ZCooling on page 165

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5.4

Installation space

Figure 8:

Installation space BM442X-S/A *: min. expansion space, also consider ZCooling on page 165

Figure 9:

Installation space BM442X-F *: min. Expansion space, also consider ZCooling on page 165

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Mounting

Figure 10:

Installation space BM442X-C

*: min. expansion space, also consider ZCooling on page 165

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5.4

Installation space

Figure 11:

Installation space BM443X-S/Z

*: min. expansion space, also consider ZCooling on page 165

Figure 12:

Installation space BM443X-A/F

*: min. expansion space, also consider ZCooling on page 165

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Mounting

Figure 13:

Installation space BM443X-C

*: min. expansion space, also consider ZCooling on page 165

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5.4

Installation space

Figure 14:

Installation space BM444X-S/Z

*: min. expansion space, also consider ZCooling on page 165

Figure 15:

Installation space BM444X-A/F

*: min. expansion space, also consider ZCooling on page 165

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Figure 16:

Installation space BM445X-S/Z

*: min. expansion space, also consider ZCooling on page 165 **: width inclusively bolt heads

Figure 17:

Installation space BM445X-A/F

*: min. Expansion space, also consider ZCooling on page 165 **: width inclusively bolt heads

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5.4

Installation space

Figure 18:

Installation space BM446X-S/Z

*: min. expansion space, also consider ZCooling on page 165 **: width inclusively bolt heads

Figure 19:

Installation space BM446X-A/F

*: min. expansion space, also consider ZCooling on page 165 **: width inclusively bolt heads

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Figure 20:

Installation space BM4-47X-F

*: min. expansion space, also consider ZCooling on page 165

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5.4

Installation space

Figure 21:

Installation space BM447X-A

*: min. expansion space, also consider ZCooling on page 165

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5.5

Drilling patterns
The following drawings show the drilling patterns of the devices. Use these drawings, to prepare the necessary drilling/cut-outs. Use the drawings under ZInstallation space from page 39, to determine the required space in the control cabinet.

Figure 22:

Drilling pattern BM441X

Figure 23:

Drilling pattern BM442X

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5.5

Drilling patterns

Figure 24:

Drilling pattern BM443X

Figure 25:

Drilling pattern BM444X

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Figure 26:

Drilling pattern BM445X

Figure 27:

Drilling pattern BM446X

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5.5

Drilling patterns

Figure 28:

Drilling pattern BM447X-F

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Figure 29:

Drilling pattern BM447X-A

5.6

Mounting instructions
There are different mounting technics. Every mounting procedure is shown as a chart (see ZFigure 30 on page 55 to ZFigure 33 on page 58. Below the chart is the list of the devices, for which the particular instruction is to be used. The screws and washers you need for mounting are to be found below the particular chart. WARNING The following may occur, if you disregard these safety notes: m serious personal injury m death The danger is: mechanical effects. A device of the size 446X weighs about 70,0 kg and can seriously injure, if it falls off. Transport the device in a way, so that it cannot drop. Use an appropriate lift when mounting it.

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Mounting instructions

CAUTION The following may occur, if you disregard these safety notes: m minor to medium personal injury. The danger is: sharp edges. In case, while installing, you lift a device with unprotected hands, fingers/palm can be cut. If the device falls off, the feet can be cut.

Wear safety gloves

Wear safety shoes

Complete the mounting in the following way: 1 if necessary, provide a suitable transportation-/lift equipment 2 provide suitable mounting accessories 3 mount the device.

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Mounting

Figure 30:

Mounting instruction BM441X, BM442X-S, BM443X-S/Z, BM444X-S/Z

Device

BM441X-XXX -XO -X1 2 x M5 2 x (5.3 x 10) c = 5 mm

BM441X-XXX -X2 4 x M5 4 x (5.3 x 10) c = 5 mm

BM442X-S

BM443X-S/Z

BM444X-S/Z

A - screws B - washers c - mount spacing

4 x M5 4 x (5.3 x 10) c = 5 mm

4 x M5 4 x (5.3 x 10) c = 5 mm

4 x M5 4 x (5.3 x 15) c = 5 mm

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Mounting instructions

Figure 31:

Mounting instruction BM445X-S/Z and BM446X-S/Z

Device A - screws B - washers c - mount spacing

BM445X-S/Z 4 x M8 4 x (8.4 x 17) c = 7 mm

BM446X-S/Z 4 x M8 4 x (8.4 x 17) c = 7 mm

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Mounting

Figure 32:

Mounting instruction BM447X-A/F

Device A - screws B - spring washers C - washers

BM447X-S/A 38 x M6

BM447X-F 22 x M6

38 x DIN6796-6-FST 22 x DIN6796-6-FST 38 x (6.4 x 12.5) 22 x (6.4 x 12.5)

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Mounting instructions

Figure 33:

Mounting instruction miscellaneous

Device A - screws B - washers

BM454X-A/F/Z/C BM443X-A/F/C BM444X-A/F 4 x M5 4 x (5.3 x 10) 14 x M4 14 x (4.3 x 9) 16 x M5

BM445X-A/F 16 x M8

BM446X-A/F 20 x M8 20 x (8.4 x 17)

16 x (5.3 x 15) 16 x (8.4 x 17)

WARNING The following may occur, if you disregard these safety notes: m serious personal injury m death The danger is: conductive fluid in connection with electricity. The mounting drills are outside of the gasket. With non-waterproof fastening holes, e. g. the liquid coolant can enter the control cabinet. Seal the mountings against water. Use, e.g., waterproof draw-in bolts and sealants between screws and bolts.

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Mounting

Type of protection: control cabinet with built in through-hole devices BM442X-A/F NOTE The following required control cabinet mounting is only valid for control cabinets with protection class IP54 or higher. IP protection class for air-cooled through-hole devices: IP44 IP protection class for air-cooled through-hole devices: IP54

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Mounting instructions

Figure 34:

Control cabinet mounting BM442X-A/F

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5.7

Connecting the water cooler

With water cooled devices (BM44XX-F and BM44XX-Z) you connect the coolant circulation before you install the electric. The water cooler has on its bottom side two pressfittingtransition pieces 15mm x R 1/2 AG for flat washers. h Connect the cooling circulation to the water cooler. Device BM442X-F BM443X-F BM443X-Z BM444X-F BM444X-Z BM445X-F BM445X-Z BM446X-F BM446X-Z BM447X-F Tube material VA VA VA VA VA VA VA VA VA VA outer tube- 15 mm 15 mm 15 mm 15 mm 15 mm 15 mm 15 mm 15 mm 15 mm 15 mm Screwing 1/2 AG for flat washer 1/2 AG for flat washer 1/2 AG for flat washer 1/2 AG for flat washer 1/2 AG for flat washer 1/2 AG for flat washer 1/2 AG for flat washer 1/2 AG for flat washer 1/2 AG for flat washer 1/2 AG for flat washer

In case you refer to UL 508 C:There must be a pressure-relief valve with a threshold pressure of maximum 6 bar in the cooling circulation.

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Connecting the water cooler

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INSTALLATION

In this chapter we describe the electric installation of the device. The mechanical installation is described in ZMounting from page 37. Before installing assure, that the technical preconditions are fulfilled: 1 Check the requirements to the electrical mains and check if the existing mains is suitable. 2 Check the requirements to the electrical cables and provide the according cables. 3 Check the characteristics of the connections and configure the connections accordingly.

6.1

General safety instructions

h Pay attention to the information in the chapters ZFundamental safety instructions from page 11. h Pay attention to all areas at the device, which could be dangerous for you during the electrical installation.

Figure 35:

Danger areas at the electrical installation

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6.2
6.2

Requirements to the executing personnel

Requirements to the executing personnel

WARNING The following may occur, if you disregard these safety notes: m serious personal injury m death The danger is: electricity.When operating with this electrical unit, inevitably certain parts of this unit are under dangerous voltage. Make sure, that only qualified personnel, who are familiar with the safety- as well as with mounting-, operating- and maintenance instructions, work on this unit.

At each case qualified personnel are persons, who are authorized by the responsible persons, to execute necessary actions and who recognize the possible dangers and who are able to avoid these dangers. They have had the training, the experience, they were given instructions as well as knowledge about the relevant standards and instructions, they have knowledge of the accident prevention regulations and of the operating environments. The required qualifications for the work with this unit are for example: m Education or instruction or to have the authorization to put into operation, ground and label circuits and devices according to the standards of safety engineering. m Training or instruction due to the standards of the safety engineering in maintenance and use of appropriate safety equipment.

6.3

Voltage check
At routine test of these units a voltage check is executed acc. to EN 50178/VDE 0160, paragraph 9.4.5 by Baumller Nrnberg GmbH. WARNING The following may occur, if you disregard these safety notes: m serious personal injury m death The danger is: electricity. Subsequent checks of unit with high voltages must be made only by Baumller Nrnberg GmbH.

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6.4

Requirements to the electrical mains

All important data is to be found in ZD.1 Requirements on the power supply on page 162. Small deviations of the electrical mains from the requirements can lead to malfunctions of the device. In case the mains deviates strongly from the requirements, the device can be destroyed. b maXX BM4400-devices must not be operated in low-voltage mains in order to supply buildings in residential areas. The destruction of the device can cause personnel injury. WARNING The following may occur, if you disregard these safety notes: m serious personal injury m death The danger is: electricity. In case you do not ensure the requirements to the electrical mains, the device can be damaged/destroyed and can thereby endanger persons severely. Assure before installation, that the requirements of the electrical mains are fulfilled.

m Connection instructions at special mains situations (is not valid for b maXX power modules) n Single phase connection (BM441X)

Figure 36:

Single phase connection BM441X

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Requirements to the electrical mains

n Connection to single phase grounded mains, is not valid for b maXX power modules (BM442X for IT systems, BM443X ... BM447X)

right
Figure 37:

wrong

Connection to single phase grounded mains (BM443X ... BM447X, without power modules)

n Connection to single phase grounded mains with isolated transformer for the following cases 1) BM441X, BM442X except for IT systems, without power modules 2) BM443X ... BM447X at operating altitude > 2000 m, without power modules

Figure 38:

Connection to single phase grounded mains with an isolated transformer

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6.5

Requirements to the connecting cables

h You must consider IEC/EN 60204-1, chapter 13 at selection of connection cables. h The protective conductor cross section of the cable must be executed accordant to IEC/EN 60204-1, section 5.2, tab. 1. h The permanent connection of the protective conductor is imperatively regulated for the operation of the device. h Use a copper cable for at least 60C (drives < 3 x 100 A) or 75C (drives 3 x 100 A) incase you consider UL 508 C. Additional data (e.g. maximum permissible length) is available in ZD.21 Cables mainsdevice from page 213 to ZD.22 Cables device-motor on page 215.

6.6

Protection of the device and of the cable respectively

In order to protect the device or the cables against damage/destruction by the mains, you must install fuses. Data of the necessary fuses are to be found in ZD.20 Fuse protection from page 198. WARNING The following may occur, if you disregard these safety notes: m serious personal injury m death The danger is: electricity. Parts, which are under tension are perilous. The use of semiconductor fuses is obligatory at the mains connection of BM447X devices. Semiconductor fuses are required in the chopper resistor connection except the user assures the short-circuit protection of resistor and cable.

6.7

PE connection and RCD compatibility

Due to the operating principle leakage current can flow via the protective conductor > 3.5 mAAC or > 10 mADC. On this account a permanent protective conductor is prescribed.In addition to the plugged protective connection, the screw terminal, which is marked with PE must be connected to the PE (see ZFigure 45 on page 80). WARNING The following may occur, if you disregard these safety notes: m serious personal injury m death This product can cause direct current in the protective conductor.If, in case of a direct or indirect contact a residual-current-operated protective device (RCD) is used, then a RCD of type B is permitted on the power supply side only.Otherwise other safety precautions must be made as e. g. environmental separation with a double or strengthened insulation or by the separation of the power supply with an isolated transformer. Due to high leakage currents, which arise due to the operating principle of the device, can result in an early enabling of the RCD or generally can avoid an enable.

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6.8

Requirements on the laying (EMC notes device)

Requirements on the laying (EMC notes device)

NOTE The emission of radio interferences is to a high level dependent on the wiring, the volume expansion and the arrangement of the components in the installation. That is why the assurance of the electromagnetic compatibility according to the statutory provisions only is possible on the completed installation and therefore is in the responsibility range of the manufacturer of the installation or of the operating authority (EMVG 6, sec. 9).

NOTE In this Manual the most important information for an EMC-compatible installation is available. Further notes, which necessarily have to be considered in order to mount a CE-conform installation are to be found in the manual filters for mains applications. m Use Baumller motor cables and Baumller components. m Use a suitable mains filter of Baumller Nrnberg GmbH m Mount all components to one single mounting board with well electroconductive surface (e. g. galvanized steel plate). m Execute the ground connection converter/ground plane as short as possible (< 30 cm) with fine-wired cables and a great cross section (> 10 mm2). m When installing, attend to the correct order: Mains - fuse - filter - choke - (ferrite core) - BM4400 - motor. Choke is not necessary for BM441X and BM442X (except BM4426) m Assure, that the motor cables always consist of one piece. Do not interrupt the motor cables e. g. by terminals, contactors, fuses a.s.o. m Run the cables directly on the surface of the grounded mounting board. (smallest possible effective aerial height). m Keep a minimum clearance of 20 cm between signal and control wires towards electric power cables at parallel laying. m Cross cables with different EMC categories (signal cables - supply cables or motor cables) only in a 90 angle. m Contact the external cable screens when passing through walls, which separate different EMC ranges. m Connect the cable shields of the b maXX-devices plane on both ends and highly conductive with ground.

6.9

Requirements to the temperature sensor of the motor

In order to protect the motor against unacceptable overheating a motor-temperature-sensor can be connected to the b maXX-device. When exceeding an adjusted limit temperature the converter switches off the motor. Requirements to the temperature sensor you will find in ZTemperature sensors of the motor on page 219.

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NOTE The motor temperature sensor is to be executed in such a way, that the electrical separation is guaranteed. The motor temperature sensors, which are build in at Baumller correspond to these requirements. At connection of an external motor the operator has to assure, that the motor temperature sensor, which was installed into the motor of the external manufacturer complies with the function Electrical separation.

6.10 Operating sequence of installation

WARNING The following may occur, if you disregard these safety notes: m serious personal injury m death The danger is: electricity. Parts, which are under tension are perilous. Assure, that during the entire mounting the device, the parts, which must be mounted (e. g. supply cables) and the mounting range are off-circuit.

NOTE Steps which are not necessary for the installation of b maXX 4400 power modules are marked.

The following steps must be carried out at installation: 1 Lay all cables EMC-compatible. 2 Connect cables (see ZConnection diagrams from page 78) (refer to the permissible torque). m Connect the motor via the terminals 1U2, 1V2, 1W2, PE. Attend to the in-phase connection (rotational direction). (refer to the permissible torque.) m Connect the fuses (S1) - not necessary for power modules. (in case you consider UL 508 C: use the semiconductor- or total-range-fuses, which are UL-listed in chapter ZD.20 Fuse protection from page 198.) m Connect the mains filter (L2) - not necessary for power modules. m Connect the choke (L1) at the mains filter output (for BM441X, BM442X (except BM4426) and for power modules not necessary) . m Connect the device via the mains input terminals 1U1, 1V1 and 1W1 to the mains choke output - not necessary for power modules. m Connect the protective conductor to the terminal PE (a permanent PE connection is required imperatively). m Connect the 24 V supply via terminals X100-1/2, X100-5/6. (in case you consider UL 508 C: limit the current to 4 A).

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m Connect the encoder (see manual of the encoder modules). NOTE The plugging and pulling of the encoder cable is not permissible under voltage.

m Connect the temperature sensor of the motor. m Connect a signal encoder for the pulse enable via terminals X3-5, X3-3. m Connect a signal encoder for the quickstop via the terminals X3-4, X3-3. m Perhaps connect (dependent on the application - not necessary for power modules) a chopper resistor (RB) via terminals Ba+, Ba-. m Perhaps connect the brake of the motor via the terminals X101-1/2 and X101-3/4. m Connect the safety relay (if existing) via X102-3 and X102-4 as well as X103-3 and X103-4 (connection data safety relay also see ZE.7 Technical data safety relay module on page 235).

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6.11 Connection diagrams

6.11.1 b maXX 44XX (without power modules)

Figure 39:

Connection diagram with a directly controlled motor brake - without power modules

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Connection diagrams

NOTE If the motor brake is connected directly via X101-2 and X101-3 (see ZFigure 39 on page 71) the shown direct installation is allowed only. It is not allowed within a multi-axis installation e.g. to connect the plus and ground connections of all motor brakes with each other.

An additional relay is necessary, if the voltage of the brake is 24V, or if the current of the brake is greater than the switching capacity of X101 (see ZX101 (SELV/PELV) on page 94) or if you consider UL508C and the current of the brake is greater 4 A. Perhaps consider a limited operating voltage range of the brake because of the internal voltage drop up to max. 2.6 V.

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Figure 40:

Connection diagram with motor brake controlled via an additional relay - without power modules

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Connection diagrams

6.11.2 b maXX 44XX power modules

Figure 41:

Connection diagram with a directly controlled motor brake - power modules

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NOTE If the motor brake is connected directly via X101-2 and X101-3 (see ZFigure 39 on page 71) the shown direct installation is allowed only. It is not allowed within a multi-axis installation e.g. to connect the plus and ground connections of all motor brakes with each other.

An additional relay is necessary, if the voltage of the brake is 24V, or if the current of the brake is greater than the switching capacity of X101 (see ZX101 (SELV/PELV) on page 94) or if you consider UL508C and the current of the brake is greater 4 A. Perhaps consider a limited operating voltage range of the brake because of the internal voltage drop up to max. 2.6 V.

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Connection diagrams

Figure 42:

Connection diagram with motor brake controlled via an additional relay - power modules

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is only valid for BM444X, BM445X and BM446X accordingly the cooling versions S and A, for BM447X cooling version -A:

Figure 43:

Connection fan BM447X-A

**

The power supply at X100 or X101 must externally be protected. At selection of the fuse you must consider the cross-section of the connecting cable and the maximum allowable load capacity (for X100: see X100 on ZPage 93, for X101: see X101 on ZPage 94). In case you consider UL 508 C, you must limit the power supply to 100 W or fuse it with a ULlisted 4 A fuse. Connections for chopper resistor and DC link, see ZFigure 44 on page 79 and the following. Chopper resistor Mains connection, see ZFigure 44 on page 79 ff. Fuses (circuit cable + device) Fuse (fan) *) Fuse chopper resistor connection (required for BM447X), see ZD.20.22 Semiconductor fuses aR (device) 447X, model NH on page 212. Mains choke (not necessary for BM441X and BM442X except BM4426) Mains filter Serial interface (RS 232), see ZFigure 51 on page 87. Connections for ready-for-use, quickstop, pulse enable, see ZFigure 51 on page 87. Connections for fan (only BM444X-S/-A, BM445X-S/-A, BM446X-S/-A, BM447X-A) Connections for 24 V power supply, additional data see ZFigure 51 on page 87 (SELV/PELV) and table ZX100 (SELV/PELV) on page 93. Connections for brake, motor temperature, see ZFigure 44 on page 79 and the following (SELV/PELV) and table X101 from ZPage 79. Connections of the safety relay, see -ZFigure 44 on page 79 and the following (SELV/PELV) and table ZX102 (option) Safety relay on page 94. Terminals of the optional, second safety relay (only BM443X-BM447X), see -ZFigure 47 on page 82 and the following (SELV/PELV) and table ZX103 (option) Safety relay on page 94.

Ba- ... 1D1 RB PE....1W1 S1 S2 S3 L1 L2 X1 X3 X36 X100 X101 X102 X103

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Connection diagrams

A:X1 ENC BRE PE....1W2

Encoder module, see manual 5,01042 (SELV/PELV) Encoder Brake Connections for motor, see ZFigure 44 on page 79

6.12 Connection diagrams

ZFigure 44 on page 79 and the following show the connections for protective conductors, mains, motor, chopper resistor, DC-link, safety relays and motor temperature sensor (X101). ZFigure 51 on page 87 shows the control voltage and the connections of the controller unit.

NOTE When having a switched off safety relay it is not possible at BM441X and BM442X to use a chopper resistor.

NOTE The characterization 1C1 and 1D1 is from the standard DIN EN 60445. 1C1 is the connection to the positive DC link cable/current bar and was labeled with ZK+ by Baumller in the past. 1D1 is the connection to the negative DC link cable/current bar and was labeled with ZK- by Baumller in the past.

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The electrical connections for devices BM4412 and BM4413 are shown in the following figure:

Figure 44:

Electrical connections for mains, motor, upon others for BM4412 and BM4413

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Connection diagrams

The electrical connections for device BM4414 are shown in the following figure:

Figure 45:

Electrical connections for mains, motor, upon others for BM4414

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The electrical connections for device BM442X are shown in the following figure:

*) Do not apply terminals when using a power module!

Figure 46: Electrical connections for mains, motor, upon others for BM442X

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Connection diagrams

The electrical connections for device BM443X are shown in the following figure:

*) Do not apply terminals when using a power module!

Figure 47: Electrical connections for mains, motor, upon others for BM443X

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The electrical connections for device BM444X are shown in the following figure:

*) Do not apply terminals when using a power module! **) only BM444X-S/-A
Figure 48: Electrical connections for mains, motor, upon others for BM444X

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Connection diagrams

The electrical connections for the devices BM445X and BM446X are shown here:

*) Do not apply terminals when using a power module! **) only BM445X-S/-A and BM446X-S/-A
Figure 49: Electrical connections for mains, motor, upon others for BM445X and BM446X

NOTE The chopper resistor is connected at the devices BM445X and BM446X between Ba- and 1C1. Also see ZFigure 39 on page 71.

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The electrical connections for device BM447X are shown in the following figure:

*) only BM447X-A
Figure 50: Electrical connections for mains, motor, upon others for BM447X

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Connection diagrams

NOTE The chopper resistor is connected at the devices BM447X and BM1X between Ba- and 1C1. Also see ZFigure 39 on page 71.

WARNING The following may occur, if you disregard these safety notes: m serious personal injury m death The danger is: electricity. Parts, which are under tension are perilous. After attaching all power cables to the device BM447X, screw on the cover careful to all screwing points by using the enclosed screws (6xM4X12) and washers.The cover only must be able to be removed from the device with use of tools.

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X100-1: +24V (SELV/PELV)1) X100-2: +24V (SELV/PELV)1) X100-3: Mains on (bus) (SELV/PELV)2) X100-4: Chopper on (SELV/PELV)2) X100-5: M24V (SELV/PELV)1) X100-6: M24V (SELV/PELV)1) UH1: green: Programmable LED yellow: Programmable LED UH2: green: Programmable LED yellow: Programmable LED H1: green: Torque direction1 yellow: Torque direction2 H2: green: Enable yellow: Power ON H3: red: Current limit reached H4: red: Error

X4: reserved

X1: SeeZFigure on page 88

H5 Display 4) 7 segment display Standard operation Display drive status Error condition Display error number

X2: Connection for Baumller memory module PSI 3)4) X3-1: BB on (NO) (SELV/PELV) X3-2: BB-On (middle selector switch)
(SELV/PELV)

X3-3: Reference potential for 4 and 5

(SELV/PELV)

X3-4: Quickstop (SELV/PELV) X3-5: Pulse enable (SELV/PELV) X3-6: BB-On (NC) (SELV/PELV)
Figure 51: Connection X100 and connections of the controller unit

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Connection diagrams

X1: According to controller type BM44XX - XXX - XX0XX[Ryy] - XX (with RS 485 interface) BM44XX - XXX - XX1XX[Ryy] - XX (with RS 485 interface) BM44XX - XXX - XX2XX[Ryy] - XX (with RS 485 interface)

1: reserved 2: TxD RS232 3: RxD RS232 4: DTR, DSR 5: Grounding RS232 6: DTR, DSR 7: RTS 8: CTS 9: reserved

BM44XX - XXX - XX3XX[Ryy] - XX (with Ethernet interface) 1: TX+ 2: TX3: RX+ 4: reserved 5: reserved 6: RX7: reserved 8: reserved
LED1 Color off yellow green Meaning no activity half duplex full duplex Color off yellow green LED2 Meaning no connection 10 Mbs 100 Mbs

NOTE
1) 2)

in case you consider UL 508 C: limit the current to 4 A. Do not apply voltage to the terminals X100-3 or X100-4, if the device is not supplied via X100-1/2 with voltage. (the signals mains on and chopper resistor are internal digital control signals of the system b maXX. They are used at applications with DC link connection.)

3)

The PSI-module may not be attached or withdrawn, if the b maXX device 24 V power supply is ON. Beforehand switch off the device. Further notes for the usage of the PSI module are to be found in parameter manual. not BM44XX - XXX - XX0XX and BM44XX - XXX - XX1XX

4)

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6.12.1 Connection data of the connections

Mains 1U1, 1V1, 1W1, PE BM441X BM442X not valid for power modules BM443X BM444X BM445X BM446X

Max. connection Connection techcross-section nology 2,5 mm2 4,0 mm2 10 mm

2

Torque 0.6 Nm 1.5 Nm 8 Nm 6 to 20 Nm 8 to 30 Nm 8 to 30 Nm

Load capacity see ZD.20 Fuse protection from page 198

plug-in contact screw terminals screw terminals screw terminals cable lug for M8 cable lug for M10 cable lug for M10

50 mm2 2 x 95 mm
2 1)3)

2 x 185 mm2 2)3)

BM447X 2 x 185 mm2 2) 4 x 95 mm2 1)

1)

The cable lug may be 25 mm wide at most. The maximum cable diameter is dependent on the cable lug. In case the cable lug, which you use, can safely clamp a stronger cable than 95 mm2, you may also use stronger cables than 95 mm2. Also see ZCables mains-device on page 213. The cable lug may be 35 mm wide at most. The maximum cable diameter is dependent on the cable lug. In case the cable lug, which you use, can safely clamp a stronger cable than 185 mm2, you may also use stronger cables than 185 mm2. Also see ZCables mains-device on page 213. One cable of the mentioned cross section is sufficient for the operation.

2)

3)

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Connection diagrams

DC link 1C1 and 1D12) Chopper resistor Ba+ and Ba- 1)

Max. connection Connection techcross-section nology BM441X BM442X BM443X BM444X BM445X BM446X BM447X
7)
1)

Torque

Load capacity 1C1 and 1D1 2) Ba+ and Ba-3) see ZD.6 Electrical data BM441X basic unit on page 167 and the following.

2,5 mm2 4,0 mm2 10 mm

2

plug-in contact Screw terminals Screw terminals Screw terminals Cable lug for M8 Cable lug for M10 Cable lug for M10

0.6 Nm 1.5 Nm 8 Nm 6 to 20 Nm 8 to 30 Nm 8 to 30 Nm

50 mm2 2 x 95 mm
2 4)6)

2 x 185 mm2 5)6) 2 x 185 mm2 5)

not short-circuit-proof, consider maximum load! See Chopper resistor external in chapter ZTechnical data from page 161. not short-circuit-proof, consider maximum load! See connected load DC link in chapter ZTechnical data from page 161. See permissible chopper resistor continuous power in chapter ZTechnical data from page 161. The cable lug may be 25 mm wide at most. The maximum cable diameter is dependent on the cable lug. In case the cable lug, which you use, can safely clamp a stronger cable than 95 mm2, you may also use stronger cables than 95 mm2. The cable lug may be 35 mm wide at most. The maximum cable diameter is dependent on the cable lug. In case the cable lug, which you use, can safely clamp a stronger cable than 185 mm2, you may also use stronger cables than 185 mm2. One cable of the mentioned cross section is sufficient for the operation. A Semiconductor fuse is required in case of using no short-circuit-proof cables and resistors.

2)

3) 4)

5)

6) 7)

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Motor 1U2, 1V2, 1W2, PE BM441X BM442X BM443X BM444X BM445X BM446X BM447X
1)

Max. connection Connection techcross-section nology 2,5 mm2 4,0 mm2 16 mm

2

Torque 0.6 Nm 4.5 Nm 8 Nm 6 to 20 Nm 8 to 30 Nm 8 to 30 Nm

Load capacity is limited by the device Also seeZAppendix D Technical data from page 161.

plug-in contact screw terminals screw terminals screw terminals cable lug for M8 cable lug for M10 cable lug for M10

50 mm2 2 x 95 mm
2 1)

2 x 185 mm2 2)3) 2 x 185 mm2 2) 4 x 95 mm2 1)

The cable lug may be 25 mm wide at most. The maximum cable diameter is dependent on the cable lug. In case the cable lug, which you use, can safely clamp a stronger cable than 95 mm2, you may also use stronger cables than 95 mm2.Also see ZCables device-motor on page 215. The cable lug may be 35 mm wide at most. The maximum cable diameter is dependent on the cable lug. In case the cable lug, which you use, can safely clamp a stronger cable than 185 mm2, you may also use stronger cables than 185 mm2. Also see ZCables device-motor on page 215. One cable of the mentioned cross section is sufficient for the operation.

2)

3)

Fan X36 BM444X-S/-A BM445X-S/-A BM446X-S/-A BM447X-S/A

1)

max. connection cross section 4.0 mm2

Connection technology spring clip

Loading max. 1.0 A1)

For fuse protection a fuse with the tripping characteristic delayed must be used.

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Connection diagrams

X1 (RS 232) BM441X to BM447X

Recommended connection cable LIYCY 6x2x0.14 mm2

Connection technology SUB-D, 9-pin

Note Available as cable sets: see ZB.1 Interface cable on page 153

WARNING The following may occur, if you disregard these safety notes: m serious personal injury m death The danger is: mechanical effects. If a PC is not connected via an isolated transformer, the machine can run unexpected actions. Connect the PC via an isolated transformer or use a battery operated PC (e. g. laptop, notebook) without connecting a charger.

NOTE Screening of the interface cables, which are used may only be connected to the controller side with the connector housing.

The cable connector can be obtained as an accessory from Baumller Nrnberg GmbH (see ZB.1 Interface cable on page 153). At the cable set the cable screen connection must be interrupted with the PC-sided Sub-D-plug connector housing. In case the cable is produced self, please use the instructions stated below: 1 Use the following materials: m Cable: LIYCY 6x2x0.14 mm2 m Sub-D connectors, 9-pin, female, cabinet plastics metallized m Sub-D connector, 9-pin, male, cabinet plastics metallized 2 connect the cable shield with the cabinet and with the shield of the Sub-D connector

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Figure 52:

Interface cable RS 232

X3 (SELV/PELV) BB-On Quickstop Pulse enable

Max. connection crosssection BM441X to BM447X 1.5 mm2

Connection technology plug-in contact

Load capacity Voltage level BB-On;X3-1, X3-2 and X3-6: max 1.0 A Quickstop X3-4 Pulse enable; X3-5: 0 (Low) 0 V to 5 V 1 (High) 12 V to 28 V

X100 (SELV/PELV) 24 V power supply BM441X to BM447X

Max. connection crosssection 1.5 mm2

Connection technology plug-in contact

Load capacity X100-1, X100-2, X100-5 and X100-6: max. 8.0 A, if you consider UL508C:max. 4.0 A

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X101 (SELV/PELV) Brake BM4412 BM4413 BM442X BM4414 BM443X BM444X BM445X BM446X BM447X

Max. connection crosssection 1.5 mm2

Connection technology plug-in contact

Load capacity X101-1 to X101-4: min. 0.1 A, max. 0.5 A X101-1 to X101-4: min. 0.1 A, max. 1.0 A X101-1 to X101-4: min. 0.1 A, max. 4.0 A X101-1 to X101-4: min. 0.1 A, max. 8.0 A In case you refer to UL508C: max. 4.0 A

1.5 mm2 1.5 mm2 1.5 mm2

plug-in contact plug-in contact plug-in contact

X102 (option) Safety relay (SELV/PELV) BM441X to BM447X

Max. connection crosssection 1.5 mm2

Connection technology plug-in contact

Load capacity Voltage level See ZE.7 Technical data safety relay module on page 235

X103 (option) Safety relay (SELV/PELV) BM443X to BM447X

Max. connection crosssection 1.5 mm2

Connection technology plug-in contact

Load capacity Voltage level See ZB.1 Interface cable on page 153

6.12.2 Requirements for the screwing

NOTE Follow the mentioned torques in ZFigure 49 on page 84 and ZFigure 50 on page 85 to ensure an adequate conductivity.

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OPERATION

In this chapter we describe, how the device works during operation and how you handle the device during operation.

7.1

Safety instructions
h Refer to the safety instructions from the chapter ZFundamental safety instructions from page 11. CAUTION The following may occur, if you disregard these safety notes: m Property damage The danger is: Environmental conditions, that do not refer to the demands. Assure, that the environmental conditions are referred to during operation (see ZD.3 Required environmental conditions on page 164).

WARNING The following may occur, if you disregard these safety notes: m serious personal injury m death The danger is: electricity. The control cabinet, in which the device is built in, shall protect against contacts with parts, which are under voltage. Assure, that during operation all doors of the control cabinet are closed. Assure, that during operation all safety devices work.

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7.2

Requirements to the executing personnel

Requirements to the executing personnel

WARNING The following may occur, if you disregard these safety notes: m serious personal injury m death The danger is: electricity.When operating with this electrical unit, inevitably certain parts of this unit are under dangerous voltage. Assure, that only qualified personnel work on this unit.

At each case qualified personnel are persons, who are authorized by the responsible persons, to execute necessary actions and who recognize the possible dangers and who are able to avoid these dangers. They have had the training, the experience, they were given instructions as well as knowledge about the relevant standards and instructions, they have knowledge of the accident prevention regulations and of the operating environments. The required qualifications for the work with this unit are for example: m Education or instruction or to have the authorization to put into operation, ground and label circuits and devices according to the standards of safety engineering. m Training or instruction due to the standards of the safety engineering in maintenance and use of appropriate safety equipment.

7.3

Operating concept
After the device has been taken into operation, it is parametrized (adjusted to the application). When the parameterization is completed, you can operate the device with one of the following systems:

System 1

m two enable signals (see ZEnable signals on page 97). m I/Os (see manuals to the I/O plug-in modules) m two enable signals (see ZEnable signals on page 97). m I/Os (see manuals to the I/O plug-in modules) m superimposed control, which controls the two enable signals and the I/Os The operating software WinBASS II is not necessary during operation. The operating software WinBASS II is only necessary, if an error occurs or if parameters have to be changed. In case of an error the service engineer can, with the help of WinBASS II, determine, which error has occurred.

System 2

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7.3.1

Enable signals These signals must have a signal level of 24 V (DC) and must be connected to the terminals X3-4 and X3-5 (ZFigure 51 on page 87).

Pulse enable Quickstop

During operation the signal pulse enable must constantly be created, so that the device supplies power. Disable the signal quickstop only, if you must stop the installation/device as quick as possible. During operation the signal quickstop must be applied, so that the device supplies power.

7.4

Mains-switch-on frequency/DC-link charging

The mains voltage may not be switched on and off arbitrarily. Between two switch-on-sequences there should be a certain time period, in order to protect the devices/fuses. NOTE Imperative for the devices BM441X and BM442X is: Between two switch-on-sequences of mains voltage at least 60 seconds must have passed 1) . Imperative for the devices BM443X, BM444X, BM445X, BM446X and BM447X is: A delay time must not be complied with.
1)

Shorter delay times can shorten the service life of the devices.By the connection of an external DC-link capacity at the DC-link terminals the prescribed minimum delay time increases to 90 seconds.The maximum allowable external DC-link capacity is dependent of the mains voltage (see ZFigure 61 on page 170 and ZFigure 63 on page 174.

7.5

Display elements - LED

BM44XX - XXX - XX0XX and BM44XX - XXX - XX1XX: On the front side of the device there are 4 LEDs. The 4 LEDs (H1 to H4) show information about the operating status and are also displayed in WinBASS II. BM44XX - XXX - XX2XX: On the front side of the device there are 6 LEDs. Both upper LEDs (UH1 and UH2: 2) are freely programmable. The four lower LEDs (H1 to H4) show information abut the operating status and are also displayed in WinBASS II. ZFigure 51 on page 87 shows the position of the display elements.

7.5.1

Freely programmable LED (UH1, UH2)*): *): not BM44XX - XXX - XX0XX and BM44XX - XXX - XX1XX Both LEDs UH1 and UH2 are not led through to the design cover.

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7.5.2

Display elements - LED

Operating condition (H1, H2) Both of the upper LEDs (H1 and H2) indicate, how the device is working at the time.

green: orange:

the motor rotates, torque direction 1. the motor rotates, torque direction 2.

NOTE The LED H1 cannot be taken as rotational direction indicator. It only shows the torque directions.

green: orange:

Pulse enable. The motor is power supplied by the power unit. Power ON, the device is ready-to-operate. In case the LED lights up orange colored during operation, maybe the pulse enable is missing or the quickstop was activated.

Flashing in turn green/orange: Pulses for field generation at asynchronous machines enabled. No torque enable yet. green with orange-colored flashing or orange with short green flashing: Memory operation active in the EEPROM, if possible do not switch off the device in this phase.

7.5.3

Current limit (H3) The third LED (H-3) indicates whether the current limit has been reached.

red: adjusted current limit of the controller has been reached. h Application is adapted or no reaction.

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Operation

7.5.4

Error (H4)

LED doesnt light up: the internal monitoring have not found an error. Red, continuously: Error. h Remove the error with help of the operating program WinBASS II. Additional data is available in ZError detection and troubleshooting from page 101. red, flashing: Warning. h Warnings you are able to see in the device manager of the operating program WinBASS II. Warnings do not affect operation of the device. Additional data is available in ZError detection and troubleshooting from page 101.

7.5.5

Display (not BM44XX - XXX - XX0XX and BM44XX - XXX - XX1XX) The 7-segment-display in normal operation shows the operation status. In case of error the error number is shown.
Display 0 1 2 3 4 5 6 7 E F Status NOT READY TO START INHIBIT START READY-TO-START SWITCHED ON OPERATION ENABLED Meaning Initialization phase, pulses inhibited. Pulses inhibited, initialization completed error-free. Pulses inhibited Pulses for field generation at asynchronous machines enabled, no torque generation yet. Pulses enabled, drive function enabled

Inhibit operation active Pulses enabled, braking procedure active Shutdown active QUICKSTOP ACTIVE ERROR REACTION ACTIVE ERROR Pulses enabled, braking procedure active Pulses enabled, braking procedure active Pulses enabled, braking procedure active Pulses inhibited, error status In the display the error number is shown.

The single drive statuses are specified in chapter device management in parameter manual 5.03039. In the status error the error numbers are shown in the display. Only the errors are shown, which enable an error reaction in the drive or have enabled one. Errors without reaction and also warnings are not displayed. The display of error No. starts therewith, that F is shown for 1.5 s. Then the three error code positions are displayed. The separate figures are displayed for about 0.8 s, interrupted by a short pause. If there are other errors, these are displayed in the same manner. The procedure is repeated as soon as all errors were displayed.

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Monitoring

Example: Error 125 and 91 are existing:

Start Erroroutput

End

Time

7.6

Monitoring
The controller unit monitors the device during the operation. If the controller unit recognizes a status, which deviates from normal operation, the device either issues a warning or an error message.

Warning

If the controller unit recognizes an operating condition, which is close to an error condition, an accordant warning message is shown in WinBASS II and by the control resp. The device shows the most important warning (current limit reached) also via the LED H3 (see ZCurrent limit (H3) on page 98). If the controller recognizes that the device is not working error-free, this is displayed via the LED H4 (see ZError (H4) on page 99) and via the 7-segment display. Either an error text is displayed by WinBASS II or the control is able to read out the error code from the device. Additional data is available in chapter (ZError detection and troubleshooting from page 101).

Error message

7.7

Maintenance
Maintenance is first of all the monitoring of the environmental conditions. With accordant projection of your installation you can execute the monitoring of the environmental conditions in the running operation and dont have to interrupt the operation for the maintenance. Additional data is available in ZMaintenance from page 137.

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ERROR DETECTION AND TROUBLESHOOTING

In this chapter the error messages of the device are described: Error- and warning messages, their meanings and how you can react.

8.1

Safety instructions
h Refer to ZFundamental safety instructions from page 11.

8.2

Requirements to the executing personnel

The personnel, who works with the b maXX device, must be introduced in the safety instructions and in the operation of the device and must be familiar with the accurate operating of the device. Especially the reaction to failure indications and -conditions requires special knowledge, which the operator must have.

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8.3

Monitoring functions

Monitoring functions
A survey of the most important monitoring functions and of the from the monitoring functions generated warning-/error messages you will find in the following table. How to recognize the errors is explained in ZError detection from page 105. Threshold adjustable

Reaction adjustable

Adjusting of Limit in parameters -

Monitoring function Mains voltage

Warning/error Mains undervoltage Mains overvoltage

X X X X X X X X 3)

X X X X X X X X X X X X X X

X X X X X X X

IS IS IS

Phase monitoring Ground fault 1) Overcurrent DC

Phase error Mains failure Fault current to ground Overcurrent motor DC link overvoltage DC-link-undervoltage relative

IS2) P0486 P0486 IS IS IS IS IS IS IS IS P0018 P0019 P0016 P0017 -

Ixt-threshold Temperature heat sink

Peak current not possible at the moment Temperature > threshold 1 Temperature > shutdown threshold

Temperature device interior space Temperature motor

Temperature > threshold 1 Temperature > shutdown threshold I2t-threshold exceeded Threshold 1 exceeded Threshold 2 exceeded 3) Short circuit sensor or temp. < -30 C 3) Sensor not connected or temp. > 250 C 3) Maximum temperature exceeded 3)

P0073 P0093 P0088 P0093 P0089 P0093 P0093 P0093

X X -

P0090 P0093

1) 2) 3) 4) 5) 6)

nonexistent at BM441X and BM442X Pulse inhibit operates according to adjustable time only when using the KTY sensor adjustable with P0299 adjustable with P0298 nonexistent at power modules

IS: Pulse inhibit SH: Quickstop X: Implemented -: not possible

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Activation by parameter -

Reaction

Warning

Error

Error detection and troubleshooting

8
Activation by parameter -

Threshold adjustable

Reaction adjustable

Monitoring function Position controller

Warning/error Position deviation dynamic Position deviation static

X -

X X X X X X X X X X X X

X X X X X X X

X X

SH P1054 P1050 SH P1055 P1050 4)

Digital output Controller synchronizing Encoder 1

Short-circuit digital output Controller not synchronous with ext. Signal Cable break Cable break (sin2 + cos2) Overspeed

P0533 P0299 P1072 P1082

IS IS IS IS IS IS IS
5)

Encoder

Cable break Cable break (sin + cos ) Overspeed

2 2

Ramp-up option modules

Error at module initialization

P0838 P0838 P0839 P0298

Cyclical set point trans- Transmission timeout mission to the optional modules Safety relay Safety relay Block monitoring
1) 2) 3) 4) 5) 6)

Supply voltage is missing or safety relay faulty Safety relay - warning Drive blocked

X -

X X

IS IS

P1260 P1260

nonexistent at BM441X and BM442X Pulse inhibit operates according to adjustable time only when using the KTY sensor adjustable with P0299 adjustable with P0298 nonexistent at power modules

IS: Pulse inhibit SH: Quickstop X: Implemented -: not possible

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Adjusting of Limit in parameters -

Reaction

Warning

Error

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8.3.1

Monitoring functions

Monitoring functions - explanations - nonexistent at power modules This monitoring function checks, if the mains voltage has a value within the adjusted voltage range. If the value is lower, the warning undervoltage mains is indicated. If the value is higher the warning overvoltage mains is indicated.

Mains voltage

Phase moni- - nonexistent at power modules toring This monitoring function checks the three phases of the mains voltage. If an outer conductor is missing, the warning Phase failure is reported after >4s. If all of the three outer conductors are missing the warning Mains failure is reported >4s to the controller.After reaching the adjusted delay time by parameter P0486 the controller generates the error message mains failure. NOTE If you work without the mains filter the mains and phase failure-recognition takes place within 100 ms. If the device is operated with the mains filter the mains and phase failure can be detected after about 5 s. According to load state the failure can also be detected considerably earlier. Ground fault This monitoring function checks, if there is a short-circuit between the motor terminals and the ground. If a short-circuit occurs, there is immediately a pulse enable. This monitoring function doesnt exist by BM441X and BM442X. Overcurrent This monitoring function checks, if the motor current is greater than 1.3 x output peak current. It serves as Disaster prevention in case of an output-sided short-circuit. DC This monitoring function checks the voltage of the. In case the voltage sinks below a value, which was internally specified (about 50 V under the setpoint), the DC link undervoltage is signaled from the controller and a warning is generated. In case the voltage exceeds an adjusted value about 820 V), the error DC link overvoltage is signaled from the controller and an immediate pulse inhibit operates. This monitoring function checks the heat sink temperature as well as the current load thereupon, if the power unit can enable the peak current or the maximum nominal current. In case the peak current is not possible, the message Ixt-threshold 1 exceeded is displayed. This monitoring function checks the temperature in the internal space of the device. m In case the temperature is higher than the warning threshold, the controller gives a warning. m In case the temperature is too high, immediately an pulse inhibit operates. This monitoring function checks the temperature of the heat sink. m In case the temperature is higher than the warning threshold, the controller gives a warning. m In case the temperature is too high, immediately an pulse inhibit operates. This monitoring function checks the temperature of the motor. In case the I2t-threshold is exceeded, the error I2t-overload is given from the controller. In case the adjusted temperature threshold 1 is exceeded, the warning temperature threshold 1 exceeded is signaled from the controller. In case the adjusted temperature threshold 2 is exceeded, the warning temperature threshold 2 exceeded is signaled from the controller. The KTY84-sensor has a minimal measuring value of about -30C. If the temperature falls below

Ixt-threshold Temperature device interior space Temperature heat sink Temperature motor only by KTY84Sensor

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if there is a short-circuit at the sensor, the error short-circuit temperature sensor is signaled. The KTY84-sensor has a maximum measuring value of 250 C. In case this temperature is exceeded, or in case the sensor is not connected, the error temperature sensor not connected is signaled from the controller. At all sensors Position controller In case the threshold (depending on the model), which is determined in the temperature switch or in the PTC-sensor is exceeded, the error overtemperature is given from the controller and immediately an pulse inhibit operates. This monitoring function checks the position deviation limit statical/dynamical. In case the position deviation error is statical/dynamical greater than the adjusted position deviation error limit, there is an error message position deviation error statical and position deviation error dynamical.After monitoring time (position deviation time), additionally an error message is given an immediate pulse inhibit operates.

Safety relay This monitoring function checks if the safety relay functions and if the control voltage in order to activate the safety relay is connected. In case of an error the controller either signals an error or a warning, depending on, if the pulse enable is active or not. Block-moni- This monitoring function checks the motor speed and the motor current. toring If, for the period of time block monitoring time, the following two conditions are fulfilled, the error/warning drive blocked is given to the controller and an immediate pulse inhibit takes place. m Motor speed = 0 m the motor current which is supplied by the device is the same as the adjusted motor limit current (current limit).

8.4

Error detection
In the following we will inform you about the different errors and the consequential error messages. The errors can either be of mechanical or of electrical causes. The devices of the series b maXX 4400 signal an error status via the lighting up of the lowest red LED H4 on the front side of the cabinet. Additionally the error No. is shown via the 7-segment display on the front side of the cabinet (not BM44XX - XXX - XX0XX and BM44XX - XXX -XX0XX). By the error number the error message can be determined with help of the error list in this manual. Furthermore the error message is shown in the operating software WinBASS II: h Start the operating program WinBASS II, if it isnt running yet.

NOTE In order to work with WinBASS II, the software version of the controller and the WinBASS II version must comply with one another.

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8.4

Error detection

In case the software version of the controller and the WinBASS II version do not comply with one another, you will receive the following message:

A further working in this condition is not possible, break up your work and contact Baumller Nrnberg GmbH in order to receive the right version.

Only max. 3 The meaning of the specific LEDs we explain in ZFigure 51 on page 87. Here mainly the lowLEDs light est red LED H4 Error is of importance. If this LED lights up, also in WinBASS II at least one up error message has been generated. NOTE If warnings or errors occur without error reaction the LED H4 error blinks. Only error messages with error reaction are signaled by constantly lighting up.

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Error detection and troubleshooting

The error message signaled with error is in WinBASS II: h Open a list in the project tree by clicking on the + in front of Management.

Figure 53:

Project tree in WinBASS II

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8.4

Error detection

h Select from this list Device management. In the ZFigure 54 on page 108 there is the window Device manager with a few exemplary (error-) messages. The messages in this window demonstrate an internal list, before the communication between controller and pc/laptop with WinBASS II begins, which is arranged according to the error numbers. After take-up of communication the newly occurring messages are added onto the end of the list.

Figure 54:

Device manager in WinBASSII

NOTE If you are not able to start the motor, although the red LED H4 isnt lighting up and although the LED H2 is lighting up green, check the parameterization of the b maXX4400 with the parameter list in WinBASS II. Error possibilities are e. g.: torque limit = 0 has been set or notch position is not correct (also see parameter manual b maXX 4400). If no LEDs are lighting up on the front side of the device, check the 24V supply. For troubleshooting you must however know, that the error messages in the system are built up hierarchically, see ZFigure 55 on page 109. An error message can result from a beneath in the hierarchic arranged error message. This is why the message SysError1 (level 1) can base on an error, which e. g. has appeared in ModuleError (level 2), because there is a failure in Function module1 (level e. g. Sincos-encoder module).This is why you always have to track an error to the lowest level, in order to detect/remove it.

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8.4.1

Structure of the error list - survey of the error parameter names

Figure 55:

Structure of the error list - survey

8.5

Troubleshooting
The error messages are based on the troubleshooting in the b maXX devices, which also are termed as error lists (seeZError parameters - error messages (error list) - error reactions from page 111). If an error appears, the according definite error message is displayed within a short time in WinBASS II in the menu device manager, whose meaning you can look up in the error list. NOTE The device is delivered with predefined error reactions. You are able to set the error reaction of the device in Depending on settings in the column Reaction marked error messages. An exception here are errors, which have to have an immediate pulse inhibit as a consequence. These can not be changed due to safety reasons.

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8.5
8.5.1

Troubleshooting

Reset errors If the red error LED is lighting up, there is at least one error. You can react upon this, by resetting the error in WinBASS II, that means, that you inform the device, that you have noted the error, that you have removed it or that you want to pass over it. Due to error reset all error messages are reset. An individual error reset is not possible. The acceptance causes a resetting of the error, in case the reset was possible due to the error situation. There are four methods to reset errors: m Via WinBASS II: Use the button Acknowledge errors (either in the dialog box Device manager or on the page Device manager Note: If errors shall be acknowledged via WinBASS, the control for WinBASS must be active in parameter Communication source. m Via writing access to control word (P0300): Here a rising edge must be generated in bit 7 (of the control or per input to parameter list of WinBASS II). Note For the according communication source the drive control must be active (see parameter P1001 Communication source).

m Via a digital input: Via the parameter P0575 digital input for error acknowledge a digital input of a DIO-module can be selected. With the rising edge at this input the errors are acknowledged. m Via the pulse enable-input: Precondition is, that the drive is only controlled via the hardware inputs (that means that the motor guide is neither set via WinBASS II nor via another communication source).Furthermore the option Acknowledge error via pulse enable in parameter P1002 Options device manager must be active.With the first rising edge of pulse enable the errors then are acknowledged.But the drive still does not start. Therefore you then need a second rising edge for the enable. Additional data according the subject resetting of error messages is available in the parameter manual.

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Error detection and troubleshooting

8.5.2

Error parameters - error messages (error list) - error reactions In the following you will find all error messages. An (error) message is shown in WinBASS II in the window device manager. In the list field Messages you find the (abbreviated) error name, at Hiperface-errors also the device unit, the error number (not at errors after Hiperface-specification) and, separated by a colon, the meaning of this error, e. g. MotorError 96: Short circuit temperature sensor. At Hiperface-errors e. g.: Encoder 1 communication: Parity error.

1st Level

SysError1, only interesting for the access to errors via parameters, to be used without WinBASS II, e. g. at Field bus communication. This error is not shown in WinBASS II. Bit mapping see description of the parameter P0200.

2. Level

Next level below SysError1. Here you find errors, which you can remove directly with help of the displayed information or also information on the next level in which the error could be. We have arranged the error messages according to the survey ZStructure of the error list - survey from page 109. In the column you find Reaction the reaction of the system to the error: m IS = pulse inhibit; m Adjustable = You can set the error reaction via WinBASS II (page Device manager 2, toolbar button Error reaction). m no reaction means, the drive is continuing to work and the red error LED is blinking. m In the column troubleshooting you will find hints for troubleshooting: Details on this you will find in the parameter manual.

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8.5

Troubleshooting

Error processor P0201

Error no. 0 1 2 reserved Watchdog-Error Incorrect or unexpected interrupt has occurred NMI interrupt/bus error reserved Not assigned = 0 IS IS Execute a restart of b maXX 4400 Execute a restart of b maXX 4400 Meaning Reaction Troubleshooting

3 4 to 15

IS

Execute a restart of b maXX 4400

Error operating system P0202

Error no. 16 17 18 19 Meaning Errors while booting Software error: Time slot configuration Time slot - time error Reaction IS IS IS IS Troubleshooting Execute a restart of b maXX 4400 Execute a restart of b maXX 4400 Execute a restart of b maXX 4400 Execute a restart of b maXX 4400; Change configuration of the time slice operation system Execute a restart of b maXX 4400 Execute a restart of b maXX 4400 Execute a restart of b maXX 4400 Contact Baumller

20 21 22 23 24 to 31

1 = No free memory Invalid error code Invalid warning code False FPGA version reserved Not assigned = 0

IS IS IS IS

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Error Proprog communication P203

Error no. 32 33 Meaning Timeout protocol Protocol structure Reaction Troubleshooting

Adjustable Execute a restart of b maXX 4400 Adjustable Execute a restart of b maXX 4400

34 35

Wrong module type too many data in the telegram

Adjustable Contact Baumller Adjustable Contact Baumller

36

Not enough data in telegram

Adjustable Contact Baumller

37

Invalid operand

Adjustable Contact Baumller

38 39 40 41 42 43

Invalid memory type Invalid operand address Value less than the minimum value

Adjustable test RAM Adjustable enter a valid address Adjustable Check data set and adjust

Value greater than the maximum value Adjustable Check data set and adjust Parameter is write-protected Adjustable Check data set and adjust

Parameters in this operation status not Adjustable Check operating condition and parameterizawriteable tion Invalid parameter value Communication error WinBASS controller reserved Not assigned = 0 Adjustable Enter with a valid value Adjustable Establish connection again or set parameter P0290 to 0.

44 45

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Troubleshooting

Error in function or option modules P0204

Error no. 48 Meaning Error in Function module A Error in Function module B Error in Function module C Error in Function module D Error in Function module E Error in Option module G Error in Option module H Error in Option module J Error in Option module K Error in Option module L Error in Option module M Reaction Level 3 error Level 3 error Level 3 error Level 3 error Level 3 error Level 3 error Level 3 error Level 3 error Level 3 error Level 3 error Level 3 error Troubleshooting see ZError function module A to E P0240 to P0244 on page 129 (= 3. level) see ZError function module A to E P0240 to P0244 on page 129 (= 3. level) see ZError function module A to E P0240 to P0244 on page 129 (= 3. level) see ZError function module A to E P0240 to P0244 on page 129 (= 3. level) see ZError function module A to E P0240 to P0244 on page 129 (= 3. level) see ZError option module G to M P0245 to P0250 on page 130 (= 3. level) see ZError option module G to M P0245 to P0250 on page 130 (= 3. level) see ZError option module G to M P0245 to P0250 on page 130 (= 3. level) see ZError option module G to M P0245 to P0250 on page 130 (= 3. level) see ZError option module G to M P0245 to P0250 on page 130 (= 3. level) see ZError option module G to M P0245 to P0250 on page 130 (= 3. level) Execute a restart

49

50

51

52

53

54

55

56

57

58

59

Timeout when waiting for the RST sig- IS nal of the slaves CRC error in SPI transmission module f controller

60

Adjustable Error indicates high EMC interferences; please reduce these. Contact Baumller. Adjustable Error indicates high EMC interferences; please reduce these. Contact Baumller.

61

CRC error in SPI transmission Controller f module reserved Not assigned = 0

62 to 63

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Error power supply P0205

Error no. 64 65 Mains failure Phase failure Meaning Reaction Troubleshooting

Adjustable Restore the connection to the power supply IS Check if all phases are correctly connected and voltage-carrying Assure the compliance with the mains specifications (see techn. data) Assure the compliance with the mains specifications (see technical data) Assure the compliance with the mains specifications (see technical data)

66

Mains undervoltage

IS

67

Mains overvoltage

IS

68

Undervoltage 24V

IS

68 to 79

reserved Not assigned = 0

Error power unit P0206

Error no. 80 Meaning Communication error after HIPERFACE specification Reaction IS Troubleshooting see ZError power unit - serial interface P0233 on page 124 (= 3. level) Let the device cool down and/or reduce the load Reduce the DC link voltage Reduce the load and check the current controller settings as well as the cabling and the motor Check the installation of the device (from b maXX 443x) and check the motor for ground fault Make sure of a sufficient ventilation in the device and/or check the temperature of cooling air Pass on the device for repair Check the safety relay, exchange it for a new Execute a restart. At recurring error messages renew the controller cartridge Complete the operational readiness to the power unit Check if all phases are correctly connected and voltage-carrying

81

Heat sink temperature

IS

82 83

U DC link overvoltage Overcurrent

IS IS

84

Ground current

IS

85

Device internal overtemperature

IS

86 87 88

Cable break temperature sensor Safety relay off (or defect) Bridge short-circuit

IS IS IS

89

Power unit not ready-to-operate

IS

90

Phase failure

IS

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Troubleshooting

Error no. 91 92 Mains failure

Meaning

Reaction IS IS

Troubleshooting Restore the mains supply Assure the compliance with the mains specification (see technical data) Assure the compliance with the mains specification (see technical data) Check the power connections

Mains undervoltage

93

Mains overvoltage

IS

94 95

Undervoltage UDC link reserved Not assigned = 0

IS

Error motor P0207

Error no. 96 Meaning Short-circuit temperature sensor (TM <= -30 C) Temperature sensor - motor not connected (TM > +300 C) Motor overtemperature Reaction Troubleshooting

Adjustable Remove the short-circuit in the temperature sensor Adjustable Remove open circuit in the temperature sensor circuit

97

98

IS

Remove motor over temperature by cooling down and/or reducing the load Leave drive in inhibited status until I2t-actual value decreases under 100 %

99

Error I2t > 100 %

IS

100

Power unit maximal current > motor maximal current reserved Not assigned = 0 Collective error finding notch position

Adjustable Set power unit maximal current P1241 lower than motor maximal current P0069

101

102

IS

see ZError finding notch position P0237 on page 129 (= 3rd level)

103 to 111

reserved Not assigned = 0

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Error Encoder1 P0208

Error no. 112 Meaning Communication error (Hiperface-Specification) reserved Error at overwriting of Encoder position information Cable break encoder 1 IS Execute the command again.If the error occurs again, contact Baumller Nrnberg GmbH. Remove the cable break in the encoder cable of encoder 1 or check the assignment of the encoder cable Check the allowable rotational speed for encoder 1 Use another encoder Check if the correct encoder is connected or use another encoder Use another encoder Use another encoder Use another encoder Use another encoder Reaction IS Troubleshooting see encoder 1 (Hiperface) P0234 (= 3rd level)

113 114

115

IS

116

Overspeed encoder 1

IS

117 118

Amplitude limit exceeded Encoder type unknown

IS IS

119 120 121 122

Invalid data field for motor data Incorrect motor data Saving error of motor data Motor data write-protected. (is not valid for BM motors) Field angle error

IS IS IS IS

123 124

IS

Check the shielding of the encoder cable

Encoder without temperature measur- Adjustable Use an encoder module with temperature meaing suring Memory capacity in the encoder for electronic type plate too small reserved not assigned = 0 Adjustable Use another encoder with a greater memory

125

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Troubleshooting

Error encoder 2 P0209

Error no. 128 Meaning Communication error (hiperface specification) Module code invalid reserved Cable break encoder 2 IS Remove the cable break in encoder encoder cable of encoder 2, check assignment of encoder cable Check the permissible speed for encoder 2 Use a different encoder Check, if the correct encoder is connected or use a different encoder Use a different encoder Use a different encoder Use a different encoder^ Use a different encoder IS Reaction Troubleshooting See encoder 2 (hiperface) P0235 (= 3rd level)

129 130 131

IS

Use a different encoder

132 133 134

Overspeed encoder 2 Amplitude limit exceeded Unknown encoder type

IS IS IS

135 136 137 138

Invalid data field for motor data IS Invalid motor data Error at storage of motor data Motor data write protected. (invalid for BM motors) Field angle error Encoder without temperature measuring reserved not assigned = 0 IS IS IS

139 140

IS no reaction

Check the screening of the encoder cables Use an encoder module with temperature measuring

141 bis 143

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Error encoder manager P0210

Error no. 144 Meaning Absolute position of encoder 1 unknown Absolute position of encoder 2 unknown Encoder module 1 is missing Reaction IS Troubleshooting Use another encoder

145

IS

Use another encoder

146

IS

Check, if the right encoder is connected to module position A Check, if the right encoder is connected to module position B Install the encoder module

147

Encoder module 2 is missing

IS

148

Encoder module for measured value storage is missing

IS

149

At resolver no measured value storage IS possible Triggering not possible, because no incremental encoder Digital I/O-module is missing IS

Use a SinCos- or incremental encoder

150

Use for this option an Incremental encoder Install the digital I/O-Module Install the incremental encoderemulation module Install the encoder module to slot A

151 152

IS

Incremental encoder emulation module IS is necessary and is missing Encoder module 1 is necessary for incremental encoder emulation and is missing Encoder module 2 is necessary for incremental encoder emulation and is missing Initialization error of the incremental encoder-emulation module Overfrequency of the incremental encoder-emulation module Configuration error of the incremental encoder-emulation module IS

153

154

IS

Install encoder module to slot B

155

IS

Restart system

156

Adjustable Reduce the speed of the IEE setpoint source or reduce the no. of increments of the IEE module IS Use for this option an incremental encoder as setpoint source (start of the emulation) or choose the option zero pulse simultaneously with trace A=1 and B=1 (only IEE-02) Install the SSI-encoder-emulation module

157

158

SSI encoder emulation module is miss- IS ing reserved not assigned = 0

159

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Error device manager P0211

Error no. 160 Meaning Timeout communication Reaction Troubleshooting

Adjustable Remove the timeout of the Proprog communication Adjustable Remove the timeout of the BACI communication option module Adjustable Remove the timeout of the Cyclic communication: Adjustable Remove the timeout of the required data communication Adjustable Check the field bus communication

161

Timeout BACI

162

Timeout cyclic communication

163

Timeout required data

164 165

Field bus error

Controller not synchronous to external Adjustable set the Sync-Offset and / or signal Sync-tolerance Error at brake control IS Check the wiring and the function of the brake Check the holding brake

166 167

No release of holding brake when start- IS ing the drive

168

No closing of holding brake at stopping Adjustable Check the holding brake of drive Error holding brake status (cyclic moni- Adjustable Check the holding brake toring) Error holding brake lining Initialize holding brake error Adjustable Check the holding brake IS Check, if there is a DIO module, if it is in the correct position and if it is correctly parameterized (also see P0883) Ensure that the torque limits are not set too small |P1402| < Min (|P1036|, |P1037|, |P1038|)

169

170 171

172

Error holding brake: holding torque not IS reached

173 to 175

reserved Not assigned = 0

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Error data record manager P0212

Error no. 176 177 Meaning EEPROM copy error Write timeout EEPROM Reaction Troubleshooting

Adjustable Copy the data set once more Adjustable The data in the EEPROM are invalid, please safe all data records IS IS EEPROM faulty or described faulty The data in the EEPROM are invalid, please safe all data records The data in the EEPROM are invalid, please safe all data records

178 179

Checksum error EEPROM No boot data set

180

Incompatible software

IS

181

There is no data set

Adjustable The data in the EEPROM are invalid, please safe all data records Adjustable PSI EEPROM faulty or described faulty Adjustable Please save all data records Adjustable The data in the PSI are invalid, please save all data records Adjustable Restart autotuning Adjustable Replace the controller cartridge IS The data in the EEPROM are invalid, please safe all data records

182 183 184

Checksum error im PSI module PSI is reset PSI data invalid

185 186 187

Autotuning tables invalid. A/D correction table invalid EEPROM is reset

188 to 191

reserved Not assigned = 0

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Error position controller P0213

Error no. 192 193 194 Meaning Position deviation dynamic Position deviation static Reaction Troubleshooting

Adjustable Remove the dynamical position deviation error Adjustable Remove the statical position deviation error activate encoder 1

Encoder 1 is used for position control, IS but is inactive. This error is also shown, if the faulty positioning is in one of the inactive data records. Encoder 2 is used for position control, IS but is inactive. This error is also shown, if the faulty positioning is in one of the inactive data records. Software limit switch 1 exceeded

195

Activate encoder 2

196

Adjustable Check the target position with the by the limit switch enabled travelling range Adjustable Check the target position with the by the limit switch enabled travelling range Adjustable Check the target position with the by the limit switch enabled travelling range Adjustable Check the target position with the by the limit switch enabled travelling range Adjustable Execute homing

197

Software limit switch 2 exceeded

198

Hardware limit switch 1 exceeded

199

Hardware limit switch 2 exceeded

200

Homing necessary and not yet executed Setpoint in mode Set-of-setpoints didnt arrive in time

201

Adjustable Assure, that positioning data and handshake take place in time (also see parameter manual)

202 to 207

Not assigned = 0

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Error speed controller P0214

Error no. 208 209 Drive blocked Meaning Reaction IS Troubleshooting Remove the blockade of the drive You have got to either activate the encoder in the encoder 1 (modeP0150) or you set the encoder 2 as encoder for the position control (parameter P1030)

Encoder 1 is parameterized as encoder IS for the motor control, but the evaluation is not activated. This error is also shown, if the faulty positioning is in one of the inactive data records. Encoder 2 is parameterized as encoder IS for the motor control, but the evaluation is not activated. This error is also shown, if the faulty positioning is in one of the inactive data records. Overspeed Open loop Not assigned = 0 IS

210

You either have got to activate the encoder in the encoder 2 (P0160) or you set the encoder 1 as encoder for the position control (parameter P1030)

211

Check parameterization and reduce speed

212 to 223

Error CANsync P0216

Error no. 240 to 245 Meaning Not assigned = 0 Reaction No reaction Troubleshooting Check the parameterization of the DC link parameters, see parameter manual

246

Invalid DIP switch settings

according Correct the wrong setting of to setting DIP switches on the module

247 to 255

Not assigned = 0

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3. Level

Error power unit - serial interface P0233 (communication error to the power unit)
Error code 6 Data overflow Meaning Troubleshooting Error indicates high EMC problems; please reduce these. Contact Baumller Error indicates high EMC problems; please reduce these. Contact Baumller Contact Baumller Restart of b maXX Error indicates high EMC problems; please reduce these. Contact Baumller Error indicates high EMC problems; please reduce these. Contact Baumller Error indicates high EMC problems; please reduce these. Contact Baumller Error indicates high EMC problems; please reduce these. Contact Baumller Error indicates high EMC problems; please reduce these. Contact Baumller Error indicates high EMC problems; please reduce these. Contact Baumller Error indicates high EMC problems; please reduce these. Contact Baumller Error indicates high EMC problems; please reduce these. Contact Baumller Error indicates high EMC problems; please reduce these. Contact Baumller

Bit frame error

8 9 10

Invalid command state Parity error Checksum error

11

Unknown error code

12

Data number error

13

Invalid argument

14

Data field is write protected

15

Invalid access code

16

Data field is not changeable in its size

17

Word address outside of data field

18

Data field is nonexistent

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Error code 36

Meaning Wrong data checksum

Troubleshooting Error indicates high EMC problems; please reduce these. Contact Baumller Error indicates high EMC problems; please reduce these. Contact Baumller Restart of b maXX

37

No response

66

Invalid response

2 encoders can be connected to a b maXX 4400 at most. Accordingly maximum errors can appear in function module 1 and function module 2. The term encoder 1 or encoder 2 in the column device part stands for one of the five currently existing encoder module types.

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Troubleshooting

Error encoder 1 - serial interface P0234 Error encoder 2 - serial interface P0235 (communication error after Hiperface specification in the encoder 1 /encoder 2)
Error code 1 Meaning Analog signals outside specification Troubleshooting Check the encoder cable and if the encoder has been connected correctly. Check the encoder cable and if the encoder has been connected correctly. Check the encoder cable and if the encoder has been connected correctly. Check the encoder cable and if the encoder has been connected correctly. Check the encoder cable and if the encoder has been connected correctly. Check the encoder cable and if the encoder has been connected correctly. Check the encoder cable and if the encoder has been connected correctly. Check the encoder cable and if the encoder has been connected correctly. Check the encoder cable and if the encoder has been connected correctly. Check the encoder cable and if the encoder has been connected correctly. Check the encoder cable and if the encoder has been connected correctly. Check the encoder cable and if the encoder has been connected correctly. Check the encoder cable and if the encoder has been connected correctly. Check the encoder cable and if the encoder has been connected correctly. Check the encoder cable and if the encoder has been connected correctly. Check the encoder cable and if the encoder has been connected correctly. Check the encoder cable and if the encoder has been connected correctly. Check the encoder cable and if the encoder has been connected correctly.

Error in internal angle offset

Data field partitioning table destroyed

Analog limit values not available

Internal I2C-bus not operative

Internal checksum error

Internal watchdog error - encoder reset

Overflow of the counter

Parity error

10

Checksum error

11

Unknown error code

12

Data number error

13

Invalid argument

14

Data field is write protected

15

Invalid access code

16

Data field is not changeable in its size

17

Word address outside of data field

18

Data field is nonexistent

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Error code 19 to 27 28 reserved

Meaning

Troubleshooting

Absolute monitoring of the analog signals

Check the encoder cable and if the encoder has been connected correctly. Check the encoder cable and if the encoder has been connected correctly. Check the motor temperature Check the encoder cable and if the encoder has been connected correctly. Internal encoder error Contact Baumller Internal encoder error Contact Baumller Internal encoder error Contact Baumller Internal encoder error Contact Baumller Check the encoder cable and if the encoder has been connected correctly. Check the encoder cable and if the encoder has been connected correctly. Check the encoder cable and if the encoder has been connected correctly. Check the encoder cable and if the encoder has been connected correctly. Check the encoder cable and if the encoder has been connected correctly. Check the encoder cable and if the encoder has been connected correctly.

29

Transmission current critical

30 31

Encoder temperature critical Speed too high - no position generation possible Position singleturn unreliable

32

33

Multiturn position error

34

Multiturn position error

35

Multiturn position error

36

Invalid power unit data checksum

37

No response from encoder

38

Encoder address unknown

39

Error reading the absolute angle position

40

Invalid checksum of received data

41

Unknown encoder type

42 to 63 64

reserved No response of Hiperface encoder Check the encoder cable and if the encoder has been connected correctly. Check the encoder cable and if the encoder has been connected correctly. Check the encoder cable and if the encoder has been connected correctly.

65

No response from EnDat encoder

66

Useless response to encoder command

67 to 79 80

reserved CRC has determined an error Check the encoder cable and if the encoder has been connected correctly.

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Error code 81 Invalid command

Meaning

Troubleshooting Check the encoder cable and if the encoder has been connected correctly. Check the encoder cable and if the encoder has been connected correctly. Restart the system Check the encoder cable and if the encoder has been connected correctly. Check the encoder cable and if the encoder has been connected correctly. Check the encoder cable and if the encoder has been connected correctly.

82

Error in response telegram

83 84

Alarm bit is set Memory is occupied

85

Incorrect data checksum

86

Motor data length and/or data version of encoder and controller firmware are not identical No EnDat interface

87

Check the encoder cable and if the encoder has been connected correctly.

88

Exceeding of transmission format which is Use another able to be evaluated Length measuring system type

89

Exceeding of the evaluable measuring step Signal period length < measuring step length reserved Error lighting Error signal amplitude Error position value Error overvoltage Error undervoltage Error overcurrent Error battery

Use another Length measuring system type Use another Length measuring system type

90

91 to 95 96 97 98 99 100 101 102

Exchange encoder Exchange encoder Exchange encoder Exchange the encoder module Exchange the encoder module Exchange the encoder module Exchange encoder

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Error finding notch position P0237

Error code 0 Meaning Overcurrent step 1 Troubleshooting Method 2: Increase maximum current P1241, decrease voltage amplitude P2122 Method 2: Increase maximum current P1241, decrease voltage amplitude P2122 Method 0: Check direction of rotation P0087, current is too low or shaft is not free enough to move Method 2: Increase voltage amplitude P2122 3 Plausibility step 2 Method 2: Increase voltage amplitude P2123. If P2123 is already at its maximum, decrease the current frequency P2121 (only values = 15,625 Hz * 2n with n = 1,2,3,4,5,6 are permitted)

Overcurrent step 2

Plausibility step 1

15 ... 4

Not assigned = 0

Error function module A to E P0240 to P0244

Error code 0 1 reserved error

Meaning

Reaction

Troubleshooting

Module not recognized

Adjustable Check if you have plugged in the right module at the right position Adjustable Check if you have plugged in the right module at the right position Adjustable Check the cabling of the digital outputs

Module not permitted at this position

3 4

24 V missing or output short-circuited

Invalid target parameter value by digital Adjustable Check the parameterization of the input chaninput nel Direct PLC-I/O access for this module not permitted. reserved error Module in controller not permitted reserved error IS Remove the module Adjustable Dont select the module

6 7 8 to 15

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Troubleshooting

Error option module G to M P0245 to P0250

Error code 4096

Meaning Wrong parameter no. at setpoint parameter 1 Wrong parameter no. at setpoint parameter 2 Wrong parameter no. at setpoint parameter 3 Wrong parameter no. at setpoint parameter 4 Wrong parameter no. at setpoint parameter 5 Wrong parameter no. at setpoint parameter 6 Wrong parameter no. at setpoint parameter 7 Wrong parameter no. at setpoint parameter 8 Wrong parameter no. at setpoint parameter 9 Wrong parameter no. at setpoint parameter 10 Wrong parameter no. at setpoint parameter 11 Wrong parameter no. at setpoint parameter 12 Wrong parameter no. at setpoint parameter 13 Wrong parameter no. at setpoint parameter 14 Wrong parameter no. at setpoint parameter 15 Wrong parameter no. at setpoint parameter 16 Wrong parameter no. at actual value parameter 1 Wrong parameter no. at actual value parameter 2

Reaction

Troubleshooting

Adjustable Check the according setpoint parameter

4097

Adjustable Check the according setpoint parameter

4098

Adjustable Check the according setpoint parameter

4099

Adjustable Check the according setpoint parameter

4100

Adjustable Check the according setpoint parameter

4101

Adjustable Check the according setpoint parameter

4102

Adjustable Check the according setpoint parameter

4103

Adjustable Check the according setpoint parameter

4104

Adjustable Check the according setpoint parameter

4105

Adjustable Check the according setpoint parameter

4106

Adjustable Check the according setpoint parameter

4107

Adjustable Check the according setpoint parameter

4108

Adjustable Check the according setpoint parameter

4109

Adjustable Check the according setpoint parameter

4110

Adjustable Check the according setpoint parameter

4111

Adjustable Check the according setpoint parameter

4112

Adjustable Check the according actual value parameter

4113

Adjustable Check the according actual value parameter

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Error detection and troubleshooting

Error code 4114

Meaning Wrong parameter no. at actual value parameter 3 Wrong parameter no. at actual value parameter 4 Wrong parameter no. at actual value parameter 5 Wrong parameter no. at actual value parameter 6 Wrong parameter no. at actual value parameter 7 Wrong parameter no. at actual value parameter 8 Wrong parameter no. at actual value parameter 9 Wrong parameter no. at actual value parameter 10 Wrong parameter no. at actual value parameter 11 Wrong parameter no. at actual value parameter 12 Wrong parameter no. at actual value parameter 13 Wrong parameter no. at actual value parameter 14 Wrong parameter no. at actual value parameter 15 Wrong parameter no. at actual value parameter 16 Invalid value at setpoint parameter no. 1 Invalid value at setpoint parameter no. 2 Invalid value at setpoint parameter no. 3 Invalid value at setpoint parameter no. 4 Invalid value at setpoint parameter no. 5

Reaction

Troubleshooting

Adjustable Check the according actual value parameter

4115

Adjustable Check the according actual value parameter

4116

Adjustable Check the according actual value parameter

4117

Adjustable Check the according actual value parameter

4118

Adjustable Check the according actual value parameter

4119

Adjustable Check the according actual value parameter

4120

Adjustable Check the according actual value parameter

4121

Adjustable Check the according actual value parameter

4122

Adjustable Check the according actual value parameter

4123

Adjustable Check the according actual value parameter

4124

Adjustable Check the according actual value parameter

4125

Adjustable Check the according actual value parameter

4126

Adjustable Check the according actual value parameter

4127

Adjustable Check the according actual value parameter

4128

Adjustable Make sure that you have got correct values within the permitted value range. Adjustable Make sure that you have got correct values within the permitted value range. Adjustable Make sure that you have got correct values within the permitted value range. Adjustable Make sure that you have got correct values within the permitted value range. Adjustable Make sure that you have got correct values within the permitted value range.

4129

4130

4131

4132

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Troubleshooting

Error code 4133

Meaning Invalid value at setpoint parameter no. 6 Invalid value at setpoint parameter no. 7 Invalid value at setpoint parameter no. 8 Invalid value at setpoint parameter no. 9 Invalid value at setpoint parameter no. 10 Invalid value at setpoint parameter no. 11 Invalid value at setpoint parameter no. 12 Invalid value at setpoint parameter no. 13 Invalid value at setpoint parameter no. 14 Invalid value at setpoint parameter no. 15 Invalid value at setpoint parameter no. 16 Invalid value for Setpoint period Invalid value for Actual value period False value for Cycle offset setpoints False value for Cycle offset actual values BACI timeout at cyclic data BACI timeout at Service data Check results in faulty checksum

Reaction

Troubleshooting

Adjustable Make sure that you have got correct values within the permitted value range. Adjustable Make sure that you have got correct values within the permitted value range. Adjustable Make sure that you have got correct values within the permitted value range. Adjustable Make sure that you have got correct values within the permitted value range. Adjustable Make sure that you have got correct values within the permitted value range. Adjustable Make sure that you have got correct values within the permitted value range. Adjustable Make sure that you have got correct values within the permitted value range. Adjustable Make sure that you have got correct values within the permitted value range. Adjustable Make sure that you have got correct values within the permitted value range. Adjustable Make sure that you have got correct values within the permitted value range. Adjustable Make sure that you have got correct values within the permitted value range. Adjustable Make sure that you have got correct values within the permitted value range. Adjustable Make sure that you have got correct values within the permitted value range. Adjustable Make sure that you have got correct values within the permitted value range. Adjustable Make sure that you have got correct values within the permitted value range. Adjustable Check the communication rate with the adjusted timeout P0839 Adjustable

4134

4135

4136

4137

4138

4139

4140

4141

4142

4143

4144

4145

4146

4147

4148

4149

4150 4151

IS

Execute a restart by switching on and off

ramp-up Timeout when waiting for the Adjustable Execute a restart by switching on and off slave type or when waiting for the resetting of config-pending-flag Invalid data transfer structure type Adjustable Contact Baumller

4152

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Error code 4153 4154

Meaning Internal error: Wrong BACI status Access conflicts with slave at cyclic Communication:

Reaction

Troubleshooting

Adjustable Contact Baumller Adjustable Contact Baumller

4155

Error cyclic Communication: Parameter Adjustable Contact Baumller value wrong Error cyclic Communication: Alivecounter conflict Adjustable Check the value of the transmitted parameter

4156

4157

Cmd interface: Channel number wrong Adjustable Check if the option module and the controller (0 or > 6) are synchronous. Cmd interface: The channel which was Adjustable Contact Baumller indicated does not exist Cmd interface: Internal error - wrong pointer Cmd interface: Internal error - wrong status Adjustable Contact Baumller

4158

4159

4160

Adjustable Contact Baumller

4161 4162

Cmd interface: Wrong package number Adjustable Contact Baumller Cmd interface: Wrong command num- Adjustable Contact Baumller ber Cmd interface: Wrong status when handling the package Cmd interface: Timeout at command processing Adjustable Contact Baumller

4163

4164

Adjustable Contact Baumller

4165 4166 4167 4168 4169

Cmd interface: Wrong package length Adjustable Contact Baumller Cmd interface: Descriptor not available Adjustable Contact Baumller Cmd interface: Wrong package type Cmd interface: Checksum error Module identification: PCI-error when reading Module identification: PCI-error when writing Adjustable Contact Baumller Adjustable Contact Baumller Adjustable Check the reliability performance of the option module Adjustable Check the reliability performance of the option module

4170

4171

Module identification: general Reading Adjustable Check the reliability performance of the option error module Module identification: general Error at writing Internal error Adjustable Check the reliability performance of the option module Adjustable Contact Baumller

4172

4173

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Troubleshooting

Error code 4174

Meaning

Reaction

Troubleshooting

Configuration cyclic services: Parame- Adjustable Select another parameter ters are not cyclic writeable Configuration cyclic services: Invalid parameter number Wrong option module error code Adjustable Select another parameter

4175

4176

Adjustable Contact Baumller

4177 to 8191 reserved 8192 Error CANopen timeout on CAN bus Adjustable Error node guarding Additional data is available in the programming manual CANopen Slave for b maXX controller

8.5.3

Parameter description warnings (warning bit list) Warning power supply P0261
Warning no. 0 1 not used = 0 Undervoltage 24V Assure the compliance with the specification (see ZAppendix D - Technical data from page 161) Assure the compliance with the mains specification (see ZAppendix D - Technical data from page 161) Assure the compliance with the mains specification (see ZAppendix D - Technical data from page 161) Restore the mains supply Check if all phases are correctly connected and voltage-carrying Meaning Troubleshooting

Mains undervoltage

Mains overvoltage

4 5

Mains failure Phase failure

6 to 15

not used = 0

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Error detection and troubleshooting

Warnings power unit P0262

Warning no. 16 Meaning Inside temperature of device Troubleshooting Establish the specified environmental conditions, assure correct ventilation conditions Reduce the power output, check the fans of the device Check the correct order of mains phases (clockwise rotating field!) and avoid that the DC link supplies energy while charging.

17 18

Heat sink temperature Timeout charge process DC link

19 20 21 to 22 23

not used = 0 Safety relay not controlled reserved warning Difference of voltage Mains DC link > 40 V Ixt-threshold 1 is exceeded Check the power connections Check the cabling of the safety relay

24

Take steps, so that the Ixt actual value doesnt exceed 100%

25 to 31

not used = 0

Warnings motor P0263

Warning no. 32 33 34 35 to 47 Meaning Temperature threshold 1 exceeded Temperature threshold 2 exceeded It threshold exceeded not used = 0 Troubleshooting Reduce the power output of the motor Reduce the power output of the motor Reduce the power output of the motor

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MAINTENANCE

In this chapter we describe, how you can safely maintain your device.

9.1

Safety instructions
h Refer to ZFundamental safety instructions from page 11. h Refer to the danger areas of the devices.

Figure 56:

Danger areas BM441X, BM442X, BM443X and BM444X

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Environmental conditions

Figure 57:

Danger areas BM445X, BM446X and BM447X

9.2

Environmental conditions
If the prescribed environmental conditions are complied with, the device is maintenancefree. The prescribed environmental conditions are to be found in chapter ZAppendix D Technical data from page 161. The most important prescribed environmental conditions are: m dustless ambient air m Temperature: min. 5 C bis max. 55 C (pay attention to the over 40 C derating!) m Relative air humidity: 5% to 85%, no condensation

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Maintenance

9.3

Inspection intervals - maintenance notes

Baumller Nrnberg GmbH recommends a steady checking of the environmental conditions. Thus you will receive the possibility, to react immediately, in case the actual conditions deviate from the prescribed conditions. WARNING The following may occur, if you disregard these safety notes: m serious personal injury m death The danger is: electricity. The unit carries dangerous voltages and currents, as well as residual charges in the DC link. Assure, that when working in the control cabinet, that all devices in the control cabinet are offcircuit and are safe against re-starting. Await the discharging of the DC link, before maintenance work is carried out. The capacitors, which are used in the device of the DC link are 10 min. after interruption of the supply voltage discharge so far, that the connections can be demounted without danger. If you have additional capacitors connected to the DC link, the discharging of the DC link also can last much longer. In this case you must determine the necessary delay time yourself and you must determine the deenergization at all terminals of the device (also see ZDangers due to residual energy on page 23). h Check at least once a day the equipment at the control cabinet, which ensure the required environmental air (e.g. air filters). h Maintain the air filters according to the indications of the manufacturer. In the case of polluted environmental air, the required cooling air rate can not be reached anymore, if dirt deposits narrow/block up the ventilation slots. If the devices are dirty, contact Baumller Nrnberg GmbH, in order to initiate a servicing or send the device to the company for inspection. WARNING The following may occur, if you disregard these safety notes: m serious personal injury m death The danger is: electricity. The device can be damaged by incorrect maintenance in such a way, that a safe operating isnt possible anymore. Do not maintain the device yourself. Never remove dirt deposits especially in the inside of the device with sharp objects like screwdrivers or by the usage of e. g. compressed air, steam jet appliances/high pressure cleaners.

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Inspection intervals - maintenance notes

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10

REPAIR

In this chapter we describe, where the devices are repaired. WARNING The following may occur, if you disregard these safety notes: m serious personal injury m death The danger is: electricity. After a faulty repair the device doesnt fulfill the safety instructions anymore. Have the devices be commissioned only by Baumller Nrnberg GmbH or the authorized service points.

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11

SHUTDOWN, STORAGE

In this chapter we describe, how you decommission and store the device.

11.1 Safety instructions

h Refer to ZFundamental safety instructions from page 11 and the information in ZTransportation and packing from page 25. The shutdown of the device may only be carried out by for this qualified personnel. DANGER The following will occur, if you disregard this safety note: m serious personal injury m death The danger is: Electricity and electrical charge, which was saved. Electrical connections, which are not in a current-free state, carry hazardous voltage levels.The modules in the device (e. g. capacitors) also can carry hazardous charges after it was switched off! Assure, that all electric connections are current-free and are safe against re-start. Before working, check at the electrical connections with suitable measuring devices, that the connections are off-circuit. Remove the connections not until the safe isolation from supply has been checked. The capacitors which are used in the device are 10 min. after interruption of supply voltage discharged so far, that the connections can be demounted without danger. Dependent on the size of the device there are different discharging times. These you find from ZD.6 Electrical data - BM441X basic unit from page 167. If you have additional capacitors connected to the DC link, the discharging of the DC link also can last much longer. In this case you must determine the necessary delay time self (also see ZDangers due to residual energy on page 23).

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11.2

Requirements to the executing personnel

11.2 Requirements to the executing personnel

The personnel, who is appointed to setting out of operation, must have the required knowledge and instructions, which is necessary for an execution according to the rules. Select the personnel in such a way, that the safety instructions, which are mounted to the device and its parts as well as to the connections, are understood and applied to.

11.3 Shutdown
Execute the setting out of operation as follows: 1 put the device off-circuit and assure the device against unintentional restart. 2 check the isolation from supply of all connections (earliest 10 minutes after switching off). 3 demount the connections and protect the connections according to the safety instructions. 4 document the shut down setting.

11.4 Demounting
The demounting assumes a completed, documented setting out of operation. CAUTION The following may occur, if you disregard these safety notes: m minor to medium personal injury. In case, while installing, you lift a device with unprotected hands, fingers/palm can be cut. If the device falls off, your feet can be cut up.

Wear safety gloves

Wear safety shoes

1 secure the device against falling off/out. 2 loosen all mechanical connections. 3 lift the device out of the control cabinet. 4 store the device in a suitable packing. 5 at transportation pay attention to, that the device is not damaged by wrong storage or severe shocks, also see ZTo be considered by transportation on page 25. In case you want to dispose the device, additional data is available in chapter ZDisposal from page 147.

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11

11.5 Storage conditions

The device is maintenance-free. If you keep to the environmental conditions during the entire period of storage, you can assume, that the device will not be damaged. In case the environmental conditions during storage are not kept, you should assume that the device is damaged after storage. CAUTION The following can occur, if you disregard this warning instruction: m Property damage The danger is: incorrect environmental conditions. Incorrect storage can damage/destroy the device. Assure, that the environmental conditions are kept during the entire period of storage: m Climatic category 1 K 4 m Temperature range - 30 C bis + 70 C The danger is: recommissioning without forming of the capacitors. From six months storage period on, the capacitors are destroyed during commissioning, if they are not formed beforehand. m Reform the DC link capacitors by supplying the device ready-to-operate for at least one hour with supply voltage, but do not transmit a pulse enable during this time. m Consider, that it is imperative, to connect the accordingly prescribed line commutating reactor for this forming procedure.Devices, where no line commutating reactor is necessary can directly be supplied with mains voltage.

11.6 Recommissioning
Execute commissioning as with a new device, see ZMounting from page 37, ZInstallation from page 63 . The danger is: recommissioning without forming of the capacitors. From six months storage period on, the capacitors can be destroyed during commissioning, if they are not formed beforehand. m Form the DC link capacitors by supplying the device ready-to-operate for at least one hour with supply voltage, but do not transmit a pulse enable during this time. m Consider, that it is imperative, to connect the accordingly prescribed line commutating reactor for this forming procedure. Devices, where no line commutating reactor is necessary can directly be supplied with mains voltage.

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11.6

Recommissioning

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12

DISPOSAL

In this chapter we describe the correct and safe disposal of the devices of the series b maXX. During the disposal you will mainly get metal parts (iron- and non-iron metal), electronic scrap and plastics.

NOTE Baumller products do not belong to the scope of the EU guideline for the disposal of electrical and electronics devices (WEEE, 2002/96/EG). Therefore, no costs are to be carried by Baumller for the canceling and disposal of old devices.

12.1 Safety instructions

h Refer to ZFundamental safety instructions from page 11. DANGER The following will occur, if you disregard this safety note: m serious personal injury m death The danger is: electricity. The containing components in the device (e. g. capacitors) can contain dangerous charges! The capacitors used in the device are after 10 min. automatically so far discharged, that they can be demounted without danger. If you have additional capacitors connected to the DC link, the discharging of the DC link also can last much longer. In this case you must determine the necessary delay time self (also see ZDangers due to residual energy on page 23). Demount the capacitors only then, if you have verified yourself of the isolation from supply.

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12.1

Safety instructions

CAUTION The following may occur, if you disregard these safety notes: m minor to medium personal injury. The danger is: sharp edges. The components of the device, sheet metal components, heat sinks and so on can have sharp edges! In case you lift a device during demounting with non-protected hands, your fingers/palms can be cut. If the device falls off, your feet can be cut up.

Wear safety gloves

Wear safety shoes

WARNING The following may occur, if you disregard these safety notes: m serious personal injury m death The danger is: mechanical effects. A device of the size 446X weighs 70,0 kg and can injure you seriously or even kill you, if it falls off. Assure, that the device cannot fall off, by appropriate actions like supports, cranes, helpers.

CAUTION The following can occur, if you disregard this warning instruction: m Environmental pollution The danger is: incorrect disposal. You may only dispose under consideration of the safety instructions. If necessary, also refer to the local regulations. In case you cannot execute a secure disposal, contact a certified disposal business. Dangerous materials may result or may be set free from a fire. Do not expose electronic components to high temperatures. The inner insulation e. g. various power semiconductors hold beryllium oxide. When opened, the beryllium dust is dangerous to your health. Do not open the electronical components.

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12

12.2 Requirements to the executing personnel

The personnel, whom you instruct to dispose/demount the device must have the knowledge and training to execute these works properly. The personnel is to be selected in such a way, that the safety instructions on the device and its parts is understood and referred to by the personnel.

12.3 Disposal instructions

Preconditions m The device has already properly been demounted. m All technical appliances for demounting are prepared and are technically in good order and condition. 12.3.1 Modules

Figure 58:

Demounting scheme

The components/modules given in round brackets you will find in the above figure. Sheet steel Aluminium Aluminium/copper compound Plastics (A) Sheet steel must be given to the iron metal recycling. (B) Aluminium must be given to the non-iron metal recycling. (C) Aluminium/copper compound must be given to the non-iron metal recycling. (D) The plastic parts of the housing as well as the plastic covers and further small plastic parts must be given to the plastics recycling. Manual b maXX BM4400 Document No. 5.04043.06

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12.4

Recycling plants/offices

CAUTION The following can occur, if you disregard this warning instruction: m Environmental pollution The danger is: incorrect disposal. Capacitors, semiconductor modules and electronic scrap is to be recycled as special waste.

Capacitors Semiconductor modules Electronic scrap

(E) Capacitors are to be recycled as special waste. Thereby refer to the relevant instructions. (F) Semiconductor modules are to be recycled as special waste. Thereby refer to the relevant instructions. (G) The electronic scrap from PCBs, which no further can be demounted, must be recycled as special waste. Thereby refer to the relevant instructions.

12.4 Recycling plants/offices

Assure, that the disposal is carried out according to your companys regulations and the regulations of the disposal companies and official administrations. In case of doubt, contact the local business administration, which is responsible for your company or the environmental office.

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APPENDIX A - ABBREVIATIONS
A AC AIO ASCII BACI BB BBext BBint BCC BSA BSD CAL CAN CiA CPU DC DIN Ampere Alternating current Function module analog input/output American Standard Code for Information Interchange Baumller drives communication interface Ready-to-operate Ready-to-operate (external) Ready-to-operate (internal) Block Check Character Reference potential analog Reference potential digital CAN Application Layer Network for controller ambience CAN in Automation Central processing unit Direct current Deutsches Institut fr Normung e.V. (German Institute for Standardization) Function module digital input/output Data set manager Electronic data sheet Electromotive force Electromagnetic compatibility European standard Function module incremental encoder Electrostatic discharge IAC IAist IDC Ieff IF IF IFmax IFmin IFsoll IEE ID-no. Inc Ink IS ISO Isoll IW EXT, ext external FI FIO GL HLG HS HSE HSF I2t Residual current Function module fast digital input output Synchronous operation Ramp function generator Main contactor Main contactor on Main contactor enable Peak current, curve shape not defined Function module overload monitoring Effective value, alternating current Armature current actual value Effective value, direct current Effective value, alternating current Impulse enable Field current Maximum field current (nominal current) Minimum field current Field current setpoint value Function module incremental encoder emulation Identification number Counting unit of position PPR count of incremental encoder Impulse inhibit International Organization Standardization Armature current setpoint Actual value for

COB-ID Identification for CAN object

DIO DSV EDS EMF EMC EN ENC ESD

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A
IWK LT M24 MR1 MR2 n=0 nist nmax nmin NN nsoll PDO PE PELV POS PSI PWM PZD RA RF SDO SELV SIE SM SR SW SWG SYNC TM U UA UAC UDC Ueff UZK V VBG Actual value channel Power unit Reference potential 24 V Torque direction 1 Torque direction 2 Speed = 0 Speed actual value Maximum speed Minimum speed Altitude over sea level Speed setpoint value Process data object Protective conductor Protective extra-low voltage with safety separation, earthed Positioning Program Storage Interface Function module pulse-width modulation Process data Armature resistance Controller enable Service data object Safety extra-low voltage with safety separation Function module SSI encoder emulation Synchronous motor Safety relay Setpoint value, software Setpoint value generator Synchronization message Motor temperature sensor Voltage Peak voltage Armature voltage Effective value, alternating voltage Effective value, direct-current voltage Effective value, alternating voltage DC-link voltage Volt German Administerial Occupation Co-operative VE ZK VDE Association for Electrical, Electroninc & Information Technologies Logic element DC-link

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APPENDIX B - SPARE PARTS AND

ACCESSORIES
In this appendix we are listing the spare-/accessory parts for the devices of the series b maXX. In case you have questions and suggestions according the accessories, do not hesitate to contact our product management. B.1 Interface cable

NOTE Screening of the interface cables, which are used may only be connected to the controller side with the connector housing.

In case the interface cable set for b maXX is used, the connection of cable screen with the Sub-D-plug housing must be interrupted PC-sided. (also see ZX1 (RS 232) on page 92).

Interface X1 (RS 232) X1 (RS 232) X1 (RS 232)

Identification Interface cable PC Interface cable PC Interface cable PC

Length 3m 5m 15 m

Item number 213 846 213 283 231 086

Other lengths on request.

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B.2
B.2

Dust cover and connector

Dust cover and connector

Dust cover (yellow) narrow Dust cover (yellow) wide Connector Motor Phoenix: GIC 2.5/4-ST-7.62, 1828825 Connector 1C1/1D1 or 1C1/1D1/Ba Phoenix: GIC 2.5/4-ST-7.62, 1828825 Connector 1C1/1D1/Ba Phoenix: GIC 2.5/2-ST-7.62 Connector mains Phoenix: GMSTB 2.5/4-ST-1766903 Wieland: 8313B/4 OBGN, 25.360.3453.7 Connector X3 Phoenix: FK-MCP 1.5/6-ST-3.81, 1851083 Connector X100 and X101 Wieland: 8513 BFK - 25.630.3653.0 Connector X102 3)4) Phoenix: FK-MCP 1.5/4-ST-3.81, 1851067 Wieland: 8513 BFK, 25.630.3453.7 Connector X103 Phoenix: FK-MCP 1.5/4-ST-3.81, 1851067
1) 2) 3) 4)

X X X X

X X X X

X X X X X

X X X X X

X -

X -

X -

X -

X -

X -

X X X -

X X X -

X X X -

X X X -

X X X -

X X X X

X X X X

X X X X

X X X X

X X X X

4)

BM441X - XXX - 01 BM441X - XXX - 02 BM44XX - XX1, BM44XX - XX3 BM44XX - XX2, BM44XX - XX4

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Part no. 351209 351210 354746 354746 381872 309377 354874 354810 363845 354809 363845

4412 4413 1)

4412 4413 2)

4414 1)

4414 2)

442X

443X

444X

445X

446X

447X

APPENDIX C DECLARATION OF CONFORMITY/ BY MANUFACTURER, UL - CERTIFICATION

In this section we provide general information about EU directives, the CE symbol and the Declaration of Conformity/by Manufacturer. C.1 What is an EU directive? EU directives specify requirements. The directives are written by the relevant bodies within the EU and are implemented by all the member countries of the EU in national law. In this way the EU directives guarantee free trade within the EU. An EU directive only contains essential minimum requirements. You will find detailed requirements 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 manufacturers 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 or legal person having affixed or been responsible for the affixing of the said marking has verified that the product conforms to all the Community total harmonization provisions which apply to it and has been the subject of the appropriate conformity evaluation procedures.

Council Decision 93/465/EEC, Annex I B. a) + c) We affix the CE mark to the equipment and to the documentation as soon as we have established that we have satisfied the requirements of the relevant directives. All converters and control systems supplied by the Baumller Nrnberg GmbH satisfy the requirements of 73/23/EEC (Low Voltage Directive). As all converters and control systems comply with the requirements of the harmonized standards EN50178, EN 60204-1, EN 60529 and HD625.1 S1, the protection targets of 73/23/EWG are reached.

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C.3

Definition of the term Declaration of Conformity

With specified application of this Baumller equipment in your machinery, you can act on the assumption that the equipment satisfies the requirements of 98/37/EG (machinery directive). Therefore the equipment is developed and constructed in such a way, that the requirements of the harmonized standard EN 60204-1 can be met by the electrical installation. Compliance with 89/336/EEC (EMC Directive) depends on how the equipment is installed. Since you are performing installation yourself, it is you who are responsible for complying with 89/336/EEC. A declaration of conformity on the EMC directive therefore cannot be issued. We will provide you with support in the form of EMC information. You will find this information in the operating manual and in filters for main applications. When you have complied with all the requirements we impose in this documentation, you can assume that the drive satisfies the requirements of the EMC Directive. The limit values and requirements for variable-speed electrical drives are determined in the harmonized product standard EN61800-3. If you are erecting an installation, for which a declaration of conformity on the EMC directive must be generated, it may be necessary to specify several harmonized standards, which you have used for the compliance of the protection targets of the directive. The harmonized product standard EN 61800-3 has to be used with electrical drives. To enable you to market your machine within the EU, you must be in possession of the following: m Conformity mark (CE mark) m Declaration(s) of Conformity regarding the directive(s) relevant to the machine C.3 Definition of the term Declaration of Conformity A Declaration of Conformity as defined by this documentation is a declaration that the electrical equipment brought into circulation conforms to all the relevant fundamental safety and health requirements. By issuing the Declaration of Conformity in this section the Baumller Nrnberg GmbH 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. C.4 Definition of the term Manufacturers Declaration A Declaration by Manufacturer as defined by this documentation is a declaration that the machine/safety component brought into circulation conforms to all the relevant fundamental safety and health requirements. By issuing the Declaration of Conformity in this section the Baumller Nrnberg GmbH 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 . The Baumller equipment is integrated into a machine. For health and safety, of the users for example, it is important for the entire machine to conform to all the relevant fundamental safety and health requirements. For this reason the Baumller Nrnberg GmbH draws attention in the Declaration by Manufacturer to the fact that it is prohibited to put the machine as a whole into operation before it has been declared that the machine conforms to the provisions of the Machinery Directive.

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Declaration of Conformity/ by Manufacturer, UL - Certification

C.5

Declaration of Conformity

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C.6
C.6

Declaration by Manufacturer

Declaration by Manufacturer

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Declaration of Conformity/ by Manufacturer, UL - Certification

C.7

UL-certification UL is a mark of conformity, which is assigned from Underwriters Laboratories Inc. (www.ul.com), an American company. The UL-certification is not statutory regulated, but takes place voluntarily. In order to be allowed to mark equipments and components with the UL-mark of confomity, tests must have to be done, which are attended and documentated by an UL-inspector. Only if all necessary tests have been passed and regular product monitoring at the production process of the equipment or the components has been passed without objections, the UL-mark of conformity may be attached to the equipment under test. Line filters of the company Baumller Nrnberg GmbH are checked in accordance of the UL-standard UL 508C (UL-Standard for Safety for Power Conversion Equipment) and are recorded under the category control number NMMS. The product- and test description is recorded under file-no. E179860. Only if all necessary tests have been completely carried out the c-mark may be attached to the equipments or components. If single tests have not already taken place at the manufacturers, but are carried out not until at the users, then only the u-mark may be attached. With products of the Baumller Nrnberg GmbH all tests are already completed at the UL-certification process, so that they may be marked with the c-mark. In case with the UL-certification process also standards of the CSA (Canadian Standard Association) are considered, then instead of the c- or u-mark the cc or U-mark may be attached to the product. With products of the company Baumller Nrnberg GmbH the CSA-standard Norm C 22.2 was considered, thats why they are marked with the cc-mark. If products of Baumller Nrnberg GmbH are mounted into an UL-certified installation, then certain application-, mounting- and installation notices must be considered, which are upon the functioning of the device. We have marked these notes in the manual with UL 508C .... Only if you follow these notes and apply to them you may go by it, that the installation has been mounted UL-conform.

The converters of the b maXX line listed below are accredited and carry the cc-mark: BM4412-XXX-XXXX-XX, BM4413-XXX-XXXX-XX BM4432-XXX-XXXX-XX, BM4433-XXX-XXXX-XX, BM4434-XXX-XXXX-XX, BM4435-XXX-XXXX-XX BM4452-XXX-XXXX-XX, BM4453-XXX-XXXX-XX, BM4454-XXX-XXXX-XX

BM4422-XXX-XXXX-XX, BM4423-XXX-XXXX-XX, BM4424-XXX-XXXX-XX, BM4425-XXX-XXXX-XX, BM4426-XXX-XXXX-XX BM4443-XXX-XXXX-XX, BM4444-XXX-XXXX-XX, BM4445-XXX-XXXX-XX

BM4462-XXX-XXXX-XX, BM4463-XXX-XXXX-XX

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UL-certification

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APPENDIX D - TECHNICAL DATA

In this chapter you find the detailed technical data for all sizes of the device series b maXX BM4400.

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D.1
D.1 Mains

Requirements on the power supply

Requirements on the power supply BM44XX - XTX12) BM44XX - XIX Industrial system with direct or low impedance grounded star point (TN-mains or TT-mains) Industrial supply network with a grounded star point (IT-system), which has no or high impedance Industrial system with direct or low impedance earthed junction of phases (grounded delta wye) min. uk = 0,4% min. uk = 2,4% min. uk = 4% max. uk = 4% max. uk = 4% max. uk = 6%

Inductance BM441X, BM442X (sum of mains inductance and mains BM4426, BM443X, choke inductance) BM444X BM445X, BM446X, BM447X Rated mains input voltage/-frequency 1) 8) (UAC) device Absolute minimum supply voltage device 1) 8) (UACmin) Absolute maximum supply voltage device 1) 8) (UACmax) Absolute minimum frequency 9) Absolute maximum frequency 9) Harmonics (mains voltage) Unbalanced mains voltage Commutating dip Voltage dip Voltage variations/-fluctuations Max. short-circuit current mains 7) Rated mains input voltage -frequency (UAC) fan 6) BM444X-S/A, BM445X-S/A, BM446X-S/A BM447X-S/A Control voltage 4) (UDC)
1) 2) 3) 4)

3 x 400 V 50/60 Hz 3 x 207 V / 50/60 Hz 3 x 528 V / 50/60 Hz 47 Hz 63 Hz THDU b 10% 2) max. 3% 3) Depth of dip < 40%, area < 250% x degree 2) 10% to 100% 11) 1) +/-10% 10) +10% to -15% at duration b 1 min 10) 18000 A 230 V 10% 50/60 Hz 3 x 400 V 10% 50/60 Hz + 24 V -15% / +20% 5)

The error power supply not ready-to-operate is generated if the supply voltage falls below UACmin for t > 0.1 s. EN 61800-3, chapter 5.2.1, class 3 EN 61000-2-4, tab. 1, class 3 The control voltage must accord to PELV (EN 61800-5-1, chapter 3.2.14) or SELV (EN 61800-5-1, chap. 3.2.28). At control voltage of < 24 V the ventilation power output is reduced. It, therefore, may be necessary, to reduce the output currents as well. In case you refer to UL508C: limit the current to 4 A with UL-listed fuses and to a voltage of max. 30 VDC. Referring to EN61131-2:1994, table 7. Output power of the power supply unit: see power loss referring to control voltage in electrical data - BM44XX. Is only valid for BM444X/BM445X/BM446X cooling versions S and A and BM447X cooling version A. Only necessary in order to comply with UL508C.

5)

6) 7)

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Technical data

8)

The rated voltage is 400 V. At mains input voltage is below 400 V the output power of the device reduces (see curves). Change rate of mains frequency max. 1 Hz/s (EN 61000-2-4, class 3) EN 61200-2-4, class 3 EN 61200-2-1 The connection or operation of a device with the marking BM44XX-XTX at an IT system or at a grounded delta wye is not permissible.

9) 10) 11) 12)

Output voltage device

Output voltage device

PNominal Continuous operation permitted

Connection voltage
Curve output voltage

Connection voltage
If you multiply the output current with the output voltage you will get the output power of the device. S output = U output xoutput x3 In order to receive the specified curve/area, it is necessary, that output current is reduced between 400 and 528. The characteristic curves Output current in dependence of the supply voltage you will find in the electrical data of the individual devices from ZPage 167.

D.2

Requirements to the motor The b maXX 4400 is dimensioned for the operation of three-phase motors with a mains voltage of 3 x 400 V and a nominal DC link voltage of v 540 V. The use of the devices also is possible with a lower-rated voltage, e.g. 3 x 230 V.This however requires that the used three-phase motors are enabled for the operation at the inverters with a DC link voltage of up to 800 V, because the chopper start-up voltage (see ZD.6 Electrical data - BM441X basic unit from page 167 and the following) remain unchanged. Therewith only three-phase motors with UDC link, nominal v 540 V is used.

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D.3
D.3

Required environmental conditions

Required environmental conditions - 30 C bis + 70 C 2 K 3 1) - 30 C bis + 70 C 1 K 4 1) Industrial supply network 2) min. 5 C bis max. 55 C 3) 3 K 3 1) absolute altitude up to 2000 m 5% to 85% no condensation 1) max 1 g 5) 2 6) 3 K 3, 3 B 1

Transportation temperature range Transportation climatic category Storage temperature range Storage climatic class Operation electrical environment Operation temperature range Operation climatic class Mounting height 4) Relative humidity (operation) Vibration, shock and repetitive shock Degree of pollution Environmental conditions (EN 60721-3-3)
1) 2)

EN 50178, table 7 For the operation in an environment of category C1/C2 according to IEC 61800-3:2005, with the utmost probability additional measures will be required.The plant manufacturer/user must, in this case, provide evidence, that these additional measures are successful and that the specified limit values of category C1/C2, which are described in IEC 61800-3, are adhered to. Rated temperature = 40 C Characteristic curve: Output apparent power S compared with the rated apparent power SRating of unit in dependence of installation altitude at standard air pressure Note Baumller devices, which are provided for the operation at grounded delta systems or IT supply systems, at these systems only may have an operating altitude of 2000 m.If the altitude is higher than 2000 m these devices must be operated at TN systems and TT systems. Such systems, e. g. can be achieved with an isolating transformer with a secondary-sided star point.

3) 4)

S SRate
d

Installation altitude above sea level Figure 59: Derating of output apparent power against the installation altitude.

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5) 6)

EN 50178, chapter 9.4.3.2 EN 50178, table 2

NOTE Normally only a non-conductive pollution occurs. Any conductive pollution (for a short period or continuous) is not permitted and can lead to the destruction of the device. The customer is responsible for destructions based on pollution with conductive substance or materials.

D.4

Cooling min. 5 C to max. 55 C 2) see electrical data min. Cooling air temperature 1) to max 60 C (to max. 40 C at BM447X) min. 4 l/min. to max. 15 L/min. BM 447X-FXX: min. 10 l/min. to max. 15 l/min. max. 6 bar 6) max. 5 K in the static and in the dynamic operation l/min power loss [ kW ] < 14,35 ----------- K ------------------------------------------------------------------kW cooling water flow [ l/min ] 0.5 bar at 10 l/min min. Cooling air temperature 1) to max 55 C 2)

Cooling air temperature 1) Cooling air requirement 3) Cooling water temperature 4)5)9)

Cooling water flow rate 4)5)8) Cooling water pressure 4)5) Cooling water hysteresis Hot water generation (cooling water inlet to -outlet) 4) 5) [K] Pressure loss at water cooler 4)5) Mounting board temperature 7)
1) 2) 3)

Air temperature in the entire suction area of the device. Rated temperature = 40 C The cooling air requirement corresponds at least to that of a free-blowing device. Free-blowing means, that the air inlet and the air outlet operates unrestricted. With the mounting of the device into a control cabinet it therefore can be necessary to use additional fans, so that the necessary cooling air requirement is covered. If the necessary cooling air requirement of the power heat sink is not provided, then the output power of the device has to be reduced. only by BM44XX - FXX and BM44XX - ZXX Rated flow = 10 l/min With other cooling water flow rates as mentioned above please contact Baumller Nrnberg. The cooling water must meet the following requirements: pH-value Conductivity Water hardness (inclusive CaCO3) Suspended matters Particle size Ryznar Stability Index (RSI) 6.5... 9.5 50... 600 S/cm < 100 ppm < 10 ppm < 100 m 5.0 ... 6.0 Manganese (Mn) Copper (Cu) Chlorine (Cl2) Chloride (Cl-) Sulfate (SO
24)

4) 5)

< 0.05 ppm < 0.1 ppm < 1 ppm < 500 ppm < 500 ppm

The corrosion-resistant compared with further materials you can take from the DECHEMA-material tables. Use a corrosion-resistant and a closed cooling circuit.

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D.5
6)

Non-electrical data

In case you refer to UL508C: max. 3 bar. There must be a pressure-relief valve with a threshold pressure of maximum 6 bar in the cooling circulation. only by BM44XX - CXX Recommendation: In order to avoid dew, the temperature of the water inlet is greater or equal to the interior temperature of the device. With other cooling water temperatures as mentioned above please contact Baumller Nrnberg.

7) 8)

D.5

Non-electrical data Dimensions (W x H x D) 80 x 347 x 263 mm / 105,5 x 347 x 263 mm 105,5 x 428 x 340 mm 155 x 540 x 340 mm 190 x 665 x 374 mm 304 x 745 x 380 mm 437 x 920 x 380 mm 580 x 660 x 340 mm Weight with controller, without plug-in modules 4,0/4,4 kg 7,0 kg 15,7 kg 26.4 kg 50,0 kg 70,0 kg 82.0 kg Noise development max. 80 db(A) 1) max. 80 db(A) 1) max. 80 db(A) 1) max. 80 db(A) 1) max. 80 db(A) 1) max. 80 db(A) 1) max. 80 db(A) 1)

Device BM441X2): BM442X3): BM443X3): BM444X3): BM445X3): BM446X3): BM447X4):

1) 2)

98/37/EG, appendix I, chapter 1.7.4.f, paragraph 8 The first value provides the measurements of the device BM441X - XXX - 00XXX - XX and BM441X - XXX - 01XXX - XX. The second value specifies the dimensions of the device BM441X - XX - 02XX - XX. Predetermined are the dimensions for the devices BM44XX-S. The dimensions for BM44XX-A..., BM44XX-C..., BM44XX-F... and BM44XX-Z...-devices are to be found in ZInstallation space from page 39. Specified are the dimensions for the device BM447X-F, the specified depth is the total depth of the device. Also see ZFigure 20 on page 47.

3)

4)

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D.6

Electrical data - BM441X basic unit BM4412 BM4413 3.3 kVA 4.8 A 110% 9.0 A 540 VDC 110 F 80 s 240 F 175 s

Input rated power 1) Input rated current

1)

1.9 kVA (Ieff) 2.8 A 119% 5.2 A

Distortion factor of the input current 1) (THDI) Input current max. (Ieff) DC-link rated voltage 1 )(UDC) DC link capacity (internal) DC link discharging time (internal DC link capacity) DC link capacity (external), permitted Delay time mains off mains on 11) Output voltage
1)

see ZFigure 61 on page 170 at least 60 s 3 x 0 V to 3 x 370 V 0 Hz to 450 Hz

3)

(UAC)
1)4)5)6)

Output frequency Output rated current (IAC) (IAC) at 4 kHz Output rated current 1)4)5)6) (IAC) Output peak current
1)4)5)7)

max. 2.5 A max. 2.5 A max. 5.0 A max. 5.0 A 60 s

max. 4.5 A max. 4.5 A max. 9.0 A max. 9.0 A

at 8 kHz 3) at 4 kHz
3)

Output peak current 1)4)5)7) (IAC) Max. peak current time

7)

at 8 kHz 3)

Output power DC link terminals 10) Chopper current, permissible () Chopper resistor external Chopper start-up voltage () Chopper peak power Permissible chopper continuous power Power loss referring to mains voltage Power loss referring to control voltage Current of the integrated brake interface
Footnotes see following page.

max. 2.0 kW max. 5.9 A 130 780 V 4.5 kW 1.0 kW 33 W max. 60 W max. 0.5 A 5.0 kW 1.5 kW 60 W

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Electrical data - BM441X basic unit

BM4414-STx 9) Input rated power 1) Input rated current

1)

BM4414-CTx 8)9) 6.9 kVA 10.0 A 113% 20.0 A

5.1 kVA (Ieff) 7.3 A 109% 20.0 A 540 VDC 330 F 240 s

Distortion factor of the input current 1) (THDI) Input current max. (Ieff) DC-link rated voltage 1 )(UDC) DC link capacity (internal) DC link discharging time (internal DC link capacity) DC link capacity (external), permitted Delay time mains off mains on 12) Output voltage
1)

330 F 240 s

see ZFigure 61 on page 170 at least 60 s 3 x 0 V to 3 x 370 V 0 Hz to 450 Hz

3)

(UAC)
1)4)5)6)

Output frequency Output rated current (IAC) (IAC) at 4 kHz Output rated current 1)4)5)6) (IAC) Output peak current
1)4)5)7)

max. 5.5 A max. 5.0 A max. 20.0 A max. 12.0 A 1s max. 3.0 kW 65 780 V 9.4 kW 3.0 kW 80 W

max. 7.5 A max. 5.0 A max. 20.0 A max. 12.0 A

at 8 kHz 3) at 4 kHz
3)

Output peak current 1)4)5)7) (IAC) Max. peak current time

7)

at 8 kHz 3)

Output power DC link terminals 10) Chopper current, permissible () Chopper resistor external Chopper start-up voltage () Chopper peak power Permissible chopper continuous power Power loss referring to mains voltage Power loss referring to control voltage Current of the integrated brake interface
1) 2) 3) 4)

max. 4.3 kW

max. 12.0 A

9.4 kW 3.0 kW 102 W max. 60 W max. 1.0 A

All rated values refer to a mains input voltage of 400 V/50 Hz and a control voltage of 24 V. The output voltage is a pulsed d.c. voltage. The operating range refers to the RMS of the fundamental wave. Switching frequency of the inverter (adjustable). RMS at an environmental temperature of 40 C.

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5)

At rated input supply voltage the device enables the rated-/maximum output currents. At input voltages above the rated supply voltage the output currents at constant output power have to accordingly be reduced. Derating of the output current Derating of the output current

Output current [%]

Output current [%]

Mains voltage [V] Derating of the output current

Mains voltage [V]

Derating of the output current

Output current [%]

Output current [%]

Mains voltage [V] Figure 60: Derating of the output current BM 441X basic unit

Mains voltage [V]

6)

Between 40 C and 55 C the output current must be reduced. The allowable output current (I0) is calculated with the following formula:

( Coolant temperature ) - 40C I o = I o ( 40C ) - 0, 03 1 ----------------------------------------------------------------------------- C

7)

This overload time is dependent on the motor current and of the heat sink temperature and is determined by the Ixt-monitoring of the device. Values are valid at mounting on a heat-conducting surface with a thermal resistance of 0.115 K/W.The maximum allowable length case temperature at the measuring point, see ZFigure 45 on page 80, is 75C.

8)

9)

NOTE For the BM4414 further limitation are valid for peak current at braking operation only. The possible peak currents are:15 A at 4 kHz and 10 A at 8 kHz switch frequency.

10)

The sum of the average active power, which was transmitted via the DC link terminals and of the average active power transmitted to the motor terminals may not exceed 3.0 kW (BM4414-STx) or 4.3 kW (BM4414-CTx).

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11)

Electrical data - BM441X basic unit

The specified value is only valid, if there is no additional DC link capacity connected to the DC link terminals. Also see ZMains-switchon frequency/DC-link charging on page 97 and ZFigure 61 on page 170.

5000 4500 4000

external DC link capacity [F]

3500 3000 2500 2000 1500 1000 500 0 200 250 300 350 400 450 500
BM 4413 BM 4414 BM 4412

maximum mains voltage [V] Figure 61: Maximum external DC link capacity BM441X

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Electrical data - BM442X basic unit BM4422 BM4423 8.6 kVA 12.4 A 109 % 23.2 A 540 VDC 470 F 340 s 470 F 340 s 705 F 510 s BM4424 11.8 kVA 17.0 A 109 % 31.8 A

Input rated power 1) Input rated current

1)

5.6 kVA (Ieff) 8.1 A 107 % 15.1 A

Distortion factor of the input current (THDI)1) Input current, max. (Ieff) DC-link rated voltage 1 )(UDC) DC link capacity (internal) DC link discharging time (internal DC link capacity) DC link capacity (external), permitted Delay time mains off mains on 9) Output voltage
1)3)

see ZFigure 63 on page 174 at least 60 s 3 x 0 V to 3 x 370 V 0 Hz to 450 Hz there is no derating required at 4 kHz 4) at 8 kHz
4)

(UAC)

Output frequency Derating at static output frequency Output rated current 1)5)6)7) (IAC) Output rated current
1)5)6)7)

max. 7.5 A max. 6.0 A max. 15.0 A max. 12.0 A

max. 11.0 A max. 8.8 A max. 22.0 A max. 17.6 A 60 s

max. 15.0 A max. 12.0 A max.30.0 A max. 24.0 A

(IAC) (IAC)
10)

Output peak current 1)5)6)8) (IAC) Output peak current

1)5)6)8)

at 4 kHz 4) at 8 kHz
4)

Max. peak current time 8) Output power DC link terminals Chopper current, permissible () Chopper resistor external Chopper start-up voltage () Chopper peak power Permissible chopper continuous power Power loss referring to mains voltage Power loss referring to control voltage Current of the brake control
Footnotes see following page.

max. 5.0 kW max. 9.0 A 86 max. 13.0 A 60 780 V 7 kW 3.4 kW 102 W 10 kW 5 kW 150 W max. 63 W max. 0.5 A 14 kW 6.8 kW 204 W max. 18.0 A 44

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.

Electrical data - BM442X basic unit

BM4425 Input rated power 1) Input rated current

1)

BM4426 13.2 kVA 19,0 A2) 54%2) 37.0 A2) 540 VDC 705 F 510 s

11.8 kVA (Ieff) 17.0 A 109% 34.0 A 705 F 510 s

Distortion factor of the input current (THDI)1) Input current, max. (Ieff) DC-link rated voltage 1 )(UDC) DC link capacity (internal) DC link discharging time (internal DC link capacity) DC link capacity (external), permitted Delay time mains off mains on 9) Output voltage
1)

see ZFigure 63 on page 174 at least 60 s 3 x 0 V to 3 x 370 V 0 Hz to 450 Hz there is no derating required at 4 kHz 4) at 8 kHz
4)

(UAC)

Output frequency Derating at static output frequency Output rated current 1)5)6)7) (IAC) Output rated current
1)5)6)7)

see ZPage 197 max. 22.5 A max. 18.0 A max. 45.0 A max. 36.0 A

max. 15.0 A max. 12.0 A max. 40.0 A max. 32.0 A 1s

(IAC) (IAC)
10)

Output peak current 1)5)6)8) (IAC) Output peak current

1)5)6)8)

at 4 kHz 4) at 8 kHz
4)

Max. peak current time 8) Output power DC link terminals Chopper current, permissible () Chopper resistor external Chopper start-up voltage () Chopper peak power Permissible chopper continuous power Power loss referring to mains voltage Power loss referring to control voltage Current of the brake control
1) 2) 3) 4) 5) 6)

max. 5.0 kW max. 25.0 A 32 780 V 20 kW 6.8 kW 204 W max. 63 W max. 0.5 A 300 W

All rated values refer to a mains input voltage of 400 V/50 Hz and a control voltage of 24 V. In case you use the commutation choke with the part No. 00368377 at a mains with uK,mains = 0.4 % The output voltage is a pulsed d.c. voltage. The operating range refers to the RMS of the fundamental wave. Switching frequency of the inverter (adjustable). RMS at an environmental temperature of 40 C. At rated input supply voltage the device supplies the rated-/maximum output currents. At input voltages above the rated supply voltage the output currents at constant output power have to accordingly be reduced.

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.
Derating of the output current Derating of the output current

Output current [%]

Mains voltage [V] Derating of the output current

Output current [%]

Mains voltage [V] Derating of the output current

Output current [%]

Mains voltage [V] Derating of the output current

Output current [%]

Mains voltage [V]

Output current [%]

Mains voltage [V] Figure 62: Derating of the output current BM 442X basic unit

7)

Between 40 C and 55 C the output current must be reduced. The allowable output current (I0) is calculated with the following formula: Coolant temperature ) - 40C I o = I o ( 40C ) 1 ( ------------------------------------------------------------------------------ 0, 03 C

8)

This overload time is dependent on the motor current and of the heat sink temperature and is determined by the Ixt-monitoring of the device.

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9)

Electrical data - BM442X basic unit

The specified value is only valid, if there is no additional DC link capacity connected to the DC link terminals. Also see ZMains-switchon frequency/DC-link charging on page 97 and ZFigure 63 on page 174. The sum of the transferred average effective power via the DC link terminals and the transferred average effective power via the motor terminals must not exceed the specified value permanently.

10)

7000 6000
external DC link capacity [F]

5000 4000 3000

BM 4422, 4423 BM 4424, 4425, 4426

2000 1000 0 200 250 300 350 400 450 500

maximum mains voltage [V] Figure 63: Maximum external DC link capacity BM442X

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Electrical data - BM443X basic unit BM4432 BM4433 16.8 kVA 24.2 A 54% 45.0 A 540 VDC 820 F 123 s max. 18.5 mF none 3 x 0 V to 3 x 370 V 0 Hz to 450 Hz
1)5)6)7) 4)

Input rated power 1)2) Input rated current

1)2)

13.3 kVA (Ieff) 19.2 A 60% 37.0 A

Distortion factor of the input current 1)2) (THDI) Input current, max.
2)

(Ieff)

DC-link rated voltage 1 )(UDC) DC link capacity (internal) DC link discharging time (internal DC link capacity) DC link capacity (external), permitted Delay time mains off mains on Output voltage
1)3)

1230 F 185 s

(UAC) (IAC) (IAC) at 4 kHz

Output frequency Output rated current Output rated current 1)5)6)7) (IAC) Output peak current
1)5)6)8)

max. 22.5 A max. 18.0 A max. 45.0 A max. 36.0 A 60 s

max. 30.0 A max. 24.0 A max. 60.0 A max. 48.0 A

at 8 kHz 4) at 4 kHz
4)

Output peak current 1)5)6)8) (IAC) Max. peak current time

8)

at 8 kHz 4)

Output power DC link terminals 9) Chopper current, permissible () Chopper resistor external Chopper start-up voltage () Chopper peak power Permissible chopper continuous power Power loss referring to mains voltage Power loss referring to control voltage Current of the brake control
Footnotes see following page.

max. 10.0 kW max. 36.0 A 22 780 V 29 kW 10 kW 300 W max. 88 W max. 1.0 A 390 W

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Electrical data - BM443X basic unit

BM4434 Input rated power 1)2) Input rated current

1)2)

BM4435 36.7 kVA 53.0 A 57% 71.0 A 540 VDC 2000 F 300 s

26.3 kVA (Ieff) 38.0 A 57% 71.0 A 1640 F 250 s

Distortion factor of the input current 1)2) (THDI) Input current, max.
2)

(Ieff)

DC-link rated voltage 1) DC link capacity (internal) DC link discharging time (internal DC link capacity) DC link capacity (external), permitted Output voltage 1) (UAC) Output frequency Output rated current 1)5)6)7) (IAC) Output rated current
1)5)6)7)

max. 20 mF 3 x 0 V to 3 x 370 V 0 Hz to 450 Hz at 4 kHz 4) at 8 kHz

4)

max. 45.0 A max. 36.0 A max. 90.0 A max. 72.0 A 60 s

max. 60.0 A max. 48.0 A max. 90.0 A max. 72.0 A

(IAC) (IAC)
9)

Output peak current 1)5)6)8) (IAC) Output peak current

1)5)6)8)

at 4 kHz 4) at 8 kHz
4)

Max. peak current time 8) Output power DC link terminals

max. 10.0 kW max. 50.0 A 16 780 V 40 kW 10 kW 600 W max. 88 W max. 1.0 A 840 W

Chopper current, permissible () Chopper resistor external Chopper start-up voltage () Chopper peak power Permissible chopper continuous power Power loss referring to mains voltage Power loss referring to control voltage Current of the brake control

1) 2)

All rated values refer to a mains input voltage of 400 V/50 Hz and a control voltage of 24 V. In case you use the following commutation chokes at a mains with uK,mains=0.4%: BM4432 Part no. 00368377, BM4433: Part no. 00368377, BM4434: Part no. 00368378, BM4435: Part no. 00368379. The output voltage is a pulsed d.c. voltage. The operating range refers to the RMS of the fundamental wave. Switching frequency of the inverter (adjustable). RMS at an environmental temperature of 40 C. At rated input supply voltage the device enables the rated-/maximum output currents. At input voltages above the rated supply voltage the output currents at constant output power have to accordingly be reduced

3) 4) 5) 6)

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.
Derating of the output current Derating of the output current

Output current [%]

Mains voltage [V] Derating of the output current

Output current [%]

Mains voltage [V] Derating of the output current

Output current [%]

Mains voltage [V] Figure 64: Derating of the output current BM 443X basic unit

Output current [%]

Mains voltage [V]

7)

Between 40 C and 55 C the output current must be reduced. The allowable output current (I0) is calculated with the following formula: Coolant temperature ) - 40C I o = I o ( 40C ) 1 ( ------------------------------------------------------------------------------ 0, 03 C

8)

This overload time is dependent on the motor current and of the heat sink temperature and is determined by the Ixt-monitoring of the device.

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D.9

Electrical data - BM444X basic unit

Electrical data - BM444X basic unit

BM4443 Input rated power 1)2) Input rated current

1)2)

BM4444 58 kVA 84 A 59 % 105 A 2350 F

BM4445 73 kVA 105 A 45 % 133 A 3055 F

BM4446 12)
(preliminary)

49 kVA (Ieff) 70,0 A 60 % 105 A 1880 F

94 kVA 136 A 38 % 187 A 3760 F

Distortion factor of the input current 1)2) (THDI) Input current, max.
2)

(Ieff)

DC-link rated voltage 1) DC link capacity (internal) DC link capacity (external), permitted DC link discharging time (internal DC link capacity) Delay time mains off mains on Output voltage
1)3)

540 VDC max. 20 mF 43 s 54 s no 3 x 0 V to 3 x 370 V 0 Hz to 450 Hz

4)

70 s

86 s

(UAC)
1)5)6)7)

Output frequency Output rated current (IAC) (IAC) at 4 kHz max. 80 A max. 75 A Output rated current 1)5)6)7) (IAC) Output peak current
1)5)6)8)

max. 100 A max. 130 A max. 150 A max. 72 A max. 94 A max. 105 A

at 8 kHz 4) at 4 kHz
4)

max. 120 A max. 130 A max. 170 A max. 200 A max. 90 A max. 94 A max. 130 A max. 150 A

Output peak current 1)5)6)8) (IAC) Max. peak current time

8)9)

at 8 kHz 4)

60 s max. 90 kW max. 67 A v 12 780 V 53 kW 36 kW 1080 W 45 kW 1350 W 80 kW 58 kW 1740 W 75 kW 2000 W max. 100 A v8

Output power DC link terminals 11) Chopper current, permissible () Chopper resistor external Chopper start-up voltage () Chopper peak power Permissible chopper continuous power Power loss referring to mains voltage Power loss referring to control voltage Power loss of equipment fan according to 230 VAC 10) Current of the brake control Cooling air requirement of power heat sink Cooling air requirement of the interior space of device
Footnotes see following page.

max. 75 W 87 W max. 4,0 A 260 m3/h 60 m3/h 210 m3/h

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1) 2)

All rated values refer to a mains input voltage of 400 V/50 Hz and a control voltage of 24 V. In case you use the following commutation chokes at a mains with uK,mains=0.4%: BM4443 Part no. 00368380, BM4444: Part no. 00368381, BM4445: Part no. 00368381. The output voltage is a pulsed d.c. voltage. The operating range refers to the RMS of the fundamental wave. Switching frequency of the inverter (adjustable). RMS at an environmental temperature of 40 C. At rated input supply voltage the device enables the rated-/maximum output currents. At input voltages above the rated supply voltage the output currents at constant output power have to accordingly be reduced. Derating of the output current Derating of the output current

3) 4) 5) 6)

Output current [%]

Mains voltage [V] Derating of the output current

Output current [%]

Mains voltage [V] Derating of the output current

Output current [%]

Mains voltage [V] Figure 65: Derating of the output current BM 444X basic unit

Output current [%]

Mains voltage [V]

7)

Between 40 C and 55 C the output current must be reduced. The acceptable output current (I0) is calculated with the following formula:

( Coolant temperature ) - 40C I o = I o ( 40C ) - 0, 03 1 ----------------------------------------------------------------------------- C

8)

This overload time is dependent on the motor current and of the heat sink temperature and is determined by the Ixt-monitoring of the device. The peak current can only be achieved at a heat sink temperature of <75 C (BM4443) or <80 C (BM4444). If the heat sink temperature threshold is exceeded, then the output current is automatically reduced to the rated current. This is only valid for cooling versions S and A. The sum of the transferred average effective power via the DC link terminals and the transferred average effective power via the motor terminals must not exceed the specified value permanently. Only available at devices with type code BM44XX-XXX-XX3XX-03-4-yyy, whereas yyy > 024 is and the controller firmware is 3.09 or newer.

9)

10) 11)

12)

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Electrical data - BM445X basic unit

Electrical data - BM445X basic unit BM4452 BM4453 94.2 kVA 136 A 38% 182 A 540 VDC 3000 F 3000 F max. 20 mF 63 s 63 s none 3 x 0 V to 3 x 370 V 0 Hz to 450 Hz see ZPage 197 at 4 kHz 4) at 8 kHz
4)
12)

BM4454 138.6 kVA 200 A 38% 270 A 6600 F

Input rated power 1)2) Input rated current

1)2)

75.5 kVA (Ieff) 109 A 42% 146 A

Distortion factor of the input current 1)2) (THDI) Input current, max.
2)

(Ieff)

DC-link rated voltage 1) DC link capacity (internal) DC link capacity (external), permitted DC link discharging time (internal DC link capacity) Delay time Mains Off Mains On Output voltage
1)

139 s

(UAC)

Output frequency Derating at static output frequency Output rated current 1)5)6)7) (IAC) Output rated current
1)5)6)7)

max. 120 A max. 96 A max. 180 A max. 144 A

max. 150 A max. 116 A max. 195 A max. 150 A 60 s max. 110 kW max. 150 A 5.2 780 V 117 kW 78 kW

max. 210 A max. 150 A max. 260 A max. 185 A

(IAC) (IAC)

Output peak current 1)5)6)8) (IAC) Output peak current

1)5)6)8)

at 4 kHz 4) at 8 kHz
4)

Max. peak current time 8) Output power DC link terminals Chopper current, permissible () Chopper resistor external Chopper start-up voltage () 11) Chopper peak power Permissible chopper continuous power Power loss referring to mains voltage Power loss referring to control voltage Power loss of equipment fan according to 230 VAC Current of the brake control Cooling air requirement of power heat sink Cooling air requirement of the interior space of device
1) 2)

1800 W
9)

2250 W max. 75 W 190 W max. 8.0 A10)

3300 W

450 m3/h 135 m3/h

450 m3/h 135 m3/h

400 m3/h 135 m3/h

All rated values refer to a mains input voltage of 400 V/50 Hz and a control voltage of 24 V. In case you use the following commutation chokes at a mains with uK,mains=0.4%: BM4452: Part no. 00368381, BM4453: Part no. 00368382, BM4454: Part no. 00368384. The output voltage is a pulsed d.c. voltage. The operating range refers to the RMS of the fundamental wave. Switching frequency of the inverter (adjustable). RMS at an environmental temperature of 40 C.

3) 4) 5)

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6)

At rated input supply voltage the device enables the rated-/maximum output currents. At input voltages above the rated supply voltage the output currents at constant output power have to accordingly be reduced. Derating of the output current Derating of the output current

Output current [%]

Mains voltage [V] Derating of the output current

Output current [%]

Mains voltage [V]

Output current [%]

Mains voltage [V] Figure 66: Derating of the output current BM 445X basic unit

7)

Between 40 C and 55 C the output current must be reduced. The acceptable output current (I0) is calculated with the following formula Coolant temperature ) - 40C I o = I o ( 40C ) 1 ( ------------------------------------------------------------------------------ 0, 03 C

8)

This overload time is dependent on the motor current and of the heat sink temperature and is determined by the Ixt-monitoring of the device. This is only valid for cooling versions S and A. In case you refer to UL508C: max. 4.0 A Also refer to ZD.2 Requirements to the motor on page 163. output current of max. 80 % of the output rated current is allowed at output frequencies lower than 0.5 Hz.

9) 10) 11)

12) An

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D.11

Electrical data - BM446X basic unit

Electrical data - BM446X basic unit BM4462 BM4463 204 kVA 295 A 50% 395 A 540 VDC 6000 F 6000 F 13200 F max. 12 mF 277 s max. 20 mF 126 s 126 s none 3 x 0 V to 3 x 370 V 0 Hz to 450 Hz
1)5)6)7) 4)

BM4466
(preliminary)

Input rated power 1)2) Input rated current

1)2)

164 kVA (Ieff) 237 A 43% 320 A

238 kVA 344 A 50% 455 A

Distortion factor of the input current 1)2) (THDI) Input current max.
2)

(Ieff)

DC-link rated voltage 1) DC link capacity (internal) DC link capacity (external), permitted DC link discharging time (internal DC link capacity) Delay time mains off mains on Output voltage
1)

(UAC) (IAC) (IAC) at 4 kHz max. 250 A max. 200 A max. 325 A max. 260 A

Output frequency Output rated current Output rated current 1)5)6)7) (IAC) Output peak current
1)5)6)8)

max. 300 A max. 240 A max. 390 A max. 312 A 60 s max. 160 kW

max. 350 A max. 240 A max. 450 A max. 312 A

at 8 kHz 4) at 4 kHz
4)

Output peak current 1)5)6)8) (IAC) Max. peak current time

8)

at 8 kHz 4)

Output power DC link terminals Chopper current, permissible () Chopper resistor external Chopper start-up voltage () Chopper peak power Permissible chopper continuous power Power loss referring to mains voltage Power loss referring to control voltage Power loss of the equipment fan according to 230 VAC 9) Current of the brake control Cooling air requirement of power heat sink Cooling air requirement of the interior space of device
1) 2)

max. 230 A 3.4

max. 236 A 3.33 780 V

11)

179 kW 130 kW 3960 W 4800 W max. 80 W 174 W max. 8.0 A10) 400 m3/h 200 m3/h

183 kW 5 kW

All rated values refer to a mains input voltage of 400 V/50 Hz and a control voltage of 24 V. In case you use the following commutation chokes at a mains with uK,mains=0.4%: BM4462: Part no. 00368384, BM4463: Part no. 00368385. The output voltage is a pulsed d.c. voltage. The operating range refers to the RMS of the fundamental wave. Switching frequency of the inverter (adjustable).

3) 4)

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5) 6)

RMS at an environmental temperature of 40 C. At rated input supply voltage the device enables the rated-/maximum output currents. At input voltages above the rated supply voltage the output currents at constant output power have to accordingly be reduced. Derating of the output current Derating of the output current

Output current [%]

Mains voltage [V] Derating of the output current

Output current [%]

Mains voltage [V]

Output current [%]

Mains voltage [V] Figure 67: Derating of the output current BM 446X basic unit

7)

Between 40 C and 55 C the output current must be reduced. The acceptable output current (I0) is calculated with the following formula Coolant temperature ) - 40C I o = I o ( 40C ) 1 ( ------------------------------------------------------------------------------ 0, 03 C

8)

This overload time is dependent on the motor current and of the heat sink temperature and is determined by the Ixt-monitoring of the device. This is only valid for cooling versions S and A. In case you refer to UL508C: max. 4.0 A Also refer to ZD.2 Requirements to the motor on page 163.

9) 10) 11)

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D.12

Electrical data - BM447X basic unit

Electrical data - BM447X basic unit BM4472 - A/FIX BM4473 - A/FIX 412 kVA 594 A 54% 760 A 540 VDC 9 mF 11 mF 95 s none 3 x 0 V to 3 x 370 V 0 Hz to 450 Hz
1)5)6)7)13) 4)

Input rated power 1)2) Input rated current

1)2)

328 kVA (Ieff) 474 A 54% 602 A

Distortion factor of the input current 1)2) (THDI) Input current max.
2)

(Ieff)

DC-link rated voltage 1) DC link capacity (internal) DC link capacity (external), permitted DC link discharging time (internal DC link capacity) Delay time mains off mains on Output voltage
1)3)

19.8 mF 0 mF 138 s

(UAC) (IAC) at 4 kHz

Output frequency 12) Output rated current Output rated current 1)5)6)7)13) (IAC) Output peak current
1)5)6)8)

max. 450 A max. 338 A max. 585 A max. 439 A 60 s max. 250 kW

max. 600 A max. 450 A max. 780 A max. 585 A

at 8 kHz 4) at 4 kHz
4)

(IAC)

Output peak current 1)5)6)8) (IAC) Max. peak current time

9)

at 8 kHz 4)

Output power DC link terminals Chopper current, permissible () Chopper resistor external Chopper start-up voltage () Chopper peak power Permissible chopper continuous power Power loss referring to mains voltage Power loss referring to control voltage Power loss of the device fans according to 400 VAC Current of the brake control
1) 2)

max. 315 kW

max. 300 A 2.6

12)

780 V 234 kW 180 kW 4700 W 6450 W

max. 170 W max. 540 W max. 8.0 A11)

All rated values refer to a mains input voltage of 400 V/50 Hz and a control voltage of 24 V. In case you use the following commutation chokes at a mains with uK,mains=0.4%: BM4472: Part no. 368388, BM4473: Part no. 368390. The output voltage is a pulsed d.c. voltage. The operating range refers to the RMS of the fundamental wave. Switching frequency of the inverter (adjustable). RMS at an environmental temperature of 40 C.

3) 4) 5)

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6)

At rated input supply voltage the device enables the rated-/maximum output currents. At input voltages above the rated supply voltage the output currents at constant output power have to accordingly be reduced. Derating of the output current Derating of the output current

Output current [%]

Mains voltage [V] Figure 68: Derating of the output current BM 447X basic unit

Output current [%]

Mains voltage [V]

7)

The output current must be reduced between 40 C and 55 C. The allowable output current (I0) is calculated with the following formula:

( Coolant temperature ) - 40C I o = I o ( 40C ) - 0, 03 1 ----------------------------------------------------------------------------- C

8)

Possibly there are two temperature values (cooling air, which flows through the inner space of the device/cooling air which flows through the heat sink). Here use the higher value. Example: output rated current) = 150 A, environmental temperature = 46 C I o - 40C = 150A 1 46C -------------------------------- 0, 03 = 150A 0, 03 C

Therewith the output current must be reduced: 123 A

9)

This overload time is dependent on the motor current and of the heat sink temperature and is determined by the Ixt-monitoring of the device. sum of the immediately via the DC link terminals taken power and at the same time the power, which is picked up from the motor (motor power/motor efficiency) may not exceed the maximum output power of 250 kW or 315 kW. case you refer to UL508C: max. 4.0 A

10) The 11) In 12) 13)

Also refer to ZD.2 Requirements to the motor on page 163. In case you refer to UL508C: The maximum permitted typical motor power is limited to 295 kW. Therefore the device BM4473 belongs to the category < 400 HP, < 298 kW ratings according table 45.1 of UL508C and the short circuit test can be done with 18 kA. Baumller offers no devices for the class up to 600 HP, 447 kW with 30 kA short circuit current according UL508C.

D.12.1 BM447X, additional information to EMC Considered standard: EN 61800-3:2005, within environments of second mode for PDS of category C3 with rated currents above 100 A. ... it can be assumed, that the EMC product standard EN 61800-3:2005 is observed, if the device is operated normally and the installation is done with exclusive use of the required (EMC)-components and EMC installation notes by the manufacturer .

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D.13

Electrical data - BM442X power module

Electrical data - BM442X power module BM4422XXX 2XXXX BM4423 XXX 2XXXX 6,2 kW 11,5 A 23,0 A 540 VDC 470 F 260 s 3 x 0 V to 3 x 370 V 0 Hz to 450 Hz no derating at 4 kHz
3) 1)4)5)6)

BM4424 XXX 2XXXX 8,2 kW 15,2 A 30,4 A

BM4425 XXX 2XXXX 8,2 kW 15,2 A 40,6 A

Input rated power 1) Input rated current

1)(I ) eff

4,3 kW 7,8 A 15,5 A (UDC)

Input current, max. (Ieff) DC link rated voltage

1)

DC link capacity (internal) DC link discharging time (internal DC link capacity) Output voltage 1)2) (UAC) Output frequency
3)

705 F 390 s

Derating at static output frequency Output rated current (IAC) max. 7,5 A max. 6,0 A max. 15,0 A max. 12,0 A

max. 11,0 A max. 8,8 A max. 22,0 A max. 17,6 A 60 s

max. 15,0 A max. 12,0 A max. 30,0 A max. 24,0 A

max. 15,0 A max. 12,0 A max. 40,0 A max. 32,0 A 1s 204 W

Output rated current 1)4)5)6) (IAC) Output peak current 1)4)5)7) (IAC) Output peak current 1)4)5)7) (IAC) Max. peak current time 7) Power loss referring to mains voltage Power loss referring to control voltage Current of the brake control
.

at 8 kHz 3) at 4 kHz 3) at 8 kHz 3)

102 W

150 W max. 63 W max. 0,5 A

1) 2) 3) 4)

All rated values refer to a DC link voltage of 540 VDC and a control voltage of 24 V. The output voltage is a pulsed d.c. voltage. The operating range refers to the RMS of the fundamental wave. Switching frequency of the inverter (adjustable) RMS at an environmental temperature of 40 C.

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5)

At rated input supply voltage the device enables the rated-/maximum output currents. At input voltages above the rated supply voltage the output currents at constant output power have to accordingly be reduced. Derating output current Derating output current

Output current [%]

DC link voltage [V] Derating output current

Output current [%]

DC link voltage [V] Derating output current

Output current [%]

DC link voltage [V] Derating output current

Output current [%]

DC link voltage [V]

Output current [%]

DC link voltage [V] Figure 69: Derating output current BM 442X power modules

6)

The output current must be reduced between 40 C and 55 C. The allowable output current (I0) is calculated with the following formula:

( Coolant temperature ) - 40C I o = I o ( 40C ) - 0, 03 1 ----------------------------------------------------------------------------- C

7)

This overload time is dependent on the motor current and of the heat sink temperature and is determined by the Ixt-monitoring of the device.

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D.14

Electrical data - BM443X power module

Electrical data - BM443X power module BM4432XXX 2XXXX BM4433 XXX 2XXXX 15,3 kW 28,4 A 56,8 A BM4434 XXX 2XXXX 23,3 kW 43,2 A 86,4 A BM4435 XXX 2XXXX 32,3 kW 59,8 A 89,7 A

Input rated power 1) Input rated current

1)(I ) eff

12,0 kW 22,3 A 44,7 A (UDC) 820 F 138 s

Input current, max. (Ieff) DC link rated voltage

1)

540 VDC 1230 F 207 s 1640 F 276 s 2000 F 336 s

DC link capacity (internal) DC link discharging time (internal DC link capacity) Output voltage 1)2) (UAC) Output frequency
3)

3 x 0 V to 3 x 370 V 0 Hz to 450 to at 4 kHz 3) at 8 kHz

3)

Output rated current 1)4)5)6) (IAC) Output rated current

1)4)5)6)

max. 22,5 A max. 18,0 A max. 45,0 A max. 36,0 A

max. 30,0 A max. 24,0 A max. 60,0 A max. 48,0 A

max. 45,0 A max. 36,0 A max. 90,0 A max. 72,0 A

max. 60,0 A max. 48,0 A max. 90,0 A max. 72,0 A

(IAC)

Output peak current 1)4)5)7) (IAC) Output peak current 1)4)5)7) (IAC) Max. peak current time 7) Power loss referring to mains voltage Power loss referring to control voltage Current of the brake control
.

at 4 kHz 3) at 8 kHz 3)

60 s 300 W 390 W 600 W 840 W

max. 88 W max. 1,0 A

1) 2) 3) 4)

All rated values refer to a DC link voltage of 540 VDC and a control voltage of 24 V. The output voltage is a pulsed d.c. voltage. The operating range refers to the RMS of the fundamental wave. Switching frequency of the inverter (adjustable) RMS at an environmental temperature of 40 C.

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5)

At rated input supply voltage the device enables the rated-/maximum output currents. At input voltages above the rated supply voltage the output currents at constant output power have to accordingly be reduced. Derating of output current Derating of output current

Output current [%]

DC link voltage [V] Derating of output current

Output current [%]

DC link voltage [V] Derating of output current

Output current [%]

DC link voltage [V] Figure 70: Derating of output current BM 443X power modules

Output current [%]

DC link voltage [V]

6)

The output current must be reduced between 40 C and 55 C. The allowable output current (I0) is calculated with the following formula:

( Coolant temperature ) - 40C I o = I o ( 40C ) - 0, 03 1 ----------------------------------------------------------------------------- C

7)

This overload time is dependent on the motor current and of the heat sink temperature and is determined by the Ixt-monitoring of the device.

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D.15

Electrical data - BM444X power module

Electrical data - BM444X power module BM4443XXX 2XXXX BM4444XXX 2XXXX 50 kW 93 A 120 A 540 VDC 1880 F 43 s 54 s 70 s 2350 F 86 s BM4445 XXX 2XXXX 64 kW 119 A 155 A BM4446 XXX 2XXXX 9)
(Preliminary)

Input rated power 1) Input rated current

1)(I ) eff

41 kW 76 A 113 A (UDC)

84 kW 155 A 207 A

Input current, max. (Ieff) DC link rated voltage

1)

DC link capacity (internal) DC link discharging time (internal DC link capacity) Output voltage 1)2) (UAC) Output frequency
3)

3 x 0 V to 3 x 370 V 0 Hz to 450 Hz at 4 kHz 3) at 8 kHz

3)

Output rated current 1)4)5)6) (IAC) Output rated current

1)4)5)6)

max. 80 A max. 75 A max. 120 A max. 90 A

max. 100 A max. 72 A max. 130 A max. 94 A

max. 130 A max. 94 A max. 170 A max. 130 A

max. 150 A max. 105 A max. 200 A max. 150 A

(IAC)

Output peak current 1)4)5)7) (IAC) Output peak current 1)4)5)7) (IAC) Max. peak current time 7) Power loss referring to mains voltage Power loss referring to control voltage

at 4 kHz 3) at 8 kHz 3)

60 s 800 W 1000 W 1300 W 1400 W

max. 75 W 87 W max. 4,0 A 260 m/h 60 m/h 210 m/h

Power loss of equipment fan according to 230 VAC 8) Current of the brake control Cooling air requirement of power heat sink Cooling air requirement of the interior space of device
1) 2) 3) 4)

All rated values refer to a DC link voltage of 540 VDC and a control voltage of 24 V. The output voltage is a pulsed d.c. voltage. The operating range refers to the RMS of the fundamental wave. Switching frequency of the inverter (adjustable) RMS at an environmental temperature of 40 C.

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5)

At rated input supply voltage the device enables the rated-/maximum output currents. At input voltages above the rated supply voltage the output currents at constant output power have to accordingly be reduced. Derating of output current Derating of output current

Output current [%]

DC link voltage [V] Derating of output current

Output current [%]

DC link voltage [V] Derating of output current

Output current [%]

DC link voltage [V] Figure 71: Derating of output current BM 444X power modules

Output current [%]

DC link voltage [V]

6)

The output current must be reduced between 40 C and 55 C. The allowable output current (I0) is calculated with the following formula:

( Coolant temperature ) - 40C I o = I o ( 40C ) - 0, 03 1 ----------------------------------------------------------------------------- C

7)

This overload time is dependent on the motor current and of the heat sink temperature and is determined by the Ixt-monitoring of the device. This is only valid for cooling versions S and A. Only available at devices with controller type code BM44XX-XXX-XX3XX-03-4-yyy, whereas yyy > 024 is and the controller firmware is 3.09 or newer.

8) 9)

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D.16

Electrical data - BM445X power module

Electrical data - BM445X power module BM4453- XXX - 2XXXX

Input rated power 1) Input rated current

1)(I ) eff

85 kW 158 A 206 A (UDC) 540 VDC 3000 F 75 s 3 x 0 V to 3 x 370 V 0 Hz to 450 Hz at 4 kHz 3) at 8 kHz
3)

Input current, max. (Ieff) DC link rated voltage

1)

DC link capacity (internal) DC link discharging time (internal DC link capacity) Output voltage 1)2) (UAC) Output frequency
3)

Output rated current 1)4)5)6) (IAC) Output rated current

1)4)5)6)

max. 150 A max. 116 A max. 195 A max. 150 A 60 s 800 W max. 75 W 190 W max. 8,0 A 9) 450 m/h 135 m/h

(IAC)

Output peak current 1)4)5)7) (IAC) Output peak current 1)4)5)7) (IAC) Max. peak current time 7) Power loss referring to mains voltage Power loss referring to control voltage

at 4 kHz 3) at 8 kHz 3)

Power loss of equipment fan according to 230 VAC 8) Current of the brake control Cooling air requirement of power heat sink Cooling air requirement of the interior space of device
.

1) 2) 3) 4)

All rated values refer to a DC link voltage of 540 VDC and a control voltage of 24 V. The output voltage is a pulsed d.c. voltage. The operating range refers to the RMS of the fundamental wave. Switching frequency of the inverter (adjustable) RMS at an environmental temperature of 40 C.

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5)

At rated input supply voltage the device enables the rated-/maximum output currents. At input voltages above the rated supply voltage the output currents at constant output power have to accordingly be reduced. Derating of output current

Output current [%]

DC link voltage [V] Figure 72: Derating of output current BM 445X power modules

6)

The output current must be reduced between 40 C and 55 C. The allowable output current (I0) is calculated with the following formula: Coolant temperature ) - 40C I o = I o ( 40C ) 1 ( ------------------------------------------------------------------------------ 0, 03 C

7)

This overload time is dependent on the motor current and of the heat sink temperature and is determined by the Ixt-monitoring of the device. This is only valid for cooling versions S and A.

8)

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D.17

Electrical data - BM446X power module

Electrical data - BM446X power module BM4462- XXX - 2XXXX BM4463- XXX - 2XXXX 180 kW 335 A 436 A 540 VDC 6000 F 150 s 3 x 0 V to 3 x 370 V 0 Hz to 450 Hz at 4 kHz 3) at 8 kHz
3)

Input rated power 1) Input rated current

1)(I ) eff

150 kW 278 A 392 A (UDC)

Input current, max. (Ieff) DC link rated voltage

1)

DC link capacity (internal) DC link discharging time (internal DC link capacity) Output voltage 1)2) (UAC) Output frequency
3)

Output rated current 1)4)5)6) (IAC) Output rated current

1)4)5)6)

max. 300 A max. 240 A max. 390 A max. 312 A 60 s 3960 W max. 80 W 174 W max. 8,0 A 9) 400 m/h 200 m/h

max. 350 A max. 240 A max. 450 A max. 312 A

(IAC)

Output peak current 1)4)5)7) (IAC) Output peak current 1)4)5)7) (IAC) Max. peak current time 7) Power loss referring to mains voltage Power loss referring to control voltage

at 4 kHz 3) at 8 kHz 3)

4800 W

Power loss of equipment fan according to 230 VAC 8) Current of the brake control Cooling air requirement of power heat sink Cooling air requirement of the interior space of device
.

1) 2) 3) 4)

All rated values refer to a DC link voltage of 540 VDC and a control voltage of 24 V. The output voltage is a pulsed d.c. voltage. The operating range refers to the RMS of the fundamental wave. Switching frequency of the inverter (adjustable) RMS at an environmental temperature of 40 C.

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5)

At rated input supply voltage the device enables the rated-/maximum output currents. At input voltages above the rated supply voltage the output currents at constant output power have to accordingly be reduced. Derating of output current Derating of output current

Output current [%]

DC link voltage [V] Figure 73: Derating of output current BM 446X power modules

Output current [%]

DC link voltage [V]

6)

The output current must be reduced between 40 C and 55 C. The allowable output current (I0) is calculated with the following formula: Coolant temperature ) - 40C I o = I o ( 40C ) 1 ( ------------------------------------------------------------------------------ 0, 03 C

7)

This overload time is dependent on the motor current and of the heat sink temperature and is determined by the Ixt-monitoring of the device. This is only valid for cooling versions S and A. In case you refer to UL508C: max. 4.0 A

8) 9)

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D.18

Additional data BM44XX with water-cooled chopper resistors

Additional data BM44XX with water-cooled chopper resistors Technical data of water-cooled chopper resistors: Type of device Chopper resistor 16 10 Chopper resistor current 49 A 78 A Peak power 38 kW 61 kW Continuous output 2) 2 kW 1.5 kW Depth of device1) + 20 mm + 35 mm

BM4434-ZIX/FIX-XXXXXR16 BM4435-ZIX/FIX-XXXXXR16 BM4444-ZIX/FIX-XXXXXR10 BM4445-ZIX/FIX-XXXXXR10 BM4446-ZIX/FIX-XXXXXR10 BM445X-ZIX/FIX-XXXXXR05 BM446X-ZIX/FIX-XXXXXR03 BM447X-FIX-XXXXXR03

1)

5 3.33 3.33

156 A 234 A 234 A

122 kW 183 kW 183 kW

3 kW 5 kW 3.5 kW

+ 35 mm + 35 mm + 35 mm

The total depth of the device in cooling version F increases by the specified value (also see ZInstallation space from page 39).The device measurings of cooling version Z do not change. The mentioned continuous output are only then achieved, if the water flow rate is at least 10 l/min. and if the inlet temperature does not exceed 45C. At flow temperatures >45C to <60C the chopper resistor dissipation decreases from the nominal value to zero.

2)

NOTE Although the water-cooled chopper resistors provide an optimum according to the amount of heat to be dissipated at a minimum volume, about 10 % of the chopper resistor power is not dissipated via the cooling water but is given off to the ambient air. At operation with nominal power, therewith the chopper resistors reach temperatures of max. 200C on the reverse side. For the devices of cooling version F (through-hole devices) this means: Make sure, that there is a sufficient protection against contact, e. g. by the mounting of lattice around the heat sink and the resistors. Assure, that the air can circulate and that no heat accumulation can occur under the protective cover. For the devices of cooling version Z (mounting in control cabinet) this means: Mount the devices in the control cabinet, so that there is no heat accumulation above the devices. Air circulation must be possible. Take into consideration, that, although there is air circulation, that there can be an increase of temperature above the devices. Do not lay cables or cable channels in the area above the devices. The connecting cables at the devices BM443X and BM444X must be installed in such a way, that they do not run directly above the devices, and therewith in the area of the hot ascending air at the mounting board. At dimensioning of control cabinet cooling, take into consideration, that 10% of the chopper resistor power is not dissipated via the cooling water, but heats up the cabinet as an additional power loss. Make sure that there is a sufficient ventilation in the device.

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D.19

Output-frequency-dependent current-derating All Baumller devices were developed in such a way, that the specified output-measuring currents are continuously, i. e. in the S1 operation, that they are permissible from an electric output frequency of more than 15 Hz. If the static converter output frequency is less than 15 Hz and if the frequency lasts longer than 5 seconds between 0 and 15 Hz, the continuously permissible output current must be reduced according to the following characteristic curve. For example the following are concerned (but not exclusively): n Applications with speed control without positioning or n Applications, where, at standstill, you must apply current in order to hold the torque/to hold the power or n Applications, where a mechanic blocking can occur, e. g. when starting cold extruders. Consequential the following applications are not concerned: n Typical positioning applications n Applications with motors, which have an operational brake at standstill. n Applications, where the higher-level control contains a standstill- and a block monitoring. Provided that the derating area is quickly passed through, the application of Irated is permitted.Hereby, to pass through quickly means, that the frequency change is 15 Hz/s. Derating of the motor-sided inverter output current I against the dimensioning output current Irated in dependence of the static inverter output frequency f.

I Irated

Static inverter output frequency f Figure 74: Derating at static inverter frequency < 15 Hz

If there is another derating at a certain device, this can be taken from the section Electrical data. Otherwise the derating is valid, which is specified here.

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D.20
D.20

Fuse protection

Fuse protection We differ between the protection of the supply cables and the protection of the device. In order to fulfill the CE specifications - here especially EN60204-1 - you have to protect the supply cables. Protect the device in UL-certified installations with suitable semiconductor- or total range fuses. NOTE In UL-certificated installations you must place the UL-listed fuses or Circuit breaker.

Cable protection

Place in safety fuses of the operation class gL DIN VDE 0636-201 / IEC 60269-2-1 / HD 630.2.1 54 or cable protection switches with the triggering characteristic K referring to DIN VDE 0636201 / IEC 60204-1 60269-2-1 / HD 630.2.1 54, to protect the cables. These fuses protect against overloading and from consequential damages from faults e. g. by fire. You cannot prevent, that the device is extensively destroyed, if a short circuit or an ground fault occurs in the DC link. Execute the protection according to EN 60204-1 (Electrical equipment of machines). Dimension the cable protection fuses, dependent on the used cross section according to the, at the time, valid, national standards and local regulations.

Device protection

Place in semiconductor fuses with the triggering characteristic aR DIN VDE 0636-201 / IEC 60269-2-1 HD 630.2.1 54. Switch these in series to the cable protection fuses. These protect the input-sided rectifier-triggering, in case of a short circuit, against completely destruction, so that a repair of the device is possible. Dimension the suitable device protection fuses, dependent on the peak current and the under ZDevice protection on page 199 required limit load integral i2tOFF.

Cable protection + device protection

You have two possibilities to protect the cable and the device: m connect fuses and semiconductors in series m use whole range fuses with trigger characteristic gR (DIN VDE 0636-201/IEC 60269-2-1/HD 630.2.154) Dimension the suitable cable and device protection fuses dependent on the used cross section of the used mains line, from the peak current and the under ZDevice protection on page 199 demanded limit load integral i2tOFF. Deviant to the fuses these devices and supply systems also may also assure be UL-listed Circuit breaker (DIVQ). Permitted are only Circuit breaker without tripping delay. Circuit breakers with a thermal tripping characteristic are not checked and therewith not approved.In case of an error it must be considered, that the device is not protected against destruction, but only is protected against fire danger. Dimension the suitable Circuit breaker dependent of the cross section of the inserted supply system, as well as from the nominal- and peak current of the converter.

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D.20.1 Cable protection The current-carrying capacity of conductors is determined in table 5 of EN60204-1. For your operation you must determine the accordant value in the standard yourself, by taking into consideration, amongst other things the cable mounting. Here you will find an extraction for the laying of PVC- isolated cables on open cable racks: Cable cross section 1.5 mm2 2.5 mm2 4 mm
2

FuseRated current 16.1 A 22 A 30 A 37 A 52 A 70 A

Cable cross section 25 mm2 35 mm2 50 mm

2

FuseRated current 88 A 114 A 123 A 155 A 192 A 221 A

2

6 mm2 10 mm
2

70 mm2 95 mm
2 2

16 mm2

120 mm2 150 mm / 185 mm

355 A

Use suitable fuses with the enable characteristic gL or gR.

D.20.2 Device protection Device BM4412: BM4413: BM4414: BM4422: BM4423: BM4424: BM4425: BM4426: BM443X: BM444X: BM445X: BM446X: BM447X:
1)

Maximum load value 1) 310 A2s 310 A2s 325 A2s 400 A2s 450 A2s 800 A2s 800 A2s 800 A2s 1.500 A2s b 15,000 A2s 97,000 A2s 245,000 A2s 1,125,000 A2s

Use fuses in the operating point of the BM4400-device, which fall below the stated tripping integral (itoff).

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D.20

Fuse protection

D.20.3 Cable protection + device protection Consider by your choice of the whole range fuses the current-carrying capacity of the, to the device connected mains cables and the allowable maximum load of the device. D.20.4 Whole range fuses gR (device and cable) BM4412X, BM4413, model NH 000 16A/690V: 170M1559 u 25A/690V: 170M1561 u SIBA 000 16A/690V: 2047734/16A U 00 20A/690V: 2047720/20A 0 16A/1000V: 2038404/16A 25A/1000V: 2038404/25A Siemens 000 16A/690V: 3NE1 813-0 U 00 25A/690V: 3NE8 015-1 U 25A/690V: 3NE8 715-1 0 32A/1000V: 3NE4 101 Size D.20.5 Semiconductors aR (device) BM4412, BM4413, model NH 20A/690V: 3NE8 714-1 25A/690V: 2047720/25A 20A/1000V: 2038404/20A 32A/1000V: 2038404/32A 20A/690V: 170M1560 u

Bussmann

Bussmann

00 20A/1000V: 170M2673 1 40A/690V: 170M3808

25A/1000V: 170M2674

Ferraz Shawmut

000 16A/690V: 6.9 URD 000 PV 016 20A/690V: 6.9 URD 000 PV 020 25A/690V: 6.9 URD 000 PV 025 00 20A/690V: 6.9 URD 00 PV 020 32A/690V: 6.9 URD 00 PV 032 0 32A/690V: 6.9 URD 0 PV 032 40A/690V: 6.9 URD 0 PV 040 25A/690V: 6.9 URD 00 PV 025

Size

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D.20.6 Whole range fuses gR (device and cable) BM4414, model NH

Bussmann Ferraz Shawmut

000 25A/690V: 170M1561

32A/690V: 170M1562

000 16A/690V: 6.9 GGR 000 PV 016 20A/690V: 6.9 GGR 000 PV 020 00 16A/690V: 6.9 GGR 00 PV 016

SIBA

000 16A/690V: 2047734/16A 00 35A/690V: 2047720/35A 0 16A/1000V: 2038404/16A 32A/1000V: 2038404/32A

20A/690V: 2047734/20A

25A/1000V: 2038404/25A 40A/1000V: 2038404/40A 20A/690V: 3NE1 814-0 U 35A/690V: 3NE8 003-1 U 32A/690V: 3NE8 701-1 U 40A/1000V: 4NE4 102

Siemens

000 16A/690V: 3NE1 813-0 U 00 25A/690V: 3NE8 015-1 U 25A/690V: 3NE8 715-1 U 0 32A/1000V: 4NE4 101

Size D.20.7 Semiconductors aR (device) BM4414, model NH

Bussmann

00 20A/1000V: 170M2673 32A/1000V: 170M2675 1 40A/690V: 170M3808

25A/1000V: 170M2674 35A/1000V: 170M2676

Ferraz Shawmut

000 20A/690V: 6.9 URD 000 PV 020 25A/690V: 6.9 URD 000 PV 025 32A/690V: 6.9 URD 000 PV 032 40A/690V: 6.9 URD 000 PV 040 00 25A/690V: 6.9 URD 00 PV 025 40A/690V: 6.9 URD 00 PV 040 0 32A/690V: 6.9 URD 0 PV 032 40A/690V: 6.9 URD 0 PV 040 32A/690V: 6.9 URD 00 PV 032

Size

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Fuse protection

D.20.8 Whole range fuses gR (device and cable) BM4422X, model NH

Bussmann

000 16A/660V: 170M1559 u 25A/660V: 170M1561 u 00 16A/690V: 170 m 25A/690V: 170 m

20A/660V: 170M1560 u 32A/660V: 170M1562 u 20A/690V: 170 m 32A/690V: 170 m

SIBA

000 16A/690V: 2047734/16A U 00 20A/690V: 2047720/20A 25A/690V: 2047720/25A 20A/660V: 3NE8 714 25A/660V: 3NE8 015

Siemens

00 16A/690V: 3NE1 813-0 U 25A/660V: 3NE8 715 32A/660V: 3NE8 701 0 32A/1000V: 3NE4 101 U

Size D.20.9 Semiconductors aR (device) BM4422, model NH

Bussmann

00 20A/1000V: 170M2673 32A/1000V: 170M2675 1 40A/660V: 170M3808

25A/1000V: 170M2674

Ferraz Shawmut

000 16A/690V: 6.9 URD 000 PV 016 20A/690V: 6.9 URD 000 PV 020 25A/690V: 6.9 URD 000 PV 025 32A/690V: 6.9 URD 000 PV 032

Size

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D.20.10 Whole range fuses gR (device and cable) BM4423X, model NH

Bussmann

000 20A/660V: 170M1560 u 32A/660V: 170M1562 u 00 20A/690V: 170M2693 32A/690V: 170M2695

25A/660V: 170M1561 u

25A/690V: 170M2694

Ferraz Shawmut

000 20A/690V: 6.9 GGR 000 PV 020 00 20A/690V: 6.9 GGR 00 PV 020

SIBA

000 20A/690V: 2047734/20A U 00 20A/690V: 2047720/20A 25A/690V: 2047720/25A 20A/690V: 3NE8 814-0 U 25A/660V: 3NE8 015

Siemens

00 20A/660V: 3NE8 714 25A/660V: 3NE8 715 32A/660V: 3NE8 701 0 32A/1000V: 3NE4 101 U

Size D.20.11 Semiconductors aR (device) BM4423, model NH

Bussmann

00 20A/1000V: 170M2673 32A/1000V: 170M2675 1 40A/660V: 170M3808

25A/1000V: 170M2674

Ferraz Shawmut

000 20A/690V: 6.9 URD 000 PV 020 25A/690V: 6.9 URD 000 PV 025 32A/690V: 6.9 URD 000 PV 032 40A/690V: 6.9 URD 000 PV 040

Size

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Fuse protection

D.20.12 Whole range fuses gR (device and cable) BM4424, BM4425 and BM4426, model NH

Bussmann

000 25A/660V: 170M1561 u 00 25A/690V: 170M2694

32A/660V: 170M1562 u 32A/690V: 170M2695

Ferraz Shawmut

000 25A/690V: 6.9 GGR 000 PV 025 00 25A/690V: 6.9 GGR 00 PV 025

SIBA

000 25A/690V: 2047734/25A U 00 25A/690V: 2047720/25A 25A/660V: 3NE8 015 32A/660V: 3NE8 701

Siemens

00 25A/660V: 3NE8 715 25A/690V: 3NE1 815-0 U 0 32A/1000V: 3NE4 101 U

Size D.20.13 Semiconductors aR (device) BM4424, BM4425 and BM4426, model NH

Bussmann

00 25A/1000V: 170M2674 40A/1000V: 170M2676 1 40A/660V: 170M3808 63A/660V: 170M3810

32A/1000V: 170M2675

50A/660V: 170M3809

Ferraz Shawmut

000 25A/690V: 6.9 URD 000 PV 025 32A/690V: 6.9 URD 000 PV 032 40A/690V: 6.9 URD 000 PV 040 50A/690V: 6.9 URD 000 PV 050

Siemens Size

00 660V/40A: 3NE8 702

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D.20.14 Whole range fuses gR (device and cable) BM443X model NH

Bussmann

000 50A/660V: 170M1564 u 00 50A/690V: 170M2697 1 50A/690V: 170M4176

63A/660V: 170M1565 u 63A/690V: 170M2698 63A/690V: 170M4177

SIBA

00 63A/690V: 2047720/63A 1 63A/690V: 2021120/63A

Siemens

00 63A/660V: 3NE8 018-1 U 0 50A/1000V: 3NE4 117

Size

D.20.15 Semiconductors aR (device) BM443X, model NH

Bussmann

00 50A/1000V: 170M2678 1 63A/690V: 170M3810

63A/1000V: 170M2679 80A/690V: 170M3811 80A/1000V: 2038404/80A 63A/660V: 3NE8 718

SIBA Siemens

0 63A/1000V: 2038404/63A 00 50A/660V: 3NE8 717 0 63A/1000V: 3NE4 118 U

Size

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Fuse protection

D.20.16 Full-range fuses gR, gRL, gR/gS, gGR (device and cable) BM444X, model NH

Bussmann

00 80A/690V: 170M2699 125A/690V: 170M2701 1) 1 80A/690V: 170M4178 125A/690V: 170M4180

100A/690V: 170M2700

100A/690V: 170M4179 160A/690V: 170M4181

Ferraz Shawmut

000 80A/690V: 6.9 GGR 000 PV 080/ 6,9 GGR 000 D08L 080 00 80A/690V: 6.9 GGR 00 PV 080/ 6,9 GGR 00 D08L 080

SIBA

1 80A/690V: 2021120-80A 80A/690V: 2021134-80A U

100A/690V: 2021120-100A 100A/690V: 2021134-100A U1)

Siemens Size
1)

000 80A/690V: 3NE1 820-0 U

For the connection of an additional DC link capacity or the parallel operation of up to five devices suitable, that means the DC link of several devices is connected with at the same time existent mains connection of every device.

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D.20.17 Semiconductors aR (device) BM444X, model NH 000 80A/690V: 170M1566 U 125A/690V: 170M1568 U 00 80A/1000V: 170M2680 125A/1000V: 170M2682 1 80A/690V: 170M3811 U 125A/690V: 170M3813 U SIBA Siemens 1 125A/690V: 2021120/125A 1) 000 80A/690V: 3NE8 720-1 U 125A/690V: 3NE8 722-1 U 00 80A/690V: 3NE8 020-1 U 125A/690V: 3NE8 022-1 U 0 80A/1000V: 3NE4 120 U 125A/1000V: 3NE4 122 U 1 100A/1000V: 3NE3 221 U 160A/1000V: 3NE3 224 U Size
1)

Bussmann

100A/690V: 170M1567 U 160A/690V: 170M1569 U 100A/1000V: 170M2681

100A/690V: 170M3812 U 160A/690V: 170M3814 U1)

100A/690V: 3NE8 721-1 U 160A/690V: 3NE8 724-1 U 100A/690V: 3NE8 021-1 U 160A/690V: 3NE8 024-1 U 100A/1000V: 3NE4 121 U

125A/1000V: 3NE3 222 U

For the connection of an additional DC link capacity or the parallel operation of up to five devices suitable, that means the DC link of several devices is connected with at the same time existent mains connection of every device.

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Fuse protection

D.20.18 Whole range fuses gR (device and cable) BM445X model NH

Bussmann

00 100A/690V: 170M2700 160A/690V: 170M2702 1 125A/690V: 170M4180 200A/690V: 170M4182 1) 2 200A/690V: 170M5881 315A/690V: 170M5883 1) 3 350A/690V: 170M6080 1)

125A/690V: 170M2701

160A/690V: 170M4181 250A/690V: 170M4183 1) 250A/690V: 170M5882 1)

Ferraz Shawmut 000 100A/690V: 6.9 GGR 000 PV 100 00 100A/690V: 6.9 GGR 00 PV 100 125A/690V: 6.9 GGR 00 PV 125 1) 160A/690V: 6.9 GGR 00 PV 160 1) SIBA 00 100A/690V: 2020934/100AU 1 100A/690V: 2021134/100AU 125A/690V: 2020934/125AU1) 125A/690V: 2021134/125AU1)

160A/690V: 2021134/160AU1) 200A/690V: 2021134/200AU1) 2 160A/690V: 2021234/160AU1) 200A/690V: 2021234/200AU1) Siemens 00 100A/690V: 3NE1 021-0 U 1 160A/690V: 3NE1 224-0 U1) Size
1)

125A/690V: 3NE1 022-0 U1) 200A/690V: 3NE1 225-0 U1)

For the connection of an additional DC link capacity or the parallel operation of up to five devices suitable, that means the DC link of several devices is connected with at the same time existent mains connection of every device.

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D.20.19 Semiconductors aR (device) BM445X, model NH 000 125A/660V: 170M1568 u 200A/660V: 170M1570 u 315A/660V: 170M1572 u1) 00 125A/1000V: 170M2682 200A/900V: 170M2684 1) 1 160A/660V: 170M3814 250A/660V: 170M3816 350A/660V: 170M3818 1) 2 400A/660V: 170M5808 1) 3 500A/660V: 170M6808 1) Ferraz Shawmut 000 125A/690V: 6.9 URD 000 PV 0125 160A/690V: 6.9 URD 000 PV 0160 200A/690V: 6.9 URD 000 PV 0200 250A/690V: 6.9 URD 000 PV 0250 1) 315A/690V: 6.9 URD 000 PV 0315 1) Siemens 00 125A/660V: 3NE8 022 U 160A/660V: 3NE8 024 200A/660V: 3NE8 725 315A/660V: 3NE8 731 1) 0 100A/1000V: 3NE4 121 U 160A/1000V: 3NE4 124 U 1 125A/1000V: 3NE3 222 U 200A/1000V: 3NE3 225 U 160A/1000V: 3NE3 224 U 250A/1000V: 3NE3 227 U1) 125A/1000V: 3NE4 122 U 125A/660V: 3NE8 722 160A/660V: 3NE8 724 250A/660V: 3NE8 727 1) 160A/1000V: 170M2683 1) 225A/900V: 170M2685 1) 200A/660V: 170M3815 315A/660V: 170M3817 1) 400A/660V: 170M3819 1) 450A/660V: 170M5809 1) 160A/660V: 170M1569 u 250A/660V: 170M1571 u1)

Bussmann

315A/1000V: 3NE3 230-0BU1) 350A/1000V: 3NE3 231 U1) 400A/1000V: 3NE3 232-0BU1) 2 400A/1000V: 3NE3 332-0BU1) Size
1)

For the connection of an additional DC link capacity or the parallel operation of up to five devices suitable, that means the DC link of several devices is connected with at the same time existent mains connection of every device.

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D.20

Fuse protection

D.20.20 Whole range fuses gR (device and cable) BM446X model NH

Bussmann

1 250A/690V: 170M4183 350A/690V: 170M4185 1) 2 250A/690V: 170M5882 350A/690V: 170M5884 1) 450A/690V: 170M58861) 3 350A/690V: 170M6080 1) 450A/690V: 170M6082 1)

315A/690V: 170M4184 1) 400A/690V: 170M4186 1) 315A/690V: 170M5883 1) 400A/690V: 170M5885 1)

400A/690V: 170M6081 1)

SIBA

1 250A/690V: 2021134/250AU1) 315A/690V: 2021134/315AU1) 2 250A/690V: 2021234/250AU1) 315A/690V: 2021234/315AU1) 350A/690V: 2021234/350AU1) 3 315A/690V: 2021334/315A1) 350A/690V: 2021334/350A1) 315A/690V: 3NE1 230-0 U1)

Siemens Size
1)

1 250A/690V: 3NE1 227-0 U1)

For the connection of an additional DC link capacity or the parallel operation of up to five devices suitable, that means the DC link of several devices is connected with at the same time existent mains connection of every device.

D.20.21 Semiconductor fuses aR (device) 446X, model NH 000 250A/660V: 170M1571 u 00 225A/900V: 170M2685 1) 1 250A/660V: 170M3816 350A/660V: 170M3818 2 400A/660V: 170M5808 500A/660V: 170M5810 1) 630A/660V: 170M58121) 3 500A/660V: 170M6808 630A/660V: 170M6810 1) Size 550A/660V: 170M6809 1) 700A/660V: 170M6811 1) 315A/660V: 170M3817 400A/660V: 170M3819 1) 450A/660V: 170M5809 1) 550A/660V: 170M58111) 315A/660V: 170M1572 u

Bussmann

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Ferraz Shawmut 000 250A/690V: 6.9 URD 000 PV 0250 315A/690V: 6.9 URD 000 PV 0315 00 250A/690V: 6.9 URD 00 PV 0250 315A/690V: 6.9 URD 00 PV 0315 0 250A/690V: 6.9 URD 0 PV 0250 1 250A/690V: 6.9 URD 1 PV 0250 350A/690V: 6.9 URD 1 PV 0350 2 250A/690V: 6.9 URD 2 PV 0250 350A/690V: 6.9 URD 2 PV 0350 315A/690V: 6.9 URD 0 PV 0315 315A/690V: 6.9 URD 1 PV 0315 400A/690V: 6.9 URD 1 PV 0400 1) 315A/690V: 6.9 URD 2 PV 0315 400A/690V: 6.9 URD 2 PV 0400

450A/690V: 6.9 URD 2 PV 0450 1) 500A/690V: 6.9 URD 2 PV 0500 1) 560A/690V: 6.9 URD 2 PV 0560 1) 630A/690V: 6.9 URD 2 PV 0630 1) 3 315A/690V: 6.9 URD 3 PV 0315 400A/690V: 6.9 URD 3 PV 0400 350A/690V: 6.9 URD 3 PV 0350 450A/690V: 6.9 URD 3 PV 0450

500A/690V: 6.9 URD 3 PV 0500 1) 560A/690V: 6.9 URD 3 PV 0560 1) 630A/690V: 6.9 URD 3 PV 0630 1) 700A/690V: 6.9 URD 3 PV 0700 1) Siemens 00 250A/660V: 3NE8 727 1 250A/1000V: 3NE3 227 U 350A/1000V: 3NE3 231 U1) 450A/1000V: 3NE3 233 U1) 2 400A/1000V: 3NE3 332-0BU1) 450A/1000V: 3NE3 333 U1) 500A/1000V: 3NE3 334-0BU1) 560A/1000V: 3NE3 335 U1) Size
1)

315A/660V: 3NE8 731 315A/1000V: 3NE3 230-0B U 400A/1000V: 3NE3 232-0BU1)

For the connection of an additional DC link capacity or the parallel operation of up to five devices suitable, that means the DC link of several devices is connected with at the same time existent mains connection of every device.

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Fuse protection

D.20.22 Semiconductor fuses aR (device) 447X, model NH

WARNING The following may occur, if you disregard these safety notes: m serious personal injury m death The danger is: electricity. Parts, which are under tension are perilous. The use of semiconductor fuses is obligatory at the mains connection of BM447X devices. Semiconductor fuses are required in the chopper resistor connection except the user assures the short-circuit protection of resistor and cable.

BM4472: Siemens Size BM4473: Siemens Size BM447X UL fuse in the chopper resistor circuit: Siemens Size 1 350A/1000V: 3NE3 231 u 2 800A/800V: 3NA3 338-8 u 2 630A/1000V: 3NE3 337-8 u

D.20.23 24V-extra-low voltage protection In case you refer to UL 508 C: Assure, that all marked e.l.v. connections (24 V) at the device have a maximum voltage of 30 VDC. Additionally these connections must be protected with fuses which are in accordance with UL 248 with a triggering current of maximum 4 A. NOTE Several connections can be protected together with a UL-listed fuse (release current max. 4 A).

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D.21

Cables mains-device Cross section 1) 4 x 0.5 to 2,5 mm2 (AWG 16 - 12) 4 x 0.5 to 4 mm2 (AWG 24 - 10) 4 x 0.5 to 10 mm2 (AWG 20 - 6) 4) Maximum length 2) mains to mains filter: userdefined mains filter to mains choke/ device: max. 30 cm Connection to device 3) flexible cable with/without wire end ferrule (plug-in terminal) flexible cable with wire end ferrule (screw terminal) flexible cable with wire end ferrule (screw terminal) Pin-cable-lugs according to DIN 46230 4) (screw terminal) 4 x 16 to 50 mm2 (AWG 6 -0) 4 x 25 to ca. 185 mm2 flexible cable with wire end ferrule (screw terminal) Cable lug max. Width: 25 mm (current bar) 5) Cable lug max. Width: 35 mm (current bar) 6) 4 x (4 x 95 mm2) 2 x (4 x 185 mm2) Cable lug max. Width: 25 mm or 35 mm (bus-bar) 7)

Device BM441X

BM442X BM443X BM4435

BM444X BM445X BM446X BM447X

1)

Possible cross section For UL conform machines/installations you must use UL certified circuit cables. The length of the cable between mains filter and mains is not of importance for the compliance to the EMC regulation. The installing of the cables is user-defined. Information according the technical data of the BM4435: The BM4435 has an input current of 53 A, the appropriate mains filter (BFN3-1-42-001) has a rated current of 56 A. 63 A-fuses must be provided for the cable protection and a cable with 16 mm2 cross section must be used. The terminals at the BM4435 are provided for cross sections up to 10 mm2, therefore at the BM4435 e. g. pin-cable-lugs according to DIN 46230 must be used.

2) 3) 4)

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D.21
5)

Cables mains-device

Connection lugs (current bars).Position see ZFigure 49 on page 84. Screw maximum two cable lugs to the current bar - one on the front side, one on the reverse side of the bar.

6)

Connection lugs (current bars). Position see ZFigure 49 on page 84 Screw maximum two cable lugs to the current bar - one on the front side, one on the reverse side of the bar.

7)

Connection lugs (current bars). Position see ZFigure 50 on page 85 At connection cross-section 95 mm2,Cable lug width max. 25 mm: Screw maximum two cable lugs to the current bar - one on the front side, one on the reverse side of the bar. At connection cross-section 185 mm2,Cable lug width max. 35 mm: Screw two cable lugs to the current bar at maximum- one on the front side, one on the reverse side of the bar.

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D.22

Cables device-motor Cross section 1) 4 x (1 to 2,5 mm2) (AWG 16 - 12) 4 x (0.2 to 4 mm2) (AWG 24 -10) maximum length 2)3) dependent on the used cross section: 4 x 1.5 to 2,5 mm2 (AWG 16 -12): 100m Connection to device flexible cable with/without wire end ferrule (plug-in terminal)

Device BM441X BM442X

BM443X 4 x (4 to 16 mm2) (AWG 20 - 4) 4 x 4 to 25 mm2 (AWG 10-3): 60m BM444X 4 x (16 to 50 mm2) (AWG 6 - 0) 4 x 35 mm2 (AWG 1): 50m

flexible cable with wire end ferrule (screw terminal)

BM445X 4 x (20 to ca. 185 mm2) 4 x 50 mm2 (AWG 1/0): 15m BM446X BM447X
6)
1)

Cable lug max. Width: 25 mm (current bar) 4) Cable lug max. Width: 35 mm (current bar) 5)

4 x (4 x 95 mm2) 4 x (2 x 185 mm2)

up to 2 x 185 mm : 30 m up to 4 x 95 mm : 15 m

Cable lug max. Width: 25 mm or 35 mm (bus-bar) 6)

Possible cross section Use a screened circuit Baumller-line, optical shield coverage > 85%. Do not use single conductors. For UL conform machines/installations you must use UL certified circuit cables. Only for Baumller cables with this maximum length and by usage of a Baumller mains filter you can assume, that the limit values of the EMC product standard EN 61800-3 are complied with. In case you use parallel-installed motor cables, the maximum length is to be reduced by the factor 1/n. Connection lugs (current bars). Position see ZFigure 49 on page 84. Screw maximum two cable lugs to the current bar - one on the front side, one on the reverse side of the bar.

2)

3) 4)

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D.23

Cable control voltage supply/signals

5)

Connection lugs (current bars). Position see ZFigure 49 on page 84 Screw maximum two cable lugs to the current bar - one on the front side, one on the reverse side of the bar.

6)

Connection lugs (current bars). Position see ZFigure 50 on page 85 At a connection cross-section of 95 mm2, cable lug width max. 25 mm: Screw maximum two cable lugs to the current bar - one on the front side, one on the reverse side of the bar. At a connection cross-section of 185 mm2, cable lug width max. 35 mm: Screw two cable lugs to the current bar at maximum- one on the front side, one on the reverse side of the bar.

D.23

Cable control voltage supply/signals 1.5 mm2 user-defined with /without wire end ferrules (plug-in terminal)

Cross section 1) Maximum length 2) Connection to device

1) 2)

The installing of the cables is user-defined. The length of the cable has no influence on the compliance to the EMC regulation.

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D.24

Type of protection

Type of protection BM 441X, BM 442X BM 443X, BM 444X BM 445X, BM 446X, BM 447X IP 20 IP 20, if safe-to-touch connection according to IP 20, otherwise IP 10 IP 00

D.25

Fire fighting appliances ABC-Pulver

Fight fire with

D.26

Mains filters BM441X to BM447X In order to comply with the required limit values of the EMC product standard a mains filter is necessary for each device. Insert in proportion of the application a mains filter from the following table. TN-mains IBem AC 1) Type 7A 16 A 30 A 42 A 56 A 75 A 100 A 130 A 180 A 250 A 320 A 400 A 600 A
1)

Item number 314277 314278 314279 314280 314281 314282 314283 314284 314285 373891 373896 373900 373901

BFN 3-1 - 7 - 001 BFN 3-1 - 16 - 001 BFN 3-1 - 30 - 001 BFN 3-1 - 42 - 001 BFN 3-1 - 56 - 001 BFN 3-1 - 75 - 001 BFN 3-1 - 100 - 001 BFN 3-1 - 130 - 001 BFN 3-1 - 180 - 001 BFN 3-1 - 250 - 001 BFN 3-1 - 320 - 001 BFN 3-1 - 400 - 001 BFN 3-1 - 600 - 001

Rated temperature = 40 C

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D.27

Mains chokes

IT-mains IBem AC 1) Type 250 A 320 A 400 A 600 A

1)

Item number 373620 373894 373898 373902

BFN 3-1 - 250 - 002 BFN 3-1 - 320 - 002 BFN 3-1 - 400 - 002 BFN 3-1 - 600 - 002

Rated temperature = 40 C

D.27

Mains chokes For the devices BM441X, BM4422, BM4423, BM4424 and BM4425 mains chokes are not necessary.

Current Inductance

Select the mains chokes depending on their application on the basis of the input rated current. Take into account that the max. input current may not bring the choke into saturation. Furthermore, chose the mains chokes dependent on the short circuit voltage of the mains, so that the demanded mains inductance, under ZRequirements on the power supply on page 162, is complied with. NOTE at 60 Hz there is another short-circuit voltage with the same choke as with 50 Hz; with the formula uk = (L x IN x 3) / UN (with = 2 x f) you can calculate the short-circuit voltage at another mains frequency.

Irated AC

Inductance

Type designation

Part No. Type -001, Connection copper conductor bar

Part No. Type -002, Connection terminal 399136 399137 399138 399139 399140 399141 -

25 A 40 A 65 A 80 A 115 A 165 A 195 A 275 A 365 A 450 A

1,18 mH 0,72 mH 0,45 mH 0,36 mH 0,26 mH 0,18 mH 0,15 mH 105 H 80 H 65 H

BK3-0025/0030 BK3-0040/0050 BK3-0065/0080 BK3-0080/0100 BK3-0115/0140 BK3-0165/0200 BK3-0195/0240 BK3-0275/0340 BK3-0365/0450 BK3-0450/0550

368377 368378 368379 368380 368381 368382 368383 368384 368385 368386

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Irated AC

Inductance

Type designation

Part No. Type -001, Connection copper conductor bar

Part No. Type -002, Connection terminal -

530 A 615 A 750 A 920 A 1020 A

55 H 48 H 39 H 32,6 H 28 H

BK3-0530/0650 BK3-0615/0750 BK3-0750/0920 BK3-0900/1100 BK3-1020/1250

368387 368388 368389 368390 395020

The listed chokes are specified for the operation at 400 V /50 Hz or 480 V / 60 Hz. At a mains voltage of 400 V and a frequency of 50 Hz at rated current the chokes have a shortcircuit voltage of 4% of the mains voltage.

D.28

Temperature sensors of the motor

Type KTY84 MSKL1) (PTC)

1)

additional requirements R = 1K at Tprotection, Imax < 2mA

Insulation SELV/PELV SELV/PELV

Motor protection PTC according to DIN 44080-082

NOTE The motor temperature sensor is to be executed in such a way, that the electrical separation (EN 61800-5-1) is guaranteed. The motor temperature sensors, which are build in at Baumller motors correspond to these requirements. When connecting an motor produced by an external manufacturer, the operator has to assure, that the motor temperature sensor, which was installed into the motor complies with the function electrical separation.

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Temperature sensors of the motor

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APPENDIX E - SAFE STOP

In this chapter we describe the safety function Safe stop. E.1 Methods to avoid an unexpected starting In order to avoid danger for persons, for example operators, service- and maintenance technics, the machine has to be kept in a safe state (safe stop), while taking action in the dangerous area of the machine. Therefore a reliable prevention of a unexpected starting is demanded (Machine Directive 89/392/EWG, attachment I, 1.6.3, last paragraph; EN 292-2, 4.1.4; EN 60204-1, 5.4). Unexpected starting is each starting, which causes a risk for persons by its unexpected occurrence (EN 292-1). Moreover, besides the transition of the enable- to the operating state of the machine also the unexpected ramp-up of the machine, this means the transition from the safe stop into an unsafe moving has to be considered. This is necessary, because the unexpected ramp-up usually is to be led back to an interruption of the control loop of the machine. In this case the drive is, because of its control system, anxious to achieve highest speed at maximum acceleration. If an unexpected starting occurs, the operator therefore doesnt have the possibility anymore to remove himself or his hand from the danger area. This is why the drive has to be stopped and has to be kept 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, if e. g. a drive supplied by a power converter is often stopped and started again. The constant dis- and re-charging of the DC link represents a great stress for the concerned parts and often leads to disturbing delays and failures of these parts. The precondition of starting an three-phase motor is the generation of a rotating field, which drives the inductor of the motor. When having variable-speed three-phase 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 amplifying 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 at the pulse pattern generation therefore cannot lead to a starting of the motor, as long as the second precondition, namely the interruption of the amplifying power supply is available and contrary. The protection against unexpected starting is reached by an electromechanical method which is superior to the electronics. It is reached by a safe isolation - elsewhere than in the load circuit.

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Methods to avoid an unexpected starting

The power supply to the windings of the motor is reached at a stoppage by inhibiting the power semiconductor. As semiconductors possibly can fail or be started, because of electromagnetic interferences, the behavior of the shut down drive has to be considered if such an error scenario arises. The breakdown or accidental turning on of a single or of several power semiconductors at the same DC-link pole does not lead to an uncontrollable starting, as no current flow is accomplished. Not until additionally a further power semiconductor is enabled at another pole, current is able to flow through the motor. If, thereby the is directly short-circuited, the fuses which are upstreamed to the converter are tripped, the motor doesnt start. If the is short-circuited over a winding of the motor, a magnetic field can be set up in the motor. If it is an asynchronous motor, then the generated d. c. magnetic properties cannot cause a lurch of the inductor. By the permanent-magnetic synchronous motor the inductor will rotate into a notch position. The therewith angular movement which is covered is dependable of the inductors position and the number of pole pairs of the motor. It amounts to maximum 180/number of pole pairs. Subsequently the enabled DC link operates like a brake, this means after the ending of the lurching movement the drive is in a blocked state. A starting of the drive is impossible. If a machine with a synchronous motor is planned, the possible sudden movement must be considered, because it can lead to a dangerous movement. Therefore the machinist must carry out a safety evaluation for the residual movement.

NOTE The function of the safety relay is limited to the prevention of an unexpected starting. The switching of the safety relay, while the inductor of the motor is rotating, causes an uncontrolled coasting of the machine, a braking with help of the converter is not possible anymore.

WARNING The following may occur, if you disregard these safety notes: m serious personal injury mdeath The danger is: electricity. Both on the motor and at the unit there can be mains voltage although safety relay is switched off. If required, switch the appliance off-circuit like an appliance without a safety relay - the safety relay does not switch the appliance and the motor off- circuit! Switching off the safety relay has no isolation from the supply system as a consequence. Therefore, mains potential can be both at the converter and at the motor. In the case of maintenance, service- and repair- works on electrical components of the drive system, the protection against dangers must be provided by other means (e. g. main switch).

NOTE When having a switched off safety relay it is not possible at BM441X and BM454X to use of a chopper resistor.

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E.2

Safety categories according to EN 954-1 Dependent on the possible dangers (these are rated due to the consideration of the severity of the injuries, the frequency of the length of stay within the danger area and possibilities in order to prevent dangers) safety-related components of machines must meet certain safety criteria. The requirements to safety-based parts are divided into five categories in the standard EN 9541. In category B basic demands, in 1 additionally safety-technical checked components and principles are claimed. In category 2 an error between inspection intervals can lead to a loss of the safety function. Category 3 accords to the level the single-error-certainty to recognize errors partially. The safety-related components must be in such a way, that a single error doesnt lead to a loss of the safety function, whereat not the complete possible errors can be self-contained recognized by the system. Therefore an accumulation 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.

The Baumller converter of series b maXX (BM443X-XX2, BM444X-XX2, BM445X-XX2, BM446X-XX2, BM447X-XX2), which can be carried out optional with two safety relays (BM4XXX-XX2), comply with die requirements of category 4 as well as with category 3 (EN 954-1) for the safety function Safe stop.

The Baumller converter of series b maXX (BM441X-XX1, BM442X-XX1, BM443X-XX1, BM444X-XX1, BM445X-XX1, BM446X-XX1, BM447X-XX1), which are optional carried out with one safety relay (BM4XXX-XX1), comply with the requirements of category 3 (EN 9541) for the safety function Safe stop.

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E.3

The safety relay

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 (X102-3/4; X103-3/4). Consequently the functioning of the safety function is guaranteed if power failure operates. In order to deactivate Safe stop a voltage of 24 V must be applied to the terminals, which are concerned (X102-3/4; X103-3/4). For external monitoring of the safety relay the present state signal can be scanned at its positively-driven status signal contacts(X102-1/2; X103-1/2). In case there is no voltage applied to the safety relay (X102-3/4; X103-3/4), that means during the Safe stop, then the status signal contacts are closed (NC contact). Also a parting of a cable can thusly be recognized as an error. If the voltage at the input terminals of the relay (X102-3/4;X103-3/4)is switched off, the converter either generates the message Power unit warning 20: Undervoltage safety relay or the message Power unit Error 87: Error safety relay. At inhibited pulse enable the warning message (warning will not be saved) is generated and at a given pulse enable the fault indication or error message (error message will be saved) is generated. A commissioning or an enable of the drive is only possible, if there is no error in the error storage. This error storage can, for example, be reset over the digital input X1/1 of the function module DIO-01. For this the input X1/1 accordingly must be configured. The switch-on pulse length at X1/1 must be 5 ms minimum.

E.3.1

Principle sketch safety relay

Figure 75:

Principle sketch safety relay

NOTE The switch-on and switch-off sequence of the enable signals as well as of the safety relay must be considered in order to assure an operation of the drive without trouble. See ZFigure 76 on page 225.

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E.3.2

Sequence diagram

Figure 76:

Sequence diagram for one or two safety relays

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The safety relay

Figure 77:

Time diagram: Recommended switch on/switch off sequence (4)

(1) TBoot controller dependent of the option module, which is used (from firmware version 03.05) about 5 s. (2) Tcharge DC: 1.5 s (exception b maXX443X: 6 s). (3) TSR pulse enable: 20 ms (exception b maXX 442X: 200 ms). (4) Deviant switch on- and switch off sequence possible. See table ZDeviant switch on-/switch off possibilities BM441x to BM446x on page 227.

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E
BM447x yes yes yes yes no no yes yes

Deviant switch on-/switch off possibilities BM441x to BM446x BM441x BM442x BM443x BM444x BM445x Switch on- and switch off requirement Auxiliary supply (24 V) and safety relay 1 + 2 and mains simultaneously ON Auxiliary supply (24 V) and safety relay 1 + 2 simultaneously ON Mains OFF mains ON at pulse inhibit Pulse enable ON at safety relay, which is activated already Pulse enable and safety relay 1 + 2 simultaneously ON Pulse enable and safety relay 1 + 2 simultaneously OFF Safety relay 1 + 2 ON 20 ms before pulse enable Safety relay 1 + 2 OFF 20 ms after pulse enable
1)

yes

yes

yes

yes

yes

yes

yes

yes

yes

yes

yes

yes

yes yes no

yes yes no

yes yes no

yes yes no

yes yes no

yes yes no

no

no

no

no

no

no

yes yes

no1) no1)

yes yes

yes yes

yes yes

yes yes

yes, if TSR pulse enable = 200 ms

Baumller devices of the series b maXX, which are made with one safety relay (optional, BMXXX-XX1), comply with the requirements of category 3 (EN 954-1) for the safety function Safe stop and the safety-related usage Protection against unexpected starting, if the configuring and installation instructions are complied with. Baumller-devices of the series b maXX, which have two safety relays (optional, BM4XXXXX2), comply with the requirements of category 4 as well as with category 3 (EN 954-1) for the safety function Safe stop and the safety and the safety-related function Protection against unexpected starting, if the configuring and installation instruction are observed. 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 released (e. g. 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 safety function of the converter doesnt have to be checked by an external monitoring, as the device checks itself on possible errors and if necessary displays a message as well as switches off the drive.

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E.4

Application example for machine of category 3

Application example for machine of category 3 Exemplary, the following diagram shows the usage and cabling of a Baumller converter of the series b maXX in a machine tool, at which the safe taking of work pieces at opened cover is possible according to category 3 (EN 954-1). m Application example for machine of category 3 with two switch-off channels: Pulse enable and einem safety relay.

Figure 78:

Version with one safety relay (BM4XXX-XX1)

The switching-off of the electrical drive motor operates dual-ported. n S2 (NC contact) and S3 (NO contact) effectuate the pulse enable input of the converter by hardware (X3-5). Only if S2 and S3 display a closed cover (and therewith a safe state) voltage is being applied to the pulse enable input of the converter. n S1 (NC contact) has hardware effects on the safety relay of the converter. Only if S1 shows a closed cover (and therewith a safe state) there is voltage at the safety relay input (X102: 3) and therewith a torque is possible to be generated at the shaft of the motor. The NO contact of S1 is connected with the monitoring circuit. n 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). The control circuit will not receive an enable signal from the monitoring circuit, if the cover is not completely closed or if there is a theoretically impossible state of the position switch contacts (e. g. if S1 and S2 are showing a differing switch state or if S2 and S3 are showing the same switch state). A missing enable signal of the monitoring device leads to a direct switching off of the converter by means of the control circuit. If

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the monitoring circuit has recognized an error (for example different switch state of S1 and S2), this is displayed to the operator and a commissioning of the drive is not possible until the error has been repaired. n The status signal contact of the safety relay (X102:1; NC contact) can additionally be evaluated by the monitoring circuit (not imperative). n The position switches, which are used, must unavoidable have actuated and mechanical connected 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 (X102-3/4) and the control as well as between the pulse enable input at the converter (X3-5) and the control must not be installed outside the control cabinet in a common cable channel.

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E.5

Application example for machine of category 4

Application example for machine of category 4 The diagram shows exemplary the usage and cabling of a Baumller converter of the series b maXX (BM443X-XX2, BM444X-XX2, BM445X-XX2, BM446X-XX2, BM447X-XX2) of a machine tool, at which the safe taking of work pieces at opened cover according to category 4 (EN 9541) is possible.

Figure 79:

Version with two safety relays (BM4XXX-XX2)

The switching-off of the electrical drive motor takes place with three channels. n S1 (NC contact) has hardware effects on the safety relay of the converter. Only if S1 shows a closed cover (and therewith a safe state) there is voltage at the safety relay input (X102: 3) and therewith a torque is possible to be generated at the shaft of the motor. The NO contact of S1 is connected with the monitoring circuit. n S2 (NC contact) and S3 (NO contact) effectuate the safety relay of the converter. Only if S2 and S3 display a closed cover (and therewith a safe state) there is voltage at the safety relay input (X103: 3) and therewith makes a generation of a torque possible at the shaft of the motor. n S3 (NO contact) has hardware effects on the pulse enable input of the converter (X3: 5). Only if S3 displays a closed barrier (and therewith a safe state) voltage is applied to the pulse enable input of the converter.

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Safe stop

n The monitoring circuit, a fail-safe monitoring control of the category 4 (EN 954-1), checks on its own the directly connected switch contacts of the position switches S1 (NO contact), S2 (NO contact), S3 (NC contact) and the status signal contacts of the safety relay (X102: 1/2 NC contact, X103: 1,2 NC contact) as well as the contactor K1 (NO contact). X103-1/2 NC contact). If the cover is not completely closed or if there is a theoretically impossible state of the position switch contacts (e. g. S1 and S2 display a differing switch state or if S2 and S3 display the same switch state or if the status signal contact of the safety relay is opened/ closed, although the status signal contact of S1 is opened/closed), the control circuit does not receive an enable signal from the monitoring circuit. A missing enable 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 (for example different switch condition of S1 and S2), this if displayed to the operator and the commissioning of the drive is not possible until the error has been repaired. n The position switches, which are used, must unavoidable have actuated and mechanical connected 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 inputs (X102-3/4; X103-3/4) as well as between the pulse enable input (X3-5) and the control circuit may not be run together in a cable channel outside the control cabinet. All information given in the manual for the converter, especially the chapters safety instructions, installation and commissioning, must absolutely be observed. For the use and the installation of the safety devices the relevant legal and official requirements of the Safety Authorities and of the EU Directives for safety-engineering regulations at installations and machines (for example EN 60204-1, security of machines, electric equipment and EN 292-2, security of machines - general configuration guidelines).

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E.6
E.6

Application upgrade

Application upgrade At the converter of series b maXX (BM443X-XX2 to BM447X-XX2) the safety function Safe stop is achieved via three independent switch off channels and a hardware pulse enable input (category 4 acc. to EN 954-1). However, in many ranges it is not necessary, that the Safe Stop is executed in category 4. In the following, application examples are viewed, at which only two of the three switch off channels are used. m Application example 1 Application example for machine of category 3 with hardwired pulse enable input and process data communication via a field bus. Switching off occurs by means of safety relay 1 and safety relay 2.

Figure 80:

Version with two safety relays (BM4XXX-XX2)

At this sample the hardware pulse enable input (X3:5) is hardwired. The activation of the Safe Stop occurs with two channels via the safety relay 1 and 2 (X102:3 / X103:3). The release of the converter and the process data communication occurs via field bus.

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m Application example 2 Application example for machine of category 3 with two switch off channels: Pulse enable and a second common switch off channel for safety relay 1 and safety relay 2.

Figure 81:

Version with two safety relays (BM4XXX-XX2)

At this example the safety relays 1 and 2 of a position switch are set and together form the first channel. The hardware pulse enable input forms the second channel, which is set, independent of the safety relay.

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Application upgrade

m Application example 3 Pulse enable and only one safety relay

Figure 82:

Version with a safety relay (BM4XXX-XX1)

This version of converter b maXX is equipped with one safety relay only. The hardware is identic with the other converters of this series - only the second relay is not equipped. The internal relay switch off paths are combined and together form the first channel. The second channel forms a hardware pulse enable input, which is set independent of the safety relay.

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E.7

Technical data safety relay module

WARNING The following may occur, if you disregard these safety notes: m serious personal injury m death The danger is: mechanical influence by failure of safety relay. Assure, the minimum current of the contacts X102-1 and X102-2 (or X103-1 and X103-2) not falling below during operation. Operate the safety relay within the specification.

BM4XXX-XX1-XXXXX-XX BM4XXX-XX2-XXXXX-XX Safety relay module with high power current contacts Coil side (X102-3, X102-4, X103-3, X103-4) Nominal voltage UDC Operating voltage range Control current IDC Status signal contact (NC contact) (X102-1, X X X Switching voltage UDC Switching current IDC Switch-on frequency Activation delay time at nominal voltage UDC Deactivation delay time Electrical durability Mechanical durability max. 6/min max. 25 ms max. 15 ms at least 105 at least 1 x 107 switching cycles 24 V 10 mA to 4 A
2)

BM4XXX-XX3-XXXXX-XX BM4XXX-XX4-XXXXX-XX Safety relay module with low power current contacts1)

24 V -15% / +20% max. 70 mA

24 V -15 % / +20 % max. 70 mA

24 V 10 mA to 300 mA2) max. 10/s max. 15 ms max. 12 ms

operating cycles at least 105 operating cycles at least 5 x 107 switching cycles

1)

only customer-specific versions Please contact Baumller Nrnberg GmbH before using this version. A current on contact of at least 20 mA is recommended. If the load is below 20 mA the current on contact can be increased (see ZFigure 83 on page 236).

2)

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Technical data safety relay module

m Installation of the feedback contact with permanent load

Figure 83:

Installation of the feedback contact with permanent load

Permanent load e.g.: Housing: Transparent cover: Resistor: Phoenix Contact, EMG12-B2 Part No.: 2948306 Phoenix Contact, BMG12-H 7,5 mm Part No.: 2947116 1,2 k / 1 W at TU = 70 C

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E.8

Prototype Test Certificate BGIA

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E.8

Prototype Test Certificate BGIA

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E.9

Supplement for the test certificate 2005 21349 The series b maXX (BM443X to BM446X) fulfills the requirements of the category 4 as well as the category 3 according to EN 954-1 provided that the circuit-technical implementation complies with the demands ZE.6 Application upgrade from page 232.

E.9.1

Supplement 2 for the test certificate The certification of the safety function "safe stop" in the servo inverter of the series b maXX (BM443X to 446X) in the year 2005 still was made on the base of the position paper DKE AK 226.03. In these documents the requirements to safety-related functions of electric device systems in the machines were described. The contents of this position paper especially the definition of the individual safety functions were used in making this new product standard IEC 61800-5-2. However the terms of the individual safety functions have been changed and have been adapted to the international linguistic usage. The safety function "Safe stop" from the position paper in the IEC 61800-5-2 is defined as "Safe Torque Off". However the requirements have not changed. "Safe stop" and "Safe torque off" are identic and describe the same safety function. The type-examination certificate accordingly is adapted on this point.

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Supplement for the test certificate 2005 21349

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Table of figures

Table of figures
Power unit (A) - controller unit (B).............................................................................................. 28 Slot combinations....................................................................................................................... 31 Danger areas BM441X, BM442X, BM443X and BM444X ......................................................... 32 Danger areas BM445X, BM446X and BM447X ......................................................................... 33 Position of type key label ........................................................................................................... 34 Danger areas by the mechanical mounting................................................................................ 38 Installation space BM441X......................................................................................................... 39 Installation space BM442X-S/A.................................................................................................. 40 Installation space BM442X-F ..................................................................................................... 40 Installation space BM442X-C..................................................................................................... 41 Installation space BM443X-S/Z.................................................................................................. 42 Installation space BM443X-A/F.................................................................................................. 42 Installation space BM443X-C..................................................................................................... 43 Installation space BM444X-S/Z.................................................................................................. 44 Installation space BM444X-A/F.................................................................................................. 44 Installation space BM445X-S/Z.................................................................................................. 45 Installation space BM445X-A/F.................................................................................................. 45 Installation space BM446X-S/Z.................................................................................................. 46 Installation space BM446X-A/F.................................................................................................. 46 Installation space BM4-47X-F .................................................................................................... 47 Installation space BM447X-A ..................................................................................................... 48 Drilling pattern BM441X ............................................................................................................. 49 Drilling pattern BM442X ............................................................................................................. 49 Drilling pattern BM443X ............................................................................................................. 50 Drilling pattern BM444X ............................................................................................................. 50 Drilling pattern BM445X ............................................................................................................. 51 Drilling pattern BM446X ............................................................................................................. 51 Drilling pattern BM447X-F.......................................................................................................... 52 Drilling pattern BM447X-A.......................................................................................................... 53 Mounting instruction BM441X, BM442X-S, BM443X-S/Z, BM444X-S/Z ................................... 55 Mounting instruction BM445X-S/Z and BM446X-S/Z................................................................. 56 Mounting instruction BM447X-A/F ............................................................................................. 57 Mounting instruction miscellaneous.......................................................................................... 58 Control cabinet mounting BM442X-A/F...................................................................................... 60 Danger areas at the electrical installation .................................................................................. 63 Single phase connection BM441X ............................................................................................. 65 Connection to single phase grounded mains (BM443X ... BM447X, without power modules) .. 66 Connection to single phase grounded mains with an isolated transformer................................ 66 Connection diagram with a directly controlled motor brake - without power modules ............... 71 Connection diagram with motor brake controlled via an additional relay - without power modules .... 73 Connection diagram with a directly controlled motor brake - power modules............................ 74 Connection diagram with motor brake controlled via an additional relay - power modules ....... 76 Connection fan BM447X-A......................................................................................................... 77 Electrical connections for mains, motor, upon others for BM4412 and BM4413 ....................... 79 Electrical connections for mains, motor, upon others for BM4414............................................. 80 Electrical connections for mains, motor, upon others for BM442X ............................................ 81 Electrical connections for mains, motor, upon others for BM443X ............................................ 82 Electrical connections for mains, motor, upon others for BM444X ............................................ 83 Electrical connections for mains, motor, upon others for BM445X and BM446X ...................... 84 Electrical connections for mains, motor, upon others for BM447X ............................................ 85 Connection X100 and connections of the controller unit............................................................ 87 Interface cable RS 232............................................................................................................... 93 Project tree in WinBASS II ....................................................................................................... 107 Manual b maXX BM4400 Document No. 5.04043.06

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Device manager in WinBASSII ................................................................................................. Structure of the error list - survey ............................................................................................. Danger areas BM441X, BM442X, BM443X and BM444X........................................................ Danger areas BM445X, BM446X and BM447X........................................................................ Demounting scheme................................................................................................................. Derating of output apparent power against the installation altitude. ......................................... Derating of the output current BM 441X basic unit ................................................................... Maximum external DC link capacity BM441X........................................................................... Derating of the output current BM 442X basic unit ................................................................... Maximum external DC link capacity BM442X........................................................................... Derating of the output current BM 443X basic unit ................................................................... Derating of the output current BM 444X basic unit ................................................................... Derating of the output current BM 445X basic unit ................................................................... Derating of the output current BM 446X basic unit ................................................................... Derating of the output current BM 447X basic unit ................................................................... Derating output current BM 442X power modules.................................................................... Derating of output current BM 443X power modules................................................................ Derating of output current BM 444X power modules................................................................ Derating of output current BM 445X power modules................................................................ Derating of output current BM 446X power modules................................................................ Derating at static inverter frequency < 15 Hz ........................................................................... Principle sketch safety relay ..................................................................................................... Sequence diagram for one or two safety relays ....................................................................... Time diagram: Recommended switch on/switch off sequence (4) ........................................... Version with one safety relay (BM4XXX-XX1).......................................................................... Version with two safety relays (BM4XXX-XX2) ........................................................................ Version with two safety relays (BM4XXX-XX2) ........................................................................ Version with two safety relays (BM4XXX-XX2) ........................................................................ Version with a safety relay (BM4XXX-XX1).............................................................................. Installation of the feedback contact with permanent load .........................................................

108 109 137 138 149 164 169 170 173 174 177 179 181 183 185 187 189 191 193 195 197 224 225 226 228 230 232 233 234 236

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Numerics
73/23/EWG 155 Controller unit versions Cooling type Cover Current grading Current limit reached 29 35 154 35 98

A
Absolute minimum voltage Accessories 162 153

D
Danger areas Dangers DC link DC-link connect Declaration by Manufacturer Declaration of Conformity Demounting Demounting scheme Device description Device generation Device management Device manager Device protection Discharge Display elements Disposal Disposal instructions Drilling patterns 32, 137 11, 24 139 78 158 155, 157 144 149 27 35 108 108 198 139 97 147 149 49

B
b maXX 4400 BM44XX - Cable protection BM44XX - Device protection 161 199 199

C
Cable EMC instructions 68 Cable control voltage supply 216 Cable protection 198 Cable screens 68 Cables laying 68 Capacitors 143 Chopper resistor connection 78 Chopper resistors, water-cooled 196 Circuit breaker 198 Class of protection 22 Components/modules 149 Connecting cable 67 Connection cross-section 89 Connection data of the connections 89 Connection diagrams 78 Connection technology 89 Connection torque 84, 89, 90, 91 Connection X100 87 Connections 78 chopper resistor 78 control voltage 78 mains 78 motor 78 motor temperature sensor 78 Connections of the controller part 87 Connector 154 Construction of the devices 27 Control cabinet 95, 139 Control voltage connected 78 Control, superordinated 96 Controller card connections 78 Controller cartridge 28 Controller slots 31 Controller type 35 Controller unit 100

E
electrical connections Electrical data EMC instructions EMC-compatible installation EN 60204 1-1 Enable signals Encoder Environmental conditions Environmental temperature Error Error detection Error indications Error list Error message Error messages Error parameters Error reactions Error text Ethernet 79, 80 167 68 68 198 96, 97 70 95, 138, 164 164 99 101, 105 101 111 100 111 111 109, 111 100 88

F
Fire fighting First steps Function module Functional modules Fuse protection 23 10 129 30 198

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Index

Fuses

67, 212

N
Non-electrical data 166

H
Hardware type HIPERFACE 35 124

O
Operating concept Operating program Operating sequence of installation Operating software Operating status Operation Option module Optional modules Overview 96 99 69 96 98 95 130 30 32

I
I/O plug-in modules IEC 60204-1 Inappropriate use Inspection intervals Installation electrical mains preconditions Installation space Interconnect the devices Interface cable RS 232 Introduction Isolation 96 67 21 139 63 65 63 37, 39 32 92, 153 9 143

P
Packing Parameter list Parameterization Personnel qualified Plug-in modules combination possibilities Power loss Power supply Power unit Prepare mounting Professional Protective conductor connection Protective measures PSI module PTC Pulse enable 25 108 108 22, 101 22 31 31 167, 168 162 28 39 22 78 11 88 105 70, 97, 98

K
KTY84 105

L
Laying LED LED H2 LED H4 Legal instructions Low Voltage Directive Low-voltage supply 68 97 108 108 20 155 162

M
Mains connection Mains chokes Mains type Mains voltage Maintenance Maintenance notes Marking Meaning of Messages Memory module PSI Modification Modules Monitorings Motor connection Motor temperature sensor connect Mounting Mounting height Mounting instructions Mounting technic 162 78 217, 218 35 162 100, 137 139 34 101 87 21 149 100 78 78 37 164 53 53

Q
Qualified personnel Quickstop 22, 38, 96 70, 97

R
Rated current Rated mains input voltage Recommissioning Recycling Relative air humidity Repair Requirements to the motor Reset errors Residual energy Responsibility and liability Rows 28 162 145 149 138 141 163 110 23 24 29

S
Safe stop Safety categories 221 223

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Index

Safety fuses 198 Safety instructions 11, 24, 101 Safety notes 24 Safety relay 35, 70, 77, 103, 105, 115, 135, 224 Durability 235 Screwing 94 Screwing (UL) 69 Screws 55 Semiconductor fuses 198 Servo converter 28 Short-circuit 104 Shutdown 143, 144 Signal level 97 Size of cabinet 35 Slot 30 Slots 30 code letters 30 Spare parts 153 State of software 35 Storage 143 Storage conditions 145 Structure of error list 109 Survey of appliance series 9 Survey of the error parameter names 109

WEEE, 2002/96/EG WinBASS II

147 96, 108

X
X100 78

T
Technical data Temperature Terminals Terms definition Torque direction1 Torque direction2 Transportation climatic category shock temperature range Troubleshooting Type key plug-in card 161 138 70 10 98 98 25 25 25 25 101, 109, 111 34 35

U
UL 508 C 61, 67, 69, 88, 162, 166, 181, 183, 185, 195 UL-certification 159 unexpected starting 221 Unpacking 25

W
Warning Warning message WinBASS II Warnings Washers 100 100 134 55

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Index

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Revision survey

Revision survey

Version
5.04043.03

Version
28.07.2005

Changing
Chapter Revision survey inserted, technical data safety relay, b maXX 4472 / 4473, interface cable RS 232, additional data water-cooled chopper resistors, instructions on hardware types XX0XX, XX1XX, XX2XX, X0XXX, X1XXX and X2XXX (type key), prototype test certification in chapter E Safe stop, polarity temperature sensor changed in the connection diagrams. Protection type BM443X, BM444X, Chapter Fuses revised, dimensions/drilling patterns updated, derating curves for the installation altitude/lower frequency range inserted, BM447X included, chapter safe stop completed, technical data safety module changed Chapter Technical data updated, power modules added. Chapter Fuses revised

5.04034.04

02.05.2006

5.04034.05 5.04034.06

03.08.2007 13.11.2007

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Notes:

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Baumller Nrnberg GmbH Ostendstrae 80-90 90482 Nrnberg T: +49(0)911-5432-0 F: +49(0)911-5432-130 www.baumueller.de

All information given in this manual is customer information, subject to change without notice. We reserve the right to futher develop and actualize our products continuously 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 of the information in hand. No liability can be accepted concerning the correctness of the information.