Baumuller b maXX 5000 Series Instruction Handbook Manual
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Baumuller b maXX 5000 Series Instruction Handbook Manual

Baumuller b maXX 5000 Series Instruction Handbook Manual

Mains rectifier/ active mains rectifier. axis units safety
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Instruction handbook
English
Language
Translation
Document No. 5.09021.17
Part No.
439683
Status
22-May-2019
E
5.09021.17
Read the Instruction handbook before starting any work!
b maXX 5000
BM5000, BM5100 
Mains rectifier/
Active mains rectifier
BM5300
Axis units safety

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Summary of Contents for Baumuller b maXX 5000 Series

  • Page 1 Instruction handbook English Language Translation Document No. 5.09021.17 Part No. 439683 Status 22-May-2019  b maXX 5000  BM5000, BM5100  Mains rectifier/ Active mains rectifier BM5300 Axis units safety Read the Instruction handbook before starting any work! 5.09021.17...
  • Page 2 Copyright This Instruction handbook may be copied by the owner in any quantity, but only for internal use. This Instruction handbook may not be copied or reproduced, in whole or in part, for any other purposes. The use and disclosure of information contained in this Instruction handbook are not permit- ted....

  • Page 3: Table Of Contents

    Table of Contents General ..............Information on the instruction handbook .
  • Page 4 Table of Contents Design and Operation ........... . . 81 Design .
  • Page 5 Table of Contents 7.13 Connection diagrams ..........143 7.13.1 Connection diagram of BM50XX-XX0X-...
  • Page 6 Table of Contents 11 Accessories and spare parts..........241 11.1 Cabling .
  • Page 7 Table of Contents Appendix A - Abbreviations ........... 297 Appendix B - Declaration of Conformity .
  • Page 8 Table of Contents Instruction handbook b maXX 5000 Document No.: 5.09021.16 Baumüller Nürnberg GmbH of 328...

  • Page 9: General

    ENERAL Information on the instruction handbook These instruction handbook provides important information on handling the device. A pre- requisite for safe work is compliance with all specified safety notes and procedural in- structions. Additionally, the valid accident prevention regulations and general safety regulations ap- plicable to the scope of application the device must be complied with.

  • Page 10: Limitation Of Liability

    Limitation of liability CAUTION! ..points out a potentially dangerous situation that could lead to minor or slight inju- ries if not avoided. NOTICE! ..points out a potentially dangerous situation that could lead to material damage if not avoided. Recommen- dations NOTE! ..highlights useful tips and recommendations, as well as information for efficient and problem-free use.

  • Page 11: Copyright Protection

    General Copyright protection The instruction handbook must be treated confidentially. It is to be used exclusively by personnel who work with the device. The consignment of the instruction handbook to third persons without the written permission of the manufacturer is prohibited. NOTE! The specific contents, text, drawings, images and other representations are copy- righted and subject to industrial property rights.

  • Page 12: Spare Parts

    Spare parts Spare parts WARNING! False or flawed spare parts can lead to damage, malfunction or complete fail- ure, thus endangering safety. Therefore: m Only use original spare parts of the manufacturer. Procure spare parts through an authorized dealer or directly from the manufacturer. Refer to ZAccessories and spare parts–...

  • Page 13: List Of Other Applicable Documents

    General 1.11 List of other applicable documents   Instruction  handbook Doc.-No. Part No. Part No. German English Instruction handbook b maXX 5000, 5100, 5300 5.09021 439682 439682 Instruction handbook b maXX 5500, 5600, 5700 5.13008 446683 446684 Instruction handbook b maXX 5800 5.16027 464134 464136...
  • Page 14 1.11 List of other applicable documents Instruction handbook b maXX 5000 Document No.: 5.09021.16 Baumüller Nürnberg GmbH of 328...

  • Page 15: Safety

    AFETY This section provides an overview of all of the important safety aspects for optimum pro- tection of personnel as well as for the safe and problem-free operation. Contents of the Instruction handbook Each person who is tasked with performing work on or with the device must have read and understood the instruction handbook before working with the device.
  • Page 16 Usage for the intended purpose WARNING! Danger arising from usage for an unintended purpose! Any usage that goes beyond the intended purpose and/or any non-compliant use of the device can lead to dangerous situations. Therefore: m Only use the device compliant with its intended purpose. m Observe all specifications of these instruction handbook.

  • Page 17: Risk Assessment According Eu Directive

    Safety Risk assessment according EU Directive Check the quality of the earth connection:  Earth current - before connecting the device to the power supply for the first time and  - within the recommended service intervals Requirements: m Cross section of the grounding cable according EN 61800-5-1 m Note the required torque of connection! m Grounded mounting plate made of metal m Mains filter, device and shielding of the motor cable are on the same HF potential...

  • Page 18: Wiring Of The Power Cables

    Risk assessment according EU Directive Mounting Unprotected hands can be injured at the sharp edges of the device. m Wear safety gloves! Unprotected eyes can be injured by thrown up metal particles caused by drilling or making cut-outs. m Wear safety glasses! Short-circuit in In case of a short-circuit high current flows.

  • Page 19: Responsibility Of The Operating Company

    Safety Responsibility of the operating company The device is used in commercial areas. Thus, the proprietor of the device is subject to the legal work safety regulations. Along with the notes on work safety in these instruction handbook, the safety, accident prevention and environmental protection regulations valid for the area of application of this device must be complied with.

  • Page 20: Training Of The Personnel

    Training of the personnel Training of the personnel WARNING! Risk of injury due to insufficient qualifications! Improper handling can lead to significant personal injury and material damage. Therefore: m Certain activities can only be performed by the persons stated in the respective chapters of these instruction handbook.

  • Page 21: Personal Protective Equipment

    Safety Personal protective equipment The wearing of personal protective equipment is required when working in order to mini- mize health and safety risks. m The protective equipment necessary for each respective type of work shall always be worn during work. m The personal safety signs present in each working area must be observed.

  • Page 22: Special Hazards

    Special hazards Special hazards In the following section, the remaining marginal risks will be stated that have been iden- tified as a result of the hazard analysis. Observe the safety notes listed here and the warning notes in the further chapters of this Instruction handbook to reduce health risks and dangerous situations.

  • Page 23: Fire Fighting

    Safety Moving compo- nents WARNING! Risk of injury from moving components! Rotating components and/or components moving linearly can result in severe injury. Therefore: m Do not touch moving components during operation. m Do not open any covering during operation. m The amount of residual mechanical energy depends on the application. Powered components still turn/move for a certain length of time even after the power supply has been switched off.

  • Page 24: Safety Equipment

    2.11 Safety equipment 2.11 Safety equipment WARNING! Risk of fatal injury due to non-functional safety equipment! Safety equipment provides for the highest level of safety in a facility. Even if safety equipment makes work processes more awkward, under no circumstances may they be circumvented.

  • Page 25: Signs And Labels

    Safety 2.13 Signs and labels The following symbols and information signs are located in the working area. They refer to the immediate vicinity in which they are affixed. WARNING! Risk of injury due to illegible symbols! Over the course of time, stickers and symbols on the device can become dirty or oth- erwise unrecognizable.

  • Page 26: Signs And Labels Bm5Xxx

    2.13 Signs and labels CAUTION! Risk of injury due to hot surface! When in operation, the top of the device can heat up to temperatures > 70 °C! Therefore: m Wear protective gloves  Figure 2: Signs and labels BM5XXX Instruction handbook b maXX 5000 Document No.: 5.09021.16 Baumüller Nürnberg GmbH...
  • Page 27 Safety Signs and labels devices  with safety level NOTE! Only a device with built in Safety Module SAF XXX, marked with the TÜV Rheinland certification label and the safety label fulfills a certified safety function within the meaning of PL classification according ISO 13849 or SIL according EN 61800. Instruction handbook b maXX 5000 Document No.: 5.09021.16 of 328...
  • Page 28 2.13 Signs and labels Instruction handbook b maXX 5000 Document No.: 5.09021.16 Baumüller Nürnberg GmbH of 328...

  • Page 29: Technical Data

    ECHNICAL DATA Dimensions The following drawings show the main dimensions of the devices in millimeters [mm]. The space requirements in the control cabinet are also determined based on these drawings. To make the necessary drill holes/cutout sections, use the drawings in ZDrilling pattern–...

  • Page 30: Bm503X-A Dimensions

    Dimensions READY PHASE FAILURE OVERTEMPERATURE DC-LINK ERROR BM503X-A 5000 b maXX Figure 4: BM503X-A dimensions *: Observe minimum clearance. Please follow the notes for mounting and ZCooling– page 56. Instruction handbook b maXX 5000 Document No.: 5.09021.16 Baumüller Nürnberg GmbH of 328...

  • Page 31: Bm504X Dimensions

    Technical data 3.1.2 BM504X dimensions Figure 5: BM504X-C/-S dimensions *: Observe minimum clearance. Please follow the notes for mounting and ZCooling– on page 56. Instruction handbook b maXX 5000 Document No.: 5.09021.16 of 328...

  • Page 32: Bm504X-A Dimensions

    Dimensions Figure 6: BM504X-A dimensions *: Observe minimum clearance. Please follow the notes for mounting and ZCooling– on page 56. Instruction handbook b maXX 5000 Document No.: 5.09021.16 Baumüller Nürnberg GmbH of 328...

  • Page 33: Bm517X Dimensions

    Technical data 3.1.3 BM517X dimensions Figure 7: BM517X-C/-S dimensions *: Observe minimum clearance. Please follow the notes for mounting and ZCooling– on page 56. Instruction handbook b maXX 5000 Document No.: 5.09021.16 of 328...

  • Page 34: Bm519X Dimensions

    Dimensions 3.1.4 BM519X dimensions BM519X-S Figure 8: BM519X-S dimensions *: Observe minimum clearance. Please follow the notes for mounting and ZCooling– on page 56. Instruction handbook b maXX 5000 Document No.: 5.09021.16 Baumüller Nürnberg GmbH of 328...

  • Page 35: Bm519X-F Dimensions

    Technical data Connection tube G1/2“ flat sealing screw joint with anti-twist protection BM519X-F Figure 9: BM519X-F dimensions *: Observe minimum clearance. Please follow the notes for mounting and ZCooling– on page 56. Instruction handbook b maXX 5000 Document No.: 5.09021.16 of 328...

  • Page 36: Bm53Xx Dimensions

    Dimensions 3.1.5 BM53XX dimensions Figure 10: BM532X-C/-S dimensions *: Observe minimum clearance. Please follow the notes for mounting and ZCooling– on page 56. Instruction handbook b maXX 5000 Document No.: 5.09021.16 Baumüller Nürnberg GmbH of 328...

  • Page 37: Bm532X-A Dimensions

    Technical data Figure 11: BM532X-A dimensions *: Observe minimum clearance. Please follow the notes for mounting and ZCooling– on page 56. Instruction handbook b maXX 5000 Document No.: 5.09021.16 of 328...

  • Page 38: Bm533X-C/-S Dimensions

    Dimensions Figure 12: BM533X-C/-S dimensions *: Observe minimum clearance. Please follow the notes for mounting and ZCooling– on page 56. Instruction handbook b maXX 5000 Document No.: 5.09021.16 Baumüller Nürnberg GmbH of 328...

  • Page 39: Bm533X-A Dimensions

    Technical data Figure 13: BM533X-A dimensions *: Observe minimum clearance. Please follow the notes for mounting and ZCooling– on page 56. Instruction handbook b maXX 5000 Document No.: 5.09021.16 of 328...

  • Page 40: Bm533X-F Dimensions

    Dimensions BM533X-F Figure 14: BM533X-F dimensions *: Observe minimum clearance. Please follow the notes for mounting and ZCooling– on page 56. Instruction handbook b maXX 5000 Document No.: 5.09021.16 Baumüller Nürnberg GmbH of 328...

  • Page 41: Bm537X-S Dimensions

    Technical data BM537X-S Figure 15: BM537X-S dimensions *: Observe minimum clearance. Please follow the notes for mounting and ZCooling– on page 56. Instruction handbook b maXX 5000 Document No.: 5.09021.16 of 328...

  • Page 42: Bm537X-F Dimensions

    Dimensions BM537X-F Figure 16: BM537X-F dimensions *: Observe minimum clearance. Please follow the notes for mounting and ZCooling– on page 56. Instruction handbook b maXX 5000 Document No.: 5.09021.16 Baumüller Nürnberg GmbH of 328...

  • Page 43: Weight

    Technical data Weight Device Weight, with controller BM503X Approx. 6 kg BM504X Approx. 7 kg BM517X S Approx. 12.5 kg BM517X C Approx. 10.0 kg BM519X Approx. 25.0 kg BM532X Approx. 5.5 kg BM533X Approx. 6.5 kg BM533X F BM537X Approx.

  • Page 44: Operating Conditions

    Operating conditions Operating conditions 3.3.1 Requirements for power supply / mains supply system Power supply mains BM50XX - XTXX / - XRXX Industrial system, with direct or low BM51XX - XTXX / - XRXX impedance grounded neutral point (TN system or TT system) BM50XX - XIXX / - XSXX Industrial system with not grounded or with...

  • Page 45: Requirements For Control Voltage / 24 V Power Supply

    Technical data In case of power supply failure ((0.9 - 0) x U for t > 0.1 s), the error „Power unit not ready-to-operate“ is generated. The rated voltage is 400 V. At an power supply voltage of less than 400 V the output power of the device is reduced, refer to correction values at changed operation conditions ZCorrection values input voltage–...

  • Page 46: Requirements For The Motor

    Operating conditions 3.3.3 Requirements for the motor The b maXX 5000 is designed to operate three phase current motors with a motor termi- nal voltage of 3 x 350 V (typical for servo motors from Baumüller) or 3 x 400 V (typical for standard asynchronous motors and for customer-specific special motors from Baumüller).

  • Page 47: Required Environmental Conditions

    Technical data 3.3.4 Required environmental conditions Transport temperature range - 25 °C to + 70 °C Transport climate class (K) 2 K 3 EN 60721-3-2 Storage temperature range - 25 °C to + 55 °C Storage climate class 1 K 4 EN 60721-3-1 Operating environment BM50XX...

  • Page 48: Correction Values At Changed Operating Conditions

    Operating conditions 3.3.5 Correction values at changed operating conditions The correction values of the permitted output power and output current must be multi- plied, if the devices b maXX 5000 are used at operation conditions with different correc- tion values. The following correction values are to be considered if nothing other is specified at the „Electrical data“...

  • Page 49: Correction Values For The Output Current Of The Mains Inverter Bm50Xx, Bm51Xx

    Technical data 3.3.5.1 Correction values for the output current of the mains inverter BM50XX, BM51XX Installation  If the devices BM50XX, BM51XX are operated above an absolute altitude of 1000 m, altitude then the permitted output current I (adjusted output rated current) must be re- permitted duced against the output rated current (see ZElectrical data BM50XX;...

  • Page 50: Correction Values For The Output Current Of The Axis Units Bm53Xx

    Operating conditions 3.3.5.2 Correction values for the output current of the axis units BM53XX Correction value operating temperature Air-cooled Water-cooled/Cold plate Operating temperature T Figure 19: Correction value k in dependence of the temperature T , BM53XX Correction value installation altitude Installation altitude H Figure 20: Correction value k...
  • Page 51 Technical data The permitted output current I (adjusted output rated current) is calculated accord- permitted ing following formula:   permitted rated Output rated current at 40 °C and up to 1000 m, rated refer to ZElectrical data of the BM53XX– as from page 66.

  • Page 52: Correction Values Input Voltage

    Operating conditions 3.3.5.3 Correction values input voltage Above  m Mains rectifier units BM503X, BM504X, BM517X, BM519X rated power  The rated power supply voltage is 3 x 400 V supply voltage The output currents must be reduced accordingly when operating with a power supply voltage higher than 400 V.
  • Page 53 Technical data Below  m Mains rectifier units BM503X, BM504X, BM517X, BM519X rated input  The rated voltage is 3 x 400 V voltage The DC link voltage must be reduced when operating with input voltage lower than 400 V. Power supply voltage Figure 23: Derating: DC link voltage as a function of the power supply voltage...
  • Page 54 Operating conditions Below  m Mains rectifier units BM517X, BM519X rated input  The rated voltage is 3 x 400 V voltage The DC link voltage must be reduced when operating with input voltage lower than 400 V. Power supply voltage Figure 25: Derating: DC link voltage as a function of the power supply voltage 100 %...

  • Page 55: Correction Values Dc Link Voltage

    Technical data 3.3.5.4 Correction values DC link voltage With the permissible continuous DC link power, the power supply current, e.g. with a  Mains rectifier  power supply voltage of 480 V , is less by a ratio BM503X,  ...

  • Page 56: Cooling

    Operating conditions 3.3.6 Cooling Cooling air temperature Min. 5 °C to max. 55 °C (rated temperature: 40 °C), refer to correction values temperature Zpage 49– Cooling air requirement Depends on the device, refer to ZElectrical data– as from page 58 Coolant temperature Min.
  • Page 57 Technical data Rated flow rate = 10 l/min For other coolant flow rates than the one stated above, please inquire with Baumüller Nürnberg GmbH.  The coolant must meet the following requirements: pH value 6.5 ... 9.5 Manganese (Mn) < 0.05 ppm Conductivity 50 ...

  • Page 58: Electrical Data

    Electrical data Electrical data 3.4.1 Electrical data BM50XX; BM51XX m BM5030 mains rectifier unit without safety function BM5030 BM5030 -XT0X-.. /-XI0X-.. / -XG0X-.. -XR0X-.. /-XS0X-.. / -XW0X-.. without charge resistor with charge resistor Input rated power 6 kVA 6.9 kVA 1) 2) 3) Input rated current (I 8.5 A...
  • Page 59 Technical data m BM5030 mains rectifier unit with safety function NOTE! Description of BM5030 with safety function BM5030-XX2X-... refer to ZC.3 Electrical data BM5030 with safety function– as from page 304. m BM503X mains rectifier unit without safety function BM5031 BM5031-A BM5031 BM5031-A...
  • Page 60 Electrical data m BM503X mains rectifier unit without safety function BM5032 BM5032-A -XT0X-.. /-XI0X-.. / -XG0X-.. without charge resistor Input rated power 21 kVA 1) 2) 3) Input rated current (I 31 A Distortion factor of the input current (THD 57 % ±...
  • Page 61 Technical data m BM504X mains rectifier unit without safety function BM5043 BM5043-A BM5043 BM5043-A -XT0X-.. /-XI0X-.. / -XG0X-.. -XR0X-.. /-XS0X-.. / -XW0X-.. without charge resistor with charge resistor Input rated power 45 kVA 61 kVA 1) 2) 3) Input rated current (I 65 A 88 A Distortion factor of the input current (THD...
  • Page 62 Electrical data m BM504X mains rectifier unit without safety function BM5044 BM5044-A -XT0X-.. /-XI0X-.. / -XG0X-.. without charge resistor Input rated power 90 kVA 1) 2) 3) Input rated current (I 130 A Distortion factor of the input current (THD 57 % ±...
  • Page 63 Technical data m BM517X active mains rectifier unit BM5173 BM5174 -XTXX-.. /-XIXX-.. / -XGXX-.. Input rated power 39 kVA 69 kVA 1) 2) 3) Input rated current (I 56 A 100 A  6 % Distortion factor of the input current (THD 1) 2) 3) Input peak current (I 84 A...
  • Page 64 Electrical data m BM519X active mains rectifier unit BM5192-S BM5192-F BM5193-F -XTXX-.. /-XIXX-.. / -XGXX-.. Input rated power 150 kVA 200 kVA 1) 2) 3) Input rated current (I 220 A 290 A  6 % Distortion factor of the input current (THD 1) 2) 3) Input peak current (I 435 A...
  • Page 65 Technical data All rated values are based on an power supply voltage of 400 V/50 Hz, a DC link voltage of 540 V (BM50XX) or 640 V (BM51XX), a control voltage of 24 V and a surrounding temperature of 40 °C. The input current must be reduced between 40 °C and 55 °C, refer to correction values at changed operation conditions, ZCorrection values for the output current of the mains inverter BM50XX, BM51XX–...

  • Page 66: Electrical Data Of The Bm53Xx

    Electrical data 3.4.2 Electrical data of the BM53XX m Double axis unit safety BM5323 BM5323-A BM5325 BM5325-A 1) 9) Input rated power 3.5 kW 5.75 kW 7.0 kW 9.9 kW 60 V - 760 V DC link voltage (U DC link capacitance (internal) 235 µF 250 s DC link discharge time ...
  • Page 67 Technical data BM5331 BM5331-A BM5332 BM5332-A BM5333 BM5333-A 1) 9) Input rated power 13.4 kW 22.4 kW 33.6 kW 60 V - 760 V DC link voltage (U DC link capacitance (internal) 330 µF 660 µF 1175 µF 240 s 480 s 900 s DC link discharge time ...
  • Page 68 Electrical data m Single axis unit safety BM5326 BM5326-A BM5327 BM5327-A Input rated power 6.7 kW 11.2 kW Input rated current (I 10.5 A 17.5 A 60 V - 760 V DC link voltage (U DC link capacitance (internal) 165 µF 330 µF 300 s DC link discharge time ...
  • Page 69 Technical data BM5328 BM5328-A BM5334 BM5334-A Input rated power 16.8 kW 22.4 kW Input rated current (I 26.5 A 35.5 A 60 V - 760 V DC link voltage (U DC link capacitance (internal) 495 µF 660 µF 300 s 480 s DC link discharge time ...
  • Page 70 Electrical data BM5335 BM5335-A BM5335-F Input rated power 33.6 kW Input rated current (I 53 A 60 V - 760 V DC link voltage (U DC link capacitance (internal) 1175 µF 900 s DC link discharge time (internal DC link capacitance) 1) 3) 0 - 500 V Output voltage (U...
  • Page 71 Technical data BM5372-S BM5373-S BM5374-S BM5376-S Input rated power 64 kW 80 kW 95 kW Input rated current (I 100 A 125 A 150 A 60 V - 760 V DC link voltage (U DC link capacitance (internal) 1230 µF 2050 µF 128 s 214 s...
  • Page 72 Electrical data BM5372-F BM5373-F BM5374-F BM5375-F BM5376-F Input rated power 64 kW 80 kW 95 kW Input rated current (I 100 A 125 A 150 A 60 V - 760 V DC link voltage (U DC link capacitance (internal) 1230 µF 2050 µF 128 s 214 s...
  • Page 73 Technical data All rated values are based on an power supply voltage of 400 V/50 Hz, a DC link voltage of 640 V, a control voltage of 24 V and a surrounding temperature of 40 °C and the switching frequency specified. The input current must be reduced between 40 °C and 55 °C, refer to correction values at changed operation conditions, ZCorrection values for the output current of the mains inverter BM50XX, BM51XX–...

  • Page 74: Output Frequency-Dependent Current Derating

    Electrical data 3.4.3 Output frequency-dependent current derating All Baumüller devices have been developed so that the rated output current, as stated, are only continuously permitted (i. e. in S1 operation) with an electrical output frequency of 15 Hz or higher. If the static inverter output frequency is smaller than 15 Hz and the frequency is between 0 and 15 Hz for more than 5 seconds, then the continuously per- missible output current must be reduced according to the following characteristic curve.

  • Page 75: Load Cycle According En61800-6

    Technical data 3.4.4 Load cycle according EN61800-6 Operation with constant load Figure 31: Typical current-time diagram: operation with constant load BM503X BM5031 10 kW (100 % P rated BM5032 18 kW (100 % P rated BM51XX BM5174 S (air-cooled) 100 A (100 % I rated BM5174 C (cold plate) BM53XX...
  • Page 76 Electrical data NOTE! Precondition for the following load cycles: Output frequency  100 Hz! Intermittent load cycle with peak value Figure 32: Typical current-time diagram: intermittent load cycle with peak value This term is valid for possible load cycles:  ...
  • Page 77 Technical data BM53XX with with with I = 200 % I with I = 233 % I with = 150 % I = 166 % I = 300 % I BM5323 10 s 3.3 s (I = 6 A) 1.1 s (I = 9 A) BM5325 10 s...
  • Page 78 Electrical data BM51XX with I = 100 % I with I = 150 % I rated rated BM5174 S (air-cooled) 20 s BM5174 C (cold plate) 0.5 s BM53XX with with with with with with = 60 % I = 300 % I = 200% I = 150% I = 60 % I...

  • Page 79: Proposal For Dimensioning

    Technical data 3.4.5 Proposal for dimensioning Refer to ZAccessories and spare parts– as from page 241 Device Fuse Line filter Power choke Cable CE+UL   2.1 mm² BM5030 NFI-020 = 8.5 A Class J Bussmann DFJ-25 =18 A (AWG14) rated rated (50 °C) = 12.5 A...
  • Page 80 Electrical data Device Fuse Line filter Power choke Cable CE+UL  BM5173 Schaffner filter BL-3-060-000 Class J Bussmann DFJ-100 FN 3120H-80-35 Part No. 388168 (device can be destroyed in case of Part No. 415096 short circuit but CE+UL are assured) CE...

  • Page 81: Design And Operation

    PERATION Design The b maXX 5000 series consists of an (active) mains rectifier unit and one or more axis units, decentralized drive solutions or multi-axis controllers. The possible number of de- vices, that can be connected depends on the connected load of the DC link of the mains rectifier unit or is limited by the signal bus to a maximum of 12.

  • Page 82: Identification Of The Device

    Identification of the device Identification of the device 4.2.1 Part number Figure 34: Part number - front Instruction handbook b maXX 5000 Document No.: 5.09021.16 Baumüller Nürnberg GmbH of 328...

  • Page 83: Type Plate

    Design and Operation 4.2.2 Type plate Examples of the locations where the type plate is affixed are shown in the figure. Among other things, the type plate also shows the type code of the device. Figure 35: Affixing of the type plate Instruction handbook b maXX 5000 Document No.: 5.09021.16 of 328...

  • Page 84: Type Code

    Identification of the device 4.2.3 Type code The type code has the format: BM5XXX - XXXX - XXXX - XXXX - XX - XXXX. The type code is explained in the following table. BM5XXX-XXXX-XXXX-XXXX-XX-XXXX Device generation BM5XXX-XXXX-XXXX-XXXX-XX-XXXX Device design 0: Mains rectifier 1: Active mains rectifier 3: Axis unit safety 5: Basic unit/power module safety...
  • Page 85 Design and Operation BM5XXX-XXXX-XXXX-XXXX-XX-XXXX SAF modules (BM53XX only) / STO function (BM5030 only) 0: No SAF module / no STO function 1: BM5030 with STO function, basic type with feedback outputs 2: BM5030 with STO function, automatic locking function refer to ZAppendix C - BM5030 with Safety Function–...
  • Page 86 Identification of the device BM5XXX-XXXX-XXXX-XXXX-XX-XXXX Add-on module 00: Without module 01: With option module IEE with external supply 03: With option module SIE with internal supply 04: With option module SVP-001-001, 4 analog inputs (for voltage),  4 analog outputs (voltage) 05: With option module SVP-001-002, 4 analog inputs (2 for voltage, ...
  • Page 87 Design and Operation Hardware configuration controller BM5XXX - XXXX - XXXX - XXXX - XX - XXXX - EXX BSCsafe Step 1 V.1 (for single and double axis), with AIO, DIO, encoder, EtherCAT® (RJ45) BSCsafe Step 1 V.2 (for single axis), with AIO, DIO, encoder, EtherCAT®...

  • Page 88: Ul Notes

    UL notes UL notes The notes below must be observed in case you consider UL 508 C. ZRequired environmental conditions– on page 47 n Note the maximum surrounding air temperature. n Use in a pollution degree 2 environment only. ZDesign– on page 81 n Axis units (BM5X23, BM5X26, BM5X27, BM5X28, BM5X31, BM5X32, BM5X33, BM5X34, BM5X35)are allowed to be used only in combination with mains rectifiers...
  • Page 89 Design and Operation ZFuses– as from page 261 n Devices are suitable for use on a circuit capable of delivering not more than 50000 rms symmetrical amperes, 480 Volt maximum, when protected by J Class fuses rated n BM5031/BM5032: branch circuit protection fuse rating: 600 V / max. 60 A n BM5043/BM5044/BM5174...

  • Page 90: Display And Operating Elements

    Display and operating elements Display and operating elements NOTE! Description of BM5030 with safety function BM5030-XX2X-... refer to ZC.4 LED display BM5030 with safety function– as from page 306. 4.4.1 LED display BM5XXX-XX0X-... without safety function LED Mains rectifier unit ready-to-operate green: Power supply and DC link voltage available, internally OK...
  • Page 91 Design and Operation Naming on the Meaning Error Blinking pattern front plate H1 (green) Ready-to-operate no error LED lights up H1 (red) Mains failure power supply failure - automatically restart LED lights up when power supply returns. power supply failure longer than 10 s - restart LED blinking after power supply return has to be acknowl- edged (X1:4).

  • Page 92: Display And Operating Elements Bm51Xx

    Display and operating elements 4.4.2 Display and operating elements BM51XX Service interface 7 segment display refer to Z7-segment display BM51XX– on page 93  LED H11 - H14 Meaning: refer to ZLED display BM51XX– on page 94.  Address switch S1 - S4 Setting: refer to ZSetting the IP address with address...

  • Page 93: 7-Segment Display Bm51Xx

    Design and Operation 4.4.2.1 7-segment display BM51XX Refer to parameter manual for detailed description of drive states and state transitions. 0: Low, 1: High State  Display Meaning drive manager NOT READY TO SWITCH ON Device message „Not ready for switching power on“ SWITCH-ON INHIBIT Device disabled READY TO SWITCH ON...

  • Page 94: Led Display Bm51Xx

    Display and operating elements 4.4.2.2 LED display BM51XX Naming on the Internal identification Meaning front plate Power direction 1.1 green, H11 green: supply power 1.1 red H11 red: regenerative braking Power on / pulse enable 24 V available 1.2 green, H12 green: power ON 1.2 red H12 red...

  • Page 95: Display And Operating Elements Bm53Xx

    Design and Operation 4.4.3 Display and operating elements BM53XX Service interface H1 7 segment display axis 1 7 segment display axis 2 (double axis unit) Display controller state Meaning refer to: Z7-segment display controller– on page 96  LED H11 - H14 LED axis 1...

  • Page 96: 7-Segment Display Controller

    Display and operating elements 4.4.3.1 7-segment display controller Refer to parameter manual for detailed description of drive states and state transitions. 0: Low, 1: High State  Display Meaning drive manager NOT READY TO SWITCH ON Drive message „Not ready for switching power on“ SWITCH-ON INHIBIT Inhibit voltage, e.g.

  • Page 97: Led Display Controller

    Design and Operation 4.4.3.2 LED display controller Naming on the Internal identification Meaning front plate 1.1 green, Axis 1: Torque direction 1.1 red H11 green: Positive torque direction H11 red: Negative torque direction 1.2 green, Axis 1: Power on / pulse enable 24 V available 1.2 red H12 green: Power ON H12 red:...

  • Page 98: Led Display Fieldbus

    Display and operating elements 4.4.4 LED display fieldbus ® LED EtherCAT Type code BM5XXX-XXXX-XXXX-01XX BM5XXX-XXXX-XXXX-07XX Naming on the  Meaning Blinking pattern front plate H31 (green) X3 Link / Act Off: No connection Connection Blinking: Data transfer H32 (yellow) ERROR ERROR (receiver error Phy1/Phy2) H41 (green) X4 Link / Act...
  • Page 99 Design and Operation Type code ® POWERLINK BM5XXX-XXXX-XXXX-04XX Naming on the  Meaning Blinking pattern front plate H31 (green) X3 Link / Act Off: No connection Connection Blinking: Data transfer H32 (yellow) ERROR Off: NMT_CT3, NMT_CT7, NMT_GT2 NMT_CT11, NMT_GT6 Blinking: Configuration error (e.g.

  • Page 100: Setting The Ip Address With Address Switches

    Display and operating elements 4.4.5 Setting the IP address with address switches ® EtherCAT CoE BM5XXX-XXXX-XXXX-01XX ® EtherCAT BM5XXX-XXXX-XXXX-07XX VARAN BM5XXX-XXXX-XXXX-02XX ® POWERLINK BM5XXX-XXXX-XXXX-04XX IP-Address  The IP address of the controller consists of 32 bits or 4 bytes (e.g. 192.168.125.203). S1 to S4 ®...
  • Page 101 Design and Operation Instruction handbook b maXX 5000 Document No.: 5.09021.16 of 328...
  • Page 102 Display and operating elements ® ® Figure 39: Address switch setting EtherCAT , POWERLINK , VARAN Instruction handbook b maXX 5000 Document No.: 5.09021.16 Baumüller Nürnberg GmbH of 328...
  • Page 103 Design and Operation ® CANopen BM5XXX-XXXX-XXXX-03XX NOTE! Switch up = 0001 Baud rate S2 20 kBit/s 125 kBit/s, default setting switch 250 kBit/s 500 kBit/s 1 MBit/s Instruction handbook b maXX 5000 Document No.: 5.09021.16 of 328...
  • Page 104 Display and operating elements Address S3/S4 ® Figure 40: Address setting CANopen Instruction handbook b maXX 5000 Document No.: 5.09021.16 Baumüller Nürnberg GmbH of 328...

  • Page 105: Transport And Packaging

    RANSPORT AND ACKAGING Safety notes for transport NOTICE! Damage due to unauthorized transport! Transport handled by untrained personnel can lead to a substantial amount of mate- rial damage. Therefore: m The unloading of the packages upon delivery as well as the in-house transport should only be done by trained personnel.

  • Page 106: Transport Inspection

    Transport inspection Transport inspection Upon receiving the delivered goods, immediately examine them for completeness and transport damage. If there is outwardly visible transport damage, proceed as follows: m Do not accept the delivery or conditionally accept it with reservations. m Note the extent of the damage on the transport documents or on the delivery note of the transport agent.

  • Page 107: Mounting

    OUNTING The device is intended for mounting in a control cabinet. Mounting comprises the following steps: 1 Mounting preparation  (for drilling holes/cutting out sections, see ZDrilling pattern– as from page 111)  only with active mains rectifier to operate within C2 surrounding, for drilling holes of toroidal cores, see ZDrilling pattern toroidal cores–...
  • Page 108 Safety notes WARNING! Danger as a result of faulty mounting! The mounting requires qualified personnel with adequate experience. Faulty mount- ing can lead to life-threatening situations or substantial material damage. Therefore: m Only allow mounting to be performed by employees of the manufacturer or by oth- er qualified personnel.
  • Page 109 Mounting CAUTION! Danger due to sharp edges. If the device is lifted with unprotected hands during mounting, palms or fingers can be cut. If the device falls, feet could be injured. Figure 41: Danger area near the mechanical mounting Therefore: m Ensure that only qualified personnel, who are familiar with the safety notes and as- sembly instructions, mount this device.

  • Page 110: Preparing For Mounting

    Preparing for mounting Preparing for mounting Based on the planning documents and the drilling patterns (see ZDrilling pattern– from page 111), the cutout sections and the positions of the attachment drill holes can be determined. NOTICE! Property damage due to conductive contamination. Therefore: m When performing installation work of any kind, it must be ensured that no foreign material (e.g.

  • Page 111: Drilling Pattern

    Mounting 6.2.1 Drilling pattern Use the drilling pattern to make the necessary drill holes/cutout sections. NOTE! Consider the minimum clearances for cooling when making the drill holes. All dimensions in millimeters [mm]. Further notes see ZDimensions– as from page 29 and ZCooling–...

  • Page 112: Mechanical Data Of The Mounting Plate For Cold Plate

    Preparing for mounting For all  versions: *: Relative tolerance of discretionary divisions: ±0.1 mm Figure 43: Drilling pattern without mounting rail for all versions 6.2.2 Mechanical data of the mounting plate for cold plate The cooling version cold plate is a particular efficient cooling alternative. The heat dissi- pation is done via 2 contact surfaces.

  • Page 113: Mounting Instructions

    Mounting NOTICE! Property damage due to overheating. Scratches and burrs can inhibit the heat dissipation of cold plate devices. Therefore m When mounting cold plate devices, ensure that the surface quality of the mounting plate meets the specifications and ensure that the device’s rear panel/mounting plate does not have any scratches or burrs.

  • Page 114: Mounting With Mounting Rail

    Mounting instructions 6.3.1 Mounting with mounting rail After attaching the mounting rail, push the device from below beneath the upper fastening bolts (1). Then, tilt the device on the mounting plate (2) and slide onto the mounting rail (3). Finally, tighten the upper fastening and grounding bolts (4). Figure 44: Mounting instructions for the BM51XX and BM53XX, with mounting rail Device...

  • Page 115: Mounting Without Mounting Rail

    Mounting 6.3.2 Mounting without mounting rail Push the device from below beneath the upper fastening bolts (1). Then, tilt the device on the mounting plate (2) and slide into the fastening bolts (3). Finally, tighten all fastening and grounding bolts (4). Image 45: Mounting instructions for the BM51XX and BM53XX, without mounting rail Device...

  • Page 116: Mounting Of The Dc Link Bar

    Mounting instructions 6.3.3 Mounting of the DC link bar Observe the following items when mounting the DC link bar: m Position of the chamber-bevel (detail Y)on bottom Position of the screw thread (detail Z) on top.  The correctly mounting of the distance bushings makes it easier to disassemble the unit in case of service and ensures the captivity of the distance bushings.

  • Page 117: Demounting

    Mounting m DC link bar Observe the correct mounting of the DC link bar. There should no mechanical stress affect to the drill hole. WRONG CORRECT Figure 48: Mounting of the DC link bar NOTE! The DC link bar must not overlap the first or last fixing bolt of the rack system. Cut the DC link bar therefore.

  • Page 118: Special Dc Link Connection Bm519X, Bm537X

    Mounting instructions 6.3.5 Special DC link connection BM519X, BM537X NOTE! The DC link connection is connected within the device if using devices BM519X and BM537X only. BM519X and BM537X devices can be connected with short DC link bars for easier demounting.

  • Page 119: Mounting Of Toroidal Cores

    Mounting Mounting of toroidal cores The use of toroidal cores, see ZToroidal cores– on page 287 is necessary to ensure the operation of the active mains rectifier BM51XX within a C2 surrounding. 6.4.1 Drilling pattern toroidal cores Use the drilling pattern for drilling the necessary holes. *: With toroidal cores Figure 50: Dimensions/drilling pattern toroidal cores...

  • Page 120: Mounting The Toroidal Cores

    Mounting of toroidal cores 6.4.2 Mounting the toroidal cores Carry out mounting as follows: 1 Keep suitable fastening components readily available. 2 Mount the toroidal cores 3 Lay the mains cable through the toroidal cores, see ZInstallation procedure– as from page 141.

  • Page 121: Connecting The Water Cooler

    Mounting 6.4.3 Connecting the water cooler With water cooled devices (BM53XX-F) you should connect the coolant circulation before electric installation. The water cooler has on its bottom side two pressfitting-transition pieces 12 mm x R 1/2‘‘ AG for flat seals. h Connect the cooling circulation to the water cooler: Tube material Outer tube-...
  • Page 122 Mounting of toroidal cores Instruction handbook b maXX 5000 Document No.: 5.09021.16 Baumüller Nürnberg GmbH of 328...

  • Page 123: Installation

    NSTALLATION This chapter describes the electrical installation of the device. The mechanical mounting is described in ZMounting– as from page 107. Initial commissioning is described in the parameter manual 5.09022 in the chapter Com- missioning. Prior to installation, ensure that the technical prerequisites have been fulfilled: Check the demands on the electrical mains.
  • Page 124 Safety notes WARNING! Danger due to faulty installation and initial commissioning! Installation and initial commissioning require qualified personnel with adequate expe- rience. Faulty installation can lead to life-threatening situations or substantial material damage. Therefore: m Only allow installation and initial commissioning to be performed by employees of the manufacturer or by other qualified personnel.

  • Page 125: Voltage Test

    Installation Danger from  residual energy DANGER! Risk of fatal injury from electrical current! Stored electric charge. Discharge time of the modular system = discharge time of the device with the longest DC link discharge time in the modular system. Refer to ZElectrical data–...

  • Page 126: Demands On The Electrical Mains

    Demands on the electrical mains Demands on the electrical mains For all important data, see ZRequirements for power supply / mains supply system– from page 44. Minor deviations from requirements in the electrical mains can lead to malfunctioning of the device. If the mains supply deviates too much from the requirements, the device can be destroyed.

  • Page 127: Connection Notes: It-System Or Grounded Phase Conductor System With Bm50Xx

    Installation 7.3.1 Connection notes: IT-system or grounded phase conductor system with BM50XX h The shown wire bridge W100 must be removed when operating on an IT-system or grounded phase conductor system (Grounded Delta) Correct False Figure 53: Connection to an IT-system or Grounded Delta system NOTICE! The removed wire bridge must not fall into the device.

  • Page 128: Requirements For The Connection Cables

    Requirements for the connection cables An operation on an IT-system or grounded phase conductor system (Grounded Delta) at installation altitudes > 2000 m is only possible with an isolating transformer. Figure 54: Connecting to IT-system or grounded phase conductor system with isolating transformer Requirements for the connection cables h Take into account IEC/EN 60204-1, chapter 13 when selecting the cable.

  • Page 129: Pe Connection And Rcd Compatibility

    Installation PE connection and RCD compatibility Depending on the functional principle, leakage current >3.5 mA or >10 mA can flow through the protective ground conductor. Consequently, a stationary ground conductor connection in accordance with EN 61800-5-1 is required. DANGER! Risk of fatal injury from electrical current! This product can cause direct and/or alternating current in the protective ground con- ductor.

  • Page 130: Grounding Concept Of The Side-By-Side Mounted System

    Grounding concept of the side-by-side mounted system Grounding concept of the side-by-side mounted system m Grounding concept, each device connected with PE Power supply PE bar Figure 55: Grounding concept, each device with PE connection 1 (Active) mains rectifier unit: screw terminals for mains connection and PE 2 Single axis unit 75 mm: screw terminals PE, screw terminals motor 3 Single axis unit 50 mm: screw terminals PE, motor connector (1 x 3 pin) 4 Double axis unit 50 mm: screw terminals PE, motor connector (2 x 3 pin)
  • Page 131 Installation m Grounding concept, PE-connection from device to device, cooling type S Power supply PE bar Figure 56: Grounding concept, PE connection from device to device 1 (Active) mains rectifier unit 2 Single axis unit 75 mm 3 Single axis unit 50 mm 4 Double axis unit 50 mm 5 Double axis unit 75 mm 6 Mounting plate, thickness at least 3 mm...

  • Page 132: Installation Requirements With Regard To Emc

    Installation requirements with regard to EMC Installation requirements with regard to EMC NOTE! The emission of radio frequency interference (RFI) is to a great extent dependent on the wiring, spatial expansiveness and the arrangement of the components in the sys- tem.

  • Page 133: Shielding Plan Side-By-Side Mounted System

    Installation Shielding plan side-by-side mounted system The shielding of the motor cable as well as of the motor temperature cable must be con- nected electrically with the mounting plate or with shield sheet (see ZShielding connec- tion with shield sheet– on page 134).

  • Page 134: Shielding Connection With Shield Sheet

    Shielding plan side-by-side mounted system 7.9.2 Shielding connection with shield sheet 7.9.2.1 Mounting shield sheet Refer to ZAccessories kit shielding– as from page 286. Air-cooled/ water-cooled  devices Figure 57: Mounting shield sheet air-cooled devices Cold plate  devices Figure 58: Mounting shield sheet cold plate devices Instruction handbook b maXX 5000 Document No.: 5.09021.16...

  • Page 135: Connecting The Shield

    Installation 7.9.2.2 Connecting the shield It is recommended to connect the shielding according following figure, see also ZAcces- sories kit shielding– as from page 286. prepare motor cable according figure 2 remove the motor temperature cable’s shield from the cable 3 wrap motor temperature cable around motor cable at least 1 turn, form no loop.
  • Page 136 Shielding plan side-by-side mounted system 4 from below wrap conductive metallic adhesive tape around Motor temperature cable conductive metallic adhesive tape Motor cable Figure 60: Tape shield motor temperature cable around NOTE! The shielding of the motor temperature cable and the shielding of the motor cable is wrapped together with a conductive metallic adhesive tape.
  • Page 137 Installation 5 connect both shielding with shield clamp on the shield sheet, note locking torque of the fixing screw! NOTE! The shield must be connected to the mounting plate with a metallic clamp, if the op- tional shield sheet is not used! Motor temperature cable Shield sheet...

  • Page 138: Avoid Bearing Currents

    7.10 Avoid bearing currents Locking torque of the fixing screw: Device Locking torque Single axis unit BM5326, BM5327, BM5328 0.8 Nm cable diameter 5 - 20 mm shielding clamp width 24 mm Double axis unit BM5323, BM5325 0.8 Nm cable diameter 3 - 14 mm shielding clamp width 17 mm Single axis unit BM5334, BM5335,...
  • Page 139 Installation Avoiding bearing m Basically the grounding system must be installed appropriately to ensure a forced re- damage turn of the common mode current. m The cause of bearing current damage, that means the amplitude and slope of the com- mon mode voltage is reduced by using toroidal cores....

  • Page 140: Requirements For The Motor Temperature Sensors

    7.11 Requirements for the motor temperature sensors Installation of toroidal cores h The three phases without shielding and without PE must be lead through the cores. The cores must be installed and attached near the motor connection of the 5000. h When using toroidal cores it is further recommended to use current isolated bearings on the nondrive end for synchronous/asynchronous main drives sizes 180 and higher.

  • Page 141: Installation Procedure

    Installation 7.12 Installation procedure DANGER! Risk of fatal injury from electrical current! Electrically live parts are life-threatening. Therefore: m Make certain that the parts to be mounted (e.g. mains cables) and the mounting areas are de-energized for the entire duration of mounting the device. h Route all cables in an EMC-compatible manner.

  • Page 142: Instruction Handbook B Maxx

    7.12 Installation procedure 11 Connect encoders (see ZFront side axis units BM53XX– as from page 175). NOTE! Plugging in and pulling out encoder cables while they are energized is prohibited, and could lead to their destruction. Therefore, always first switch off the 24 V supply voltage and lock the plug connectors in place.

  • Page 143: Connection Diagrams

    Installation 7.13 Connection diagrams The connection diagrams are separated in connection diagrams for the electrical mains, motor etc., Zpage 145– and the front side connections Zpage 171–. NOTE! The identifiers 1C1 and 1D1 were taken over from DIN EN 60445. 1C1 is the connec- tion to the positive DC link cable/bar, and in the past was identified by Baumüller in some devices as ZK+.
  • Page 144 7.13 Connection diagrams BM50XX-XX01 Normally closed contact expected on the inhibit input. External brake resistor NOTICE: Connection for external brake resistor, only. Do not connect an additional capacitance. Figure 65: Connection diagram for the BM50XX-XX01 without safety function NOTE! The use of a power choke (L1) is mandatory for the function of the mains rectifier unit. An operation without power choke is not allowed.

  • Page 145: Connection Diagram For The Bm51Xx Active Mains Rectifier Unit

    Installation 7.13.2 Connection diagram for the BM51XX active mains rectifier unit Image 66: Connection diagram for the BM51XX NOTE! The use of a power choke (L1) is mandatory for the function of the active mains rec- tifier unit. Operation without power choke is not allowed. The mains cable must be led through a toroidal core to ensure an operation in a C2 environment (see also ZMounting of toroidal cores–...
  • Page 146 7.13 Connection diagrams 1C1, 1D1 Connections for the DC link, see ZFigure 75– on page 158. Power supply PE-connection 1U1, 1V1, Power supply connection, see ZFigure 75– on page 158. Fuses (cable + device) Power choke Line filter Main contactor X101 Quick discharge R +, R...

  • Page 147: Connection Proposal Bm51Xx

    Installation 7.13.2.1 Connection proposal BM51XX Image 67: Connection proposal BM51XX Instruction handbook b maXX 5000 Document No.: 5.09021.16 of 328...

  • Page 148: Connection Proposal Bm51Xx Pulse Enable Control

    7.13 Connection diagrams 7.13.2.2 Connection proposal BM51XX pulse enable control Figure 68: Connection proposal BM51XX pulse enable control NOTE! The user must enable pulses intentionally, to recharge and enable the active mains unit after an error or after quick discharge, when using this connection proposal. Instruction handbook b maXX 5000 Document No.: 5.09021.16 Baumüller Nürnberg GmbH...

  • Page 149: Timing Diagram For Switching On Bm51Xx

    Installation 7.13.2.3 Timing diagram for switching on BM51XX Power supply 24V < 10 s (boot the device) Ready for mains contactor ON Output signal Mains contactor ON < 25 s (offset (10 s), rotating field (5 s) and synchronisation with mains (10 s)) Ready for pulse-enable Output signal Pulse enable ON...

  • Page 150: Connection Diagram Single Axis Unit

    7.13 Connection diagrams 7.13.3 Connection diagram single axis unit 7.13.3.1 Connection diagram BM5326, BM5327, BM5328 Depends on type Ready-to-operate Ready-to-operate Digital output 1 Digital output 2 Digital output 3 Digital output 4 Depends on type n.c. n.c. +24V M24V Digital input 1 Digital input 2 Digital input 3 Digital input 4...

  • Page 151: Connection Diagram Bm5334, Bm5335

    Installation 7.13.3.2 Connection diagram BM5334, BM5335 Depends on type Ready-to-operate Ready-to-operate Digital output 1 Digital output 2 Digital output 3 Digital output 4 Depends on type n.c. n.c. +24V M24V Digital input 1 Digital input 2 Digital input 3 Digital input 4 Digital input 5 Digital input 6 Digital input 7...

  • Page 152: Connection Diagram Bm537X

    7.13 Connection diagrams 7.13.3.3 Connection diagram BM537X Depends on type Ready-to-operate Ready-to-operate Digital output 1 Digital output 2 Digital output 3 Digital output 4 Depends on type n.c. n.c. +24V M24V Digital input 1 Digital input 2 Digital input 3 Digital input 4 Digital input 5 Digital input 6...
  • Page 153 Installation 1C1, 1D1 Connections for the DC link, see ZFigure 77– on page 160. Connections for pulse enable, etc. see ZX2 Digital inputs/outputs– on page 177 Encoder evaluation X107 Motor connection BM5326, BM5327, BM5328, see ZFigure 77– on page 160 1U2, 1V2, 1W2 Connections for the motor BM5334, BM5335, see ZFigure 78–...

  • Page 154: Connection Diagram For The Double Axis Unit

    7.13 Connection diagrams 7.13.4 Connection diagram for the double axis unit 7.13.4.1 Connection diagram BM5323, BM5325 Depends on type Ready-to-operate 1 Ready-to-operate 1 Digital output 1 Digital output 2 Digital output 3 Digital output 4 Depends on type Ready-to-operate 2 Ready-to-operate 2 +24V M24V...

  • Page 155: Connection Diagram Bm5331, Bm5332, Bm5333

    Installation 7.13.4.2 Connection diagram BM5331, BM5332, BM5333 Depends on type Ready-to-operate 1 Ready-to-operate 1 Digital output 1 Digital output 2 Digital output 3 Digital output 4 Depends on type Ready-to-operate 2 Ready-to-operate 2 +24V M24V Digital input 1 Digital input 2 Digital input 3 Digital input 4 Digital input 5...
  • Page 156 7.13 Connection diagrams 1C1, 1D1 Connections for the DC link, see ZFigure 81– on page 164. Connections for pulse enable, etc. see ZX2 Digital inputs/outputs– on page 177 Encoder evaluation 1 Encoder evaluation 2 X107 BM5323, BM5325 Motor connection 1 BM5331, BM5332, BM5333...

  • Page 157: Electrical Connections

    Installation 7.14 Electrical connections NOTE! Description of BM5030 with safety function BM5030-XX2X-... ZC.6 Electrical connections BM5030 with safety function– as from page 310. 7.14.1 Electrical connections of the BM50XX-XX0X-... without safety function Error NOTICE: Connection for external brake resistor, only. Do not connect an additional capacitance.

  • Page 158: Electrical Connections Of The Bm51Xx

    7.14 Electrical connections 7.14.2 Electrical connections of the BM51XX Figure 75: Electrical connections of the BM517X Instruction handbook b maXX 5000 Document No.: 5.09021.16 Baumüller Nürnberg GmbH of 328...

  • Page 159: Bm519X Connections

    Installation 7.14.3 BM519X connections DC link Signal Quick discharge Power supply Figure 76: Electrical connections of the BM519X Instruction handbook b maXX 5000 Document No.: 5.09021.16 of 328...

  • Page 160: Electrical Connections Of The Single Axis Bm5326, Bm5327, Bm5328

    7.14 Electrical connections 7.14.4 Electrical connections of the single axis BM5326, BM5327, BM5328 Figure 77: Electrical connections of the single axis BM5326, BM5327, BM5328 Instruction handbook b maXX 5000 Document No.: 5.09021.16 Baumüller Nürnberg GmbH of 328...

  • Page 161: Electrical Connections Of The Single Axis Bm5334, Bm5335

    Installation 7.14.5 Electrical connections of the single axis BM5334, BM5335 Figure 78: Electrical connections of the single axis BM5334, BM5335 Instruction handbook b maXX 5000 Document No.: 5.09021.16 of 328...

  • Page 162: Electrical Connections Of The Single Axis Bm537X

    7.14 Electrical connections 7.14.6 Electrical connections of the single axis BM537X Figure 79: Electrical connections of the single axis BM537X Instruction handbook b maXX 5000 Document No.: 5.09021.16 Baumüller Nürnberg GmbH of 328...
  • Page 163 Installation Connection motor/PE bolt BM537X Connection 1 x 50 mm² Connection 2 x 16 mm² Spacer Washer Washer Cable lug Cable lug 1 x 50 mm² 2 x 16 mm² Figure 80: Connection motor/PE bolt BM537X Instruction handbook b maXX 5000 Document No.: 5.09021.16 of 328...

  • Page 164: Electrical Connections Of The Double Axis Bm5323, Bm5325

    7.14 Electrical connections 7.14.7 Electrical connections of the double axis BM5323, BM5325 Figure 81: Electrical connections of the double axis BM5323, BM5325 Instruction handbook b maXX 5000 Document No.: 5.09021.16 Baumüller Nürnberg GmbH of 328...

  • Page 165: Electrical Connections Of The Double Axis Bm5331, Bm5332, Bm5333

    Installation 7.14.8 Electrical connections of the double axis BM5331, BM5332, BM5333 Figure 82: Electrical connections of the double axis BM5331, BM5332, BM5333 Instruction handbook b maXX 5000 Document No.: 5.09021.16 of 328...

  • Page 166: Connection Data

    7.14 Electrical connections 7.14.9 Connection data NOTE! Description of BM5030 with safety function BM5030-XX2X-... ZC.6.1 Connection data of BM5030 with safety function– as from page 311. NOTE! To ensure sufficient current load capacity of the connections, adhere to the specified torques! Connection Connection...
  • Page 167 Installation Connection Connection Torque Load capacity cross section method of the connector X101 BM503X- Max. 6 mm² Plug connector, Max. 41A Brake resistor XX0X spring-clamp BM504X Max. 16 mm² Plug connector, Min. 1.7 Nm Max. 76 A threaded connection X101 BM517X Max.
  • Page 168 7.14 Electrical connections Connection cross section Connection Torque Load method capacity Motor PE BM5323 refer to motor cable Cable lug Min. 1.4 Nm BM5325 for M4 Max. 1.8 Nm ZElectrical BM5331 data– BM5332 from page BM5333 BM5326 refer to motor cable Cable lug Min.
  • Page 169 Installation Connection Connection Load capacity cross section method BM5323 X207 Max. 1.0 mm² Plug connector, Max. 2 A Motor temperature BM5325 spring-clamp and brake motor 1 BM5331 connection BM5332 BM5333 BM5326 Max. 4 A BM5327 BM5328 BM5334 BM5335 BM537X Max. 1.5 mm² Max.
  • Page 170 7.14 Electrical connections X300 (SELV/PELV) Connection method Signal bus BM50XX Configured cable BM51XX BM53XX (max. allowable number of axis units: 12) Notes for the laying of the signal bus cable: Figure 83: Laying of the signal bus cable Fix the ribbon cable bracket at the first unit from the left side always on this place. Rib- bon cable leftover as a loop between the ribbon cable bracket and the connector.

  • Page 171: Connections On The Front Side

    Installation 7.15 Connections on the front side 7.15.1 Front side of mains rectifier unit BM50XX-XX0X-... without safety function NOTE! Description of BM5030 with safety function BM5030-XX2X-... ZC.6.2 Connections front side BM5030 with safety function– as from page 313. X1 Digital inputs/outputs 1:M24V 2: Inhibit input 3: Quick discharge DC link voltage...
  • Page 172 7.15 Connections on the front side Pin assignment X1 Pin No. Assignment dig. input/output GND 24 V digital input Inhibit input BM50XX-XX00 BM50XX-XX01 input is high active, input is low active, expects NO contact expects NC contact Quick discharge of  digital input DC link voltage digital input...

  • Page 173: Front Side Of Active Mains Rectifier Bm51Xx

    Installation 7.15.2 Front side of active mains rectifier BM51XX X1: Service interface NOTE! Only the service cable BM5-K-USB-XXX is allowed to be used for the service interface X1, refer to ZService interface– on page 205. X2 Digital inputs/outputs *) 1 11 1:see Zpage 174–...
  • Page 174 7.15 Connections on the front side X2 Digital inputs/outputs Assessment Signal edge, programmable Input current of each input 2 mA digital input, 20 mA fast digital input Input propagation delay Max. 4 ms Max. 10 µs for fast inputs Level Low (0 ...

  • Page 175: Front Side Axis Units Bm53Xx

    Installation 7.15.3 Front side axis units BM53XX Type code:  BM53XX-XXXX-XXXX-XX01 or XX06 X1: Service interface NOTE! Only the service cable BM5-K-USB-XXX is allowed to be used for the service interface X1, refer to ZService interface– on page 205 X2 Digital inputs/outputs *) 1 11 1:see Zpage 178–...
  • Page 176 7.15 Connections on the front side Type code: from BM53XX-XXXX-XXXX-XX08 X1: Service interface NOTE! Only the service cable BM5-K-USB-XXX is allowed to be used, see ZService interface– on page 205 X2: Digital inputs/outputs *) 1 11 1:+24V (SELV/PELV) 2 to 3: BB1 On (SELV/PELV) 4 to 7: Digital output (SELV/PELV) 8: M24V (SELV/PELV) 9 to 10: BB2 On (SELV/PELV)
  • Page 177 Installation X2 Digital inputs/outputs Assessment Signal edge, programmable Input current per input 2 mA digital input, 20 mA fast digital input Input delay Max. 4 ms Max. 10 µs for fast inputs Level Low (0 ... 5 V) High (12 … 28 V) Output current per output 500 mA Galvanic separation...
  • Page 178 7.15 Connections on the front side Pin assignment X2 Pin Nr. BM53XX BM53XX Single axis Double axis N.C. +24 V (supply digital IN/OUT) Ready-to-operate Ready-to-operate 1, axis 1 Ready-to-operate Ready-to-operate 1, axis 1 Digital output 1 Digital output 2 Digital output 3 Digital output 4 N.C.
  • Page 179 Installation X3 / X4 - fieldbus connection ® ® EtherCAT Type code b maXX 5000 with EtherCAT CoE profile: BM5XXX-XXXX-XXXX-01XX ® Type code b maXX 5000 with EtherCAT SoE profile: BM5XXX-XXXX-XXXX-07XX ® X3 EtherCAT IN ® EtherCAT Number of bus connections 1 IN / 1 OUT Bus connection RJ 45...
  • Page 180 7.15 Connections on the front side VARAN Type code b maXX 5000 with VARAN profile: BM5XXX-XXXX-XXXX-02XX X3 VARAN IN VARAN OUT Number of bus connections 1 IN / 1 OUT Bus connection RJ 45 Number of parameters refer to parameter handbook b maXX 5000 Data size of parameters 16 / 32 Bit Baud rates...
  • Page 181 Installation ® ® CANopen Type code b maXX 5000 with CANopen BM5XXX-XXXX-XXXX-03XX ® X3 CANopen IN ® CANopen 4 kByte DP-RAM, 256 kByte RAM,  Memory 1 MByte Flash-EEPROM Number of bus connections 2, no slot rules Bus connection 2 connectors RJ45, 8-pin Baud rates 20/125/250/500/1000 kBit/s Address range...
  • Page 182 7.15 Connections on the front side ® ® POWERLINK Type code b maXX 5000 with POWERLINK BM5XXX-XXXX-XXXX-04XX ® X3 POWERLINK IN ® POWERLINK Number of bus connections 1 IN / 1 OUT Bus connection RJ 45 Number of parameters refer to parameter handbook b maXX 5000 Data size of parameters 16 / 32 Bit...
  • Page 183 Installation Add-on module IEE with external supply Incremental encoder emulation, 2 channels, BM53XX-XXXX-XX01 Set values for incremental encoder emulation can be evaluated from following sources: m Position actual values encoder 1 or encoder 2 m Position set values (e. g. internal from positioning) m Fieldbus set value (external set via bus) The generated signal can be used either for synchronization of the following axis or for position evaluation of the axis by the master control.
  • Page 184 7.15 Connections on the front side Add-on module SIE with internal supply SSI encoder emulation, 2 channels, BM53XX-XXXX-XX03 Set values for SSI encoder emulation can be evaluated from following sources: m Position actual values encoder 1 or encoder 2 m Position set values (e. g. internal from positioning) m Fieldbus set value (external set via bus) The generated signal can be used either for synchronization of the following axis or for position evaluation of the axis by the master control.
  • Page 185 Installation Add-on module SVP Module with additional analog/digital inputs/outputs, BM53XX-XXXX-XX04 BM53XX-XXXX-XX05 BM53XX-XXXX-XX06 LED display green: 24V available orange: Internal power supply available green: FPGA loaded Figure 86: LED display add-on module SVP Digital inputs/outputs Evaluation: Edges, programmable Input current (per input): 2 mA digital input Time delay input: Max.
  • Page 186 7.15 Connections on the front side Analog inputs Voltage input Current input Resolution 14 bit Type Differential input Approx. 100  Input resistance Approx. 50 k Input current Max. 250 µA Min. (0) 4 A,  Max. 20 mA Input voltage -10 V to +10 V Max.
  • Page 187 Installation Pin assignment front side connectors: 2 x 24V in 2 x GND in Digital out 1 Digital in 1 Digital out 2 Digital in 2 Digital out 3 Digital in 3 Digital out 4 Digital in 4 24V out Analog in 1 + GND out Analog in 1 -...
  • Page 188 7.15 Connections on the front side Connection m Analog input/output Power supply analog and digital Analog input -10 V to +10 V Analog input (0) ... 4 to 20 mA Analog output -10 V to +10 V reference potential BSA Figure 87: Connection of analog inputs/outputs SVP m Digital inputs/outputs...
  • Page 189 Installation X6 Analog inputs/outputs 1: Input 1 + 2: Input 2 + 3: GND 4: Output 1 + 5: Output 2 + 6: Input 1 - 7: Input 2 - 8: Output 1 (GND) 9: Output 2 (GND) Only one encoder can be connected to each encoder connection.
  • Page 190 7.15 Connections on the front side X6 Analog inputs/ There are two analog inputs and outputs available. outputs Pin assignment X6 Pin No. Assignment Analog input 1 + Analog input 2 + Ground Analog output 1 + Analog output 2 + Analog input 1 - Analog input 2 - Analog output 1 -...
  • Page 191 Installation X7 / X8 Encoder evaluation, see ZFigure 89– on page 189 Connector assignment depends on encoder selection. Resolver  All encoders, that comply with the following technical specification, may also be used: evaluation Pole pair number The ratio between the pole pair number of the motor and the pole pair number of the encoder must be an integer.
  • Page 192 7.15 Connections on the front side ® Encoder  The encoder evaluation is provided with a HIPERFACE -interface. evaluation  The encoders, which meet the following technical specifications, can be used: ® HIPERFACE Voltage supply 10 V ® Signal level HIPERFACE - specification of the process data channel (~1 V...
  • Page 193 Installation Encoder evalua- The encoders, which meet the following technical specifications, can be used: tion with  ® EnDat 2.1 or SSI Voltage supply controlled Signal level ~1 V Current input Max. 250 mA GND encoder supply +5 V encoder supply Clock+ A + (COS +) A - (COS -)
  • Page 194 7.15 Connections on the front side Encoder  The encoders, which meet the following technical specifications, can be used: evaluation with ® EnDat Voltage supply controlled Signal level ~1 V Current input Max. 250 mA GND encoder supply +5 V encoder supply Clock+ reserved * reserved *...
  • Page 195 Installation Sine or square The encoders, which meet the following technical specifications, can be used: wave encoder evalua- Voltage supply controlled tion Signal level RS422 (TTL) for square wave incremental encoders ~1 Vss for sine incremental encoders Current input Max. 250 mA GND encoder supply +5 V encoder supply reserved *...
  • Page 196 7.15 Connections on the front side Encoder evalua- The encoders, which meet the following technical specifications, can be used: tion with ® HIPERFACE DSL ® Signal level HIPERFACE DSL Current input Max. 250 mA GND encoder supply 10 V encoder supply reserved * reserved * reserved *...
  • Page 197 Installation Sine incremental Encoders with high-resolution incremental signals (sine and cosine signals, e.g. 2048 sig- encoder with com- nal periods per revolution) and in addition commutation signals (sine and cosine track mutation signals with 1 signal period per revolution), available firmware 1.15 and higher. Voltage supply controlled Signal level...
  • Page 198 7.15 Connections on the front side Motor brake/ Single axis unit BM5326, BM5327, BM5328, BM5334, BM5335 temperature X206/X207/X208 X206 Pin No. Assignment +24V motor brake Supply voltage for  M24V motor brake motor brake +24V motor brake M24V motor brake X207 Pin No.
  • Page 199 Installation Motor brake/ Single axis unit BM537X temperature X206/X207 X206 Pin No. Assignment +24V motor brake Supply voltage for  M24V motor brake motor brake +24V motor brake M24V motor brake X207 Pin No. Assignment Motor brake 1- Motor 1 Response, motor brake 1- motor temperature and...
  • Page 200 7.15 Connections on the front side Motor brake/ Double axis unit BM5323, BM5325, BM5328, BM5331, BM5332, BM5333 temperature X206/X207/X208 X206 Pin No. Assignment +24V motor brake Supply voltage for  M24V motor brake motor brake +24V motor brake M24V motor brake X207 Pin No.
  • Page 201 Installation X300 signal bus If a system is constructed of BM50XX, BM51XX, BM5300 and BM55XX, then all devices are linked with each other via the signal bus. This bus can poll every client device, including the mains rectifier unit, and send individual signals. Via this bus, the mains rectifier unit can register errors to the axes so that the individual axes can react to these.
  • Page 202 7.15 Connections on the front side Instruction handbook b maXX 5000 Document No.: 5.09021.16 Baumüller Nürnberg GmbH of 328...

  • Page 203: Operation

    PERATION Basic information WARNING! Risk of injury due to improper operation! Improper operation can lead to severe personal injury or material damage. Therefore: m Perform all operational steps according to the details of these instruction hand- book. m Before beginning any work, ensure that all coverings and protective devices are installed and are functioning properly.

  • Page 204: Operating Concept

    Operating concept WARNING! Risk of injury due to insufficient qualifications! Inevitably, when operating this electrical device, certain parts of this device are ener- gized with hazardous voltage. Improper handling can lead to significant personal in- jury and material damage. Therefore: m Only qualified personnel may work on this device! Operating concept After the device has been commissioned it is parameterized (i.

  • Page 205: Service Interface

    Operation 8.1.2 Service interface The service interface is used to transmit controller parameter from a PC/laptop to the con- troller with the software ProDrive. The mains rectifier unit BM50XX has no service interface. h connect a not used USB port of the PC/laptop with the controller via the service cable HINWEIS! Only the service cable BM5-K-USB-XXX is allowed to be used for the service inter- face X1, refer to...

  • Page 206: Timing Diagrams Bm50Xx

    Timing diagrams BM50XX Timing diagrams BM50XX HINWEIS! Signals, that do not change its level are not considered. m Quick discharge X1:3 Quick discharge X101 Voltage at 20 ms brake resistor 20 ms X1:6 Ready-to-operate X300:1 Signal bus ready-to-operate 2.6 s DC link was totally discharged 20 ms...
  • Page 207 Operation m Power supply ON after 24 V ON Power supply X200 Supply 24 V X300:2 Signal bus phase failure 300 ms X1:6 Ready-to-operate X300:1 Signal bus ready-to-operate Using a BM5030: T ~ 6 50      Figure 93: Timing diagram power supply ON after 24 V ON m 24 V ON before power supply ON signal bus...
  • Page 208 Timing diagrams BM50XX Short power failure (< 10 s) Power supply t < 10 s X300:2 Signal bus phase failure 300 ms One period of power supply X1:6 Ready-to-operate Depending on the loading 1,2 s bis 3,2 s X300:1 Signal bus ready-to-operate state of the DC link Using a BM5030: 150 ms...
  • Page 209 Operation m Long power failure (> 10 s) Power supply Using a BM50XX-XXX0 t > 10 s X300:2 Phase failure 300 ms One period of power supply X1:6 Ready-to-operate Depending on 1.2 s to 3.2 s X300:1 Signal bus ready-to-operate the loading state of the DC link Usning a BM5030:...
  • Page 210 Timing diagrams BM50XX m Error acknowledge in case of power recovery Power supply Using a BM50XX-XXX1 The power supply was not available more than10 s or another error was generated, but is not active anymore. X1:5 Error 150 ms 1,4 s bis 3 s Depending on the loading X1:6 Ready-to-operate state of the DC link...
  • Page 211 Operation m Inhibit input X1:2 X1:2 Inhibit input at BM50XX-XXX0 > 1 s < 1 s X1:2 Inhibit input at BM50XX-XXX1 > 1 s < 1 s Depending on 1,2 s bis 3,2 s X1:6 Ready-to-operate the loading X300:1 Signal bus ready-to-operate state of the DC link Using a BM5030: 1,2 s <...

  • Page 212: Monitoring

    Monitoring Monitoring 8.3.1 Monitoring BM50XX The controller unit monitors the device during operation. If the controller unit detects a state that deviates from the normal operation condition, the device generates an error message. Error message If the controller unit detects that the device is not working error-free, then this is shown via the LEDs H1 to H4 (see ZDisplay and operating elements–...

  • Page 213: Fieldbus Communication

    Operation Fieldbus communication Depending on the version of b maXX 5000 (see ZType plate– on page 83 and ZType code– as from page 84) different fieldbus systems are provided. ® 8.4.1 EtherCAT ® Type code b maXX 5000 with EtherCAT ®...
  • Page 214 Fieldbus communication ® slave in operation.  Parameters The parameter settings determine the behavior of the EtherCAT Parameters are set with the software ProDrive. 1 Start ProDrive 2 Click on „Project Tree“. 3 Communication settings with ProDrive n Project Tree: Configuration/Fieldbus Slave  (refer also Parameter manual b maXX 5000) m set Synchronization to „On“...

  • Page 215: Varan

    Operation 8.4.2 VARAN. Type code b maXX 5000 with VARAN: BM5XXX-XXXX-XXXX-02XX- A b maXX 5000 with fieldbus option VARAN can communicate with a VARAN master. X3 and X4 on the front side of the device are the RJ45 connections for VARAN (also see ZConnections on the front side–...
  • Page 216 Fieldbus communication n Please, observe an EMC-compatible laying of the Ethernet connection cables! n The following cables were released for use by Baumüller: Ethernet connection cable;  ® ® Further information see ZEtherCAT , VARAN, POWERLINK cable– on page 249. Commissioning.

  • Page 217: Canopen

    Operation ® 8.4.3 CANopen ® Type code b maXX 5000 with CANopen BM5XXX-XXXX-XXXX-03XX- ® The data can be transmitted to all the other CAN-users (e g from CANopen master) via the b maXX 5000. X3 and X4 are the RJ45 connections for CAN bus cables (also see ZConnections on the front side–...
  • Page 218 Fieldbus communication Process of  The test-commissioning is divided into the following sections: commissioning ® 1 Configuration of the CANopen slave ® 2 Testing of the CANopen slave ® Configuring the CANopen slave ® The CANopen is configured at the running device with ProDrive and a NMT-Master. ®...

  • Page 219: Powerlink

    Operation ® 8.4.4 POWERLINK ® Type code b maXX 5000 with POWERLINK BM5XXX-XXXX-XXXX-04XX- ® b maXX 5000 devices can communicate with a POWERLINK Managing Node via the ® fieldbus connection POWERLINK ® X3 and X4 on the front side of the device are the RJ45 connections for POWERLINK (also see ZFront side of active mains rectifier BM51XX–...
  • Page 220 Fieldbus communication Instruction handbook b maXX 5000 Document No.: 5.09021.16 Baumüller Nürnberg GmbH of 328...

  • Page 221: Maintenance

    AINTENANCE Basic information WARNING! Risk of injury due to improperly performed maintenance work! Improper maintenance can lead to severe personal injury and material damage. Therefore: m Before beginning work, make sure that there is enough space for mounting. m Make sure that the mounting area is kept clean and orderly. Parts and tools that are loosely stacked or lying around are a potential accident source.

  • Page 222: Environmental Condition

    Environmental condition Environmental condition If the prescribed environmental conditions are adhered to, then the device is mainte- nance-free. For the prescribed environmental conditions, see ZRequired environmental conditions– on page 47. The most important prescribed environmental conditions are: m Dust-free environmental air m Temperature: Min.
  • Page 223 Maintenance DANGER! Risk of fatal injury from electrical current! Stored electric charge. Discharge time of the rack system = discharge time of the device with the longest DC link discharge time in the rack system. Refer to ZElectrical data– as from page 58. Therefore: m Do not touch before taking into account the discharge time of the capacitors and electrically live parts.
  • Page 224 Inspection intervals - maintenance notes m Mechanical parts Check points Methods and criteria Inspection intervals Daily Semi- Annu- annu- ally ally Are there any abnormal noises or vibrations? Visual and audio check Are there any loose screws? Tighten the screws. Are there any bent or damaged parts? Visual inspection Have there been any color changes due to over-...
  • Page 225 Maintenance m Solenoid switch and relay in the power supply circuit Check points Methods and criteria Inspection intervals Daily Semi- Annu- annu- ally ally Are there any loose screws? Visual and audio check Tighten screws, if necessary. Do the switches function correctly? Visual inspection m Plug connectors in the power supply circuit Check points...

  • Page 226: Repairs

    Repairs Repairs In case of device damage, please inform your sales office or: Baumüller Nürnberg GmbH Ostendstr. 80 - 90  90482 Nuremberg Germany Tel. +49 9 11 54 32 - 0 Fax: +49 9 11 54 32 - 1 30 Mail: mail@baumueller.de...

  • Page 227: Troubleshooting And Fault Correction

    ROUBLESHOOTING AND AULT CORRECTION 10.1 Behavior in case of malfunctions Basic information DANGER! Risk of fatal injury from electrical current! Inevitably, when operating this electrical device, certain parts of it are energized with hazardous voltage. Therefore: m Pay heed to areas on the device that could be dangerous. WARNING! Risk of injury due to improper fault correction! Therefore:...

  • Page 228: Monitoring Functions

    10.2 Monitoring functions 10.2 Monitoring functions Monitoring function Warning/error Power supply voltage Power supply undervoltage Power supply overvoltage Phase monitoring Phase failure Power supply failure Power supply frequency too high  or too low Power supply synchronization lost No mains synchronization possible Ground fault Fault current to ground 6)7)
  • Page 229 Troubleshooting and Fault correction Monitoring function Warning/error Overload monitoring Peak current not possible at this time Heat sink temperature Temperature > threshold 1 Temperature > switch-off threshold Internal temperature  Temperature > threshold 1 of device Temperature > switch-off threshold 6)7) Motor temperature t threshold exceeded...
  • Page 230 10.2 Monitoring functions Monitoring function Warning/error Cyclical specified value Time-out during transmission transmission to the fieldbus 6)7) Blocking monitoring Drive blocked Signal bus Feed-in ready-to-operate Phase failure Brake resistance on Malfunction Signal bus warning X: Implemented Pulses are inhibited after a adjustable time period (not provided for BM51XX). -: Not possible Only if KTY/PT1000 sensors are used Threshold adjustable...

  • Page 231: Monitoring Function - Explanations Bm50Xx

    Troubleshooting and Fault correction 10.2.1 Monitoring function - explanations BM50XX Power supply  This monitoring function checks whether the power supply voltage has a value within the voltage set voltage range (see ZRequirements for power supply / mains supply system– on page 44).

  • Page 232: Monitoring Function - Explanations Bm51Xx

    10.2 Monitoring functions 10.2.2 Monitoring function - explanations BM51XX Power supply  The BM51XX provides 2 settable thresholds to check the power supply voltage. The ac- voltage tive mains rectifier generates a message if the power supply voltage is above/below the set thresholds.
  • Page 233 Troubleshooting and Fault correction Cyclic set value The active mains rectifier is able to exchange cyclic data with the master control. If this transmission to data exchange is not within a defined time period, the device will generate the errors „Ac- the fieldbus tual values are not received in time“...

  • Page 234: Monitoring Function - Explanations Bm53Xx

    10.2 Monitoring functions 10.2.3 Monitoring function - explanations BM53XX Ground fault This monitoring function checks whether there is a short circuit between at least one mo- tor terminal and ground. If a short circuit is detected, pulses are inhibited immediately. Overcurrent This monitoring function checks whether the motor current or the mains current is larger than 1.3 times of the peak output current.
  • Page 235 Troubleshooting and Fault correction Blocking  This monitoring function checks the motor speed and the motor current.  monitoring If the following two conditions are met for at least the „Blocking monitoring time“, then the error message „Drive blocked“ is generated by the controller and the pulses are inhibited immediately.
  • Page 236 10.2 Monitoring functions Signal bus - Brake resistor on This signal activates the brake resistors of several supplying devices simultaneously. Both mains rectifier unit and mono units provide a brake resistor connection and an own monitoring of the DC link voltage. If the DC link voltage exceeds a fixed threshold, the brake resistor is switched on.

  • Page 237: Error Detection

    Troubleshooting and Fault correction 10.3 Error detection 10.3.1 BM50XX error detection The error state is signalized by the lighting up of the red LEDs H1 to H4 on the front side of the housing. The meaning of the individual LEDs is explained in ZDisplay and operating elements–...

  • Page 238: Error Handling

    10.4 Error handling 10.4 Error handling NOTE! The device is shipped with predefined error reactions. With regard to the error mes- sages identified with „depending on the setting“ in the „Reaction“ column, the device's error reaction can be adjusted. Error messages that, due to safety reasons, have an immediate pulse inhibit as a consequence, may not be changed.

  • Page 239: Error Acknowledgment Of Bm51Xx And Bm53Xx

    Troubleshooting and Fault correction 10.4.2 Error acknowledgment of BM51XX and BM53XX If the red error LEDs H14 or H24 light up, at least one error has been detected. All error messages are reset by error acknowledgment. Individual acknowledgment of er- rors is not possible.
  • Page 240 10.4 Error handling Instruction handbook b maXX 5000 Document No.: 5.09021.16 Baumüller Nürnberg GmbH of 328...

  • Page 241: Accessories And Spare Parts

    CCESSORIES AND SPARE PARTS Accessories/spare parts for devices of the b maXX series are listed in this appendix. Product management is happy to handle any queries and suggestions on accessory parts. 11.1 Cabling 11.1.1 Device - mains cabling Device Cross-section Maximum length Connection to device BM503X...

  • Page 242: Cable Device - Motor

    11.1 Cabling 11.1.2 Cable device - motor NOTE The total parasitic cable capacitance wire/shielding of the motor cables within the system must not exceed 30 nF. Additional measurements have to be taken (e.g. the use of DC link filters) in case of cable capacitances higher than 30 nF. 2) 3) Device Cross-section...

  • Page 243: Hybrid Cable Device-Encoder-Motor

    Accessories and spare parts 11.1.3 Hybrid cable device-encoder-motor Selection The trailing cables are suitable for mobile deployment, for example in mobile cable han- dlers. In addition, the cable sheath can be used in environments with acids and bases (e.g. coolant). ®...
  • Page 244 11.1 Cabling ® m Motor cable with HIPERFACE DSL 15 A Connect the cable shielding via the strain relief clamp 400 mm of the connector housing. Data cable shielded Cable length (according order) DSL- blue DSL+ white GN/GE Connect cable shield with the housing of the connector.
  • Page 245 Accessories and spare parts ® m Motor cable with HIPERFACE DSL 20 A Connect the cable shielding 400 mm via the strain relief clamp Data cable shielded of the connector housing. Cable length DSL- blue (according order) DSL+ white GN/GE Connect cable shield with the housing of the connector.
  • Page 246 11.1 Cabling ® m Motor cable with HIPERFACE DSL 21 A Connect the cable shielding via the strain relief clamp 400 mm of the connector housing. Cable length Data cable shielded (according order) DSL- blue DSL+ white GN/GE Connect cable shield with the housing of the connector.
  • Page 247 Accessories and spare parts ® m Motor cable with HIPERFACE DSL 28 A Connect the cable shielding via the strain relief clamp 400 mm of the connector housing. Cable length Data cable shielded (according order) DSL- blue DSL+ white GN/GE Connect cable shield with the housing of the connector.
  • Page 248 11.1 Cabling ® m Motor cable with HIPERFACE DSL 36 A Connect the cable shielding via the strain relief clamp of the connector housing. 400 mm Cable length Data cable shielded (according order) DSL- blue DSL+ white GN/GE Connect cable shield with the housing of the connector.

  • Page 249: Control Voltage Supply/Signal Cable

    Accessories and spare parts 11.1.4 Control voltage supply/signal cable 1.5 mm² Cross-section Maximum length (without digital I/O) User-defined Maximum length with digital I/O 30 m Connection to device Without/with wire end ferrule (clamp terminal) The type of routing is user-defined. The length of the cable has no influence on adherence to the EMC law.

  • Page 250: Accessories - Canopen

    11.1 Cabling ® 11.1.7 Accessories - CANopen ® m CANopen -connection cables: Type Model Length [m] Part No. RJ45-connector,  BM4-CAN-K-31-01 346568 male sub D con- BM4-CAN-K-31-02 on request nector BM4-CAN-K-31-03 346571 BM4-CAN-K-31-05 / 10 5 / 10 on request RJ45-connector, ...

  • Page 251: Encoder Cables

    Accessories and spare parts 11.1.9 Encoder cables Selection of the The trailing cables are suitable for mobile deployment, for example in mobile cable han- encoder cables dlers. In addition, the cable sheath can be used in environments with acids and bases (e.g.
  • Page 252 11.1 Cabling Encoder with Encoder with Encoder with ® ® ® EnDat /SSI EnDat HIPERFACE DSL Part No. Part No. ZHybrid cable device-encoder-motor– ® ® Length speedtec speedtec on page 243 429986 448796 458805 465906 429987 448797 458806 465907 429988 448798 458807 465908...

  • Page 253: Connecting Cable For Resolver

    Accessories and spare parts 11.1.9.1 Connecting cable for Resolver The connecting cable is available as accessory part from Baumüller Nürnberg GmbH. Follow the instructions below if a self-made cable is to be used: 1 Utilize the following materials: m Cable: Li9YC 1x2x0.25-Li9Y 2x2x0,25-Li9Y C11Y 1x2x0.34GN. m High-density D-sub connector: 26-pin, male m Round connector: 12-pin, female (e.g.

  • Page 254: Connecting Cable For Encoder With Hiperface

    11.1 Cabling ® 11.1.9.2 Connecting cable for encoder with HIPERFACE The connecting cable is available as accessory part from Baumüller Nürnberg GmbH. Follow the instructions below if a self-made cable is to be used: 1 Utilize the following materials: m Cable: Li9YC3x2x0.25-Li9Y3x2x0,25-Li9Y C11Y 1x2x0.34GN. Two cable pairs are not needed and also not connected.

  • Page 255: Connecting Cable For Encoder With Endat ® Or Ssi

    Accessories and spare parts ® 11.1.9.3 Connecting cable for encoder with EnDat or SSI The connecting cable is available as accessory part from Baumüller Nürnberg GmbH. Follow the instructions below if a self-made cable is to be used: 1 Utilize the following materials: m Cable: Li9YC3x2x0.25-Li9Y3x2x0,25-Li9Y C11Y 1x2x0.34GN.

  • Page 256: Connecting Cable For Encoder With Endat ® 2.2

    11.1 Cabling ® 11.1.9.4 Connecting cable for encoder with EnDat ® The connecting cable is available as accessory part with M12 or speedtec M23 from Baumüller Nürnberg GmbH. Follow the instructions below if a self-made cable with M12 is to be used: 1 Utilize the following materials: m Cable: 4x0,38 + 1x(4x0,14) m High-density D-sub connector: 26-pin, male...
  • Page 257 Accessories and spare parts ® ® speedtec Follow the instructions below if a self-made cable with speedtec M23 is to be used: 1 Utilize the following materials: m Cable: 4x0,38 + 1x(4x0,14) m High-density D-sub connector: 26-pin, male ® m Round connector: 9-pin speedtec M23, female (Intercontec) 2 Fully adjoin the cable shield with the housing of the round connector and with the shielding of the D-sub connector.

  • Page 258: Connecting Cable For Sine/Square-Wave Incremental Encoder

    11.1 Cabling 11.1.9.5 Connecting cable for sine/square-wave incremental encoder The connecting cable is available as accessory part from Baumüller Nürnberg GmbH. Follow the instructions below if a self-made cable is to be used: 1 Utilize the following materials: m Cable: Li9YC3x2x0.25-Li9Y3x2x0,25-Li9Y C11Y 1x2x0.34GN. Two cable pairs are not needed and also not connected.

  • Page 259: Connection Cable Add-On Modules

    Accessories and spare parts 11.1.10Connection cable add-on modules The connection cable is not offered by Baumüller and must be made by the user: 1 Use the following materials: m Cable: LiYCY 3 x (2 x 0.14 mm²) + 2 x 0,34 mm² Cu braiding. m D-sub connector: 9-pin, female (IEE side) m E.g.
  • Page 260 11.1 Cabling The connection cable is not offered by Baumüller and must be made by the user: 1 Use the following materials: m Cable: LiYCY 2 x (2 x 0.14 mm²) + 1x0.34 mm² Cu braiding. m D-sub connector: 9-pin, female (SIE side) m E.g.

  • Page 261: Fuses

    Accessories and spare parts 11.2 Fuses A distinction is made between protecting the power supply cables and protecting the de- vice. To fulfill CE specifications – here in particular EN 60204-1 – fuse the power supply cables. NOTE! Approved, UL-listed safety fuses must be used in UL-authorized systems, refer to ZUL notes–...

  • Page 262: Bm5030

    11.2 Fuses Protection of the Use semiconductor fuses with the tripping characteristic aR (VDE 0636-201 / DIN EN devices 60269-2-1 / HD 630.2.1 54). In the event of a short circuit, these protect the mains rectifier unit circuit on the input side against complete destruction, in order that it is possible to repair the device.

  • Page 263: Bm5043, Bm5044

    Accessories and spare parts 11.2.3 BM5043, BM5044 m Semiconductor fuses aR (device) BM504X, type NH (for CE only) Bussmann 000 80A/690V: 170M1566 U 100A/690V: 170M1567 U 125A/690V: 170M1568 U 00 80A/1000V: 170M2680 100A/1000V: 170M2681 1 80A/690V: 170M3811 U 100A/690V: 170M3812 U 125A/690V: 170M3813 U 160A/690V: 170M3814 U Class J: DFJ-80 U for BM5043...

  • Page 264: Bm5192, Bm5193

    11.2 Fuses 11.2.5 BM5192, BM5193 n Semiconductor fuses aR (device) BM5192, BM5193, type NH (for CE only) SIBA 1 125A/690V: 2021120.125 Siemens 1 125A/1000V: 3NE3 222 Size Instruction handbook b maXX 5000 Document No.: 5.09021.16 Baumüller Nürnberg GmbH of 328...

  • Page 265: Brake Resistors

    Accessories and spare parts 11.3 Brake resistors The minimum permissible resistance value R depends on the b maXX that min brake resistor is used. DC link+ Brake resistor DC link measurement Brake resistor current evaluation logic Chopper transistor DC link- = DC link voltage threshold for brake resistor on ...
  • Page 266 11.3 Brake resistors The machine cycle of the application determines the further resistor data. = torque of the motor when braking Brake   -- - n M (calculation by means of drive profile) Bake max. Brake Brake  --------------- - Brake rated Brake max.
  • Page 267 Accessories and spare parts Verification of the required data by means of the resistance data sheet h Rated output at 100% ED, e.g. 250 W h Peak output at calculated ED, e.g. 500 W at 40% ED h Verification of the braking time for the brake resistor usage, e.g. 30 s Instruction handbook b maXX 5000 Document No.: 5.09021.16 of 328...

  • Page 268: Fixed Tube Resistors

    11.3 Brake resistors 11.3.1 Fixed tube resistors Protection class: IP 20 Approval: UL Resis- Rated Dimensions Weight Tempera- Electrical Type Part tance output A x B x C ture connection number value switch 145  100 W 121 x 93 x 305 2 kg 210 °C 4 mm²...

  • Page 269: Fixed Frame Resistors

    Accessories and spare parts 11.3.2 Fixed frame resistors Protection class: IP 20 Approval: UL Resis- Rated Dimensions Weight Temperature Electrical Type Part tance output A x B x C switch connection number value 25  2800 W 171 x 430 x 550 10 kg 120 °C 4 mm²...

  • Page 270: Line Filters

    11.4 Line filters 11.4 Line filters Block diagram of filter for mains applications (simplified) Figure 116: Block diagram 11.4.1 Baumüller mains filter type code Figure 117: Line filter type code Instruction handbook b maXX 5000 Document No.: 5.09021.16 Baumüller Nürnberg GmbH of 328...

  • Page 271: Selection Of The Mains Filter

    Accessories and spare parts 11.4.2 Selection of the mains filter IT systems NOTE! EMC limit values are not defined for transient emission in power systems without grounded star point (IT system). A fault state (motor ground fault) can lead to the damage of the mains filter.
  • Page 272 11.4 Line filters Required mains filter surrounding conditions Transport temperature range -30 °C to +70 °C Transport climate class (K) 2 K 3 Storage temperature range -30 °C to +70 °C Storage climate class 1 K 4 Operating environment Outside of residential areas Operating temperature range T Min.
  • Page 273 Accessories and spare parts DANGER! Risk of fatal injury due to high leakage current! The cross-section of the protective ground conductor must be at least 10 mm² (EN 61800-5-1, Chapter 4.3.5.5.2). BFN 3-1- ... -001 0007 0016 0030 0042 0056 0075 0100 0130...
  • Page 274 11.4 Line filters Figure 118: Dimensions HOWCORE NFI-20 192 max. 104 +/-2 70 +/- 2 192 max. Figure 119: Dimensions LGF FFU 3x295AB-SBM Instruction handbook b maXX 5000 Document No.: 5.09021.16 Baumüller Nürnberg GmbH of 328...

  • Page 275: Power Chokes

    Accessories and spare parts 11.5 Power chokes It is required to use a power choke when operating (active) mains converter BM50XX and BM51XX. An operation without power choke is prohibited. NOTE UL certified power chokes must be used in UL compliant machines/systems. 11.5.1 Power choke BM50XX Current Select the power chokes dependent upon your application and based on the input rated...
  • Page 276 11.5 Power chokes Example: A transformer with a u value of 5%, 400 V rated voltage and 500 kVA output is operated in a 50 Hz mains. A device with the corresponding three-phase power choke, with 4 % u is connected to this mains. Thus, the transformer has an inductance of ...
  • Page 277 Accessories and spare parts Electrical data Rated voltage max. 550 V, rated frequency 50/60 Hz, flat connector, IP 00,  = 4% (50 Hz) / 4.8% (60 Hz),  rated voltage 400 V, u over 80 A up to 40 °C,  operating temperature for I up to 80 A up to 45 °C and for I with a derating of the current by 1% per °C up to 55 °C.
  • Page 278 11.5 Power chokes Dimensional drawing Figure 120: Dimensions of choke BM50XX Connection  diagram Figure 121: Connection diagram of choke BM50XX Instruction handbook b maXX 5000 Document No.: 5.09021.16 Baumüller Nürnberg GmbH of 328...

  • Page 279: Power Chokes For Bm51Xx

    Accessories and spare parts 11.5.2 Power chokes for BM51XX NOTE Only the power choke mentioned below is permitted for use with BM51XX devices. BM5173 Marking Inductance Part number BL-3-060-000 1 mH 388168 This power chokes are specified for operation at 400 V/50 Hz bzw. 480 V/60 Hz. Figure 122: Power choke BM5173 Connection...
  • Page 280 11.5 Power chokes BM5174 Marking Inductance Part number BL-3-100-001 0.6 mH 430926 UL approval The chokes are design-tested in accordance with UL (e.g. UL1561) and signified by the „ú“ “ symbol. Figure 123: Power choke BM5174 Connection: Cable lugs 10-50 Fixing: Connection ...
  • Page 281 Accessories and spare parts BM5192, BM5193 Marking Inductance Part number TRAMAG 0.2 mH 463082 D400/110/-20-D5-01 < (UGXQJ 0[  p  p  p  p  p Figure 125: Power choke BM519X Instruction handbook b maXX 5000 Document No.: 5.09021.16 of 328...

  • Page 282: Spare Parts

    11.6 Spare parts 11.6 Spare parts 11.6.1 Plug connectors (Active) mains rectifier unit Connector X200 9 - 10 mm X 417197 Wago 231-2302 Connector „Ba+/Ba-“ X101 15 mm X 425794 Phoenix SPC5/2-STCL-7.62, 1718481 Connector „Ba+/Ba-“ X101 12 mm 424416 Phoenix IPC16/2-STF-10.16 Connector „RD+/RD-“...
  • Page 283 Accessories and spare parts Axis units BM5XXX - XXXX - XXXX - XXXX - XX - XXXX - [EXX] - #XX double axis Connector X200 9 - 10 mm 417197 Wago 231-2302 Connector motor X107 7 mm 436300 Weidmüller 3-pol. Connector motor X107/108 15 mm 433298...
  • Page 284 11.6 Spare parts Axis units BM5XXX - XXXX - XXXX - XXXX - XX - XXXX - [EXX] - #XX - M0 double axis Connector X200 9 - 10 mm 417197 Wago 231-2302 Connector motor X107 7 mm 436300 Weidmüller 3-pol. Connector motor X108 7 mm 436299...
  • Page 285 Accessories and spare parts Axis units single axis Connector X200  9 - 10 mm X 417197 Wago 231-2302 Connector motor X107 15 mm X 434867 Phoenix 3-pol. Connector DIO X2 7 mm X 479956 Weidmüller Push-In Connector X206 10 mm X 424601 Weidmüller 1690450000 Connector X206...

  • Page 286: Accessories Kit Shielding

    11.6 Spare parts 11.6.2 Accessories kit shielding NOTE! Option, not included in delivery! Air-cooled/ water-cooled Device Width Part No. devices Single axis unit BM5326 50 mm 437738 BM5327 BM5328 75 mm 437739 BM5334 75 mm 437741 BM5335 BM537X connection 2 x 16 mm² 175 mm 460011 connection 2 x 25 mm²...

  • Page 287: Connection Rails

    Accessories and spare parts 11.7 Connection rails m DC link bar Length Part No. 424188 Accessories Part No. DC link spacer bushing 424129 Screw 420020 m Mounting rail Length Part No. 424187 m Accessories kit PE connection from device to device Accessories Part No.
  • Page 288 11.8 Toroidal cores Toroidal cores for Toroidal cores for reduction of bearing currents. motor cables NOTE The number of the toroidal cores must be increased depending on the core tempera- ture when using the converter at low speed (<100 rpm) for a longer period or in case the motor is supplied at standstill.

  • Page 289: Shutdown, Storage

    HUTDOWN TORAGE In this chapter we describe, how you decommission and store the device. 12.1 Safety instructions h Refer to ZSafety– as from page 15 and the information in ZTransport and Packaging– as from page 105. The shutdown of the device may only be carried out by for this qualified personnel. DANGER! Risk of fatal injury from electrical current! Stored electric charge.

  • Page 290: Requirements To The Executing Personnel

    12.2 Requirements to the executing personnel 12.2 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.

  • Page 291: Storage Conditions

    Shutdown, Storage 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 ZWhat to observe when transporting–...

  • Page 292: Recommissioning

    12.6 Recommissioning 12.6 Recommissioning Execute commissioning as with a new device, see  ZMounting– as from page 107, ZInstallation– as from page 123. NOTICE! Recommissioning without forming of the capacitors. From six months storage period on, the capacitors are destroyed during commission- ing, if they are not formed beforehand m Reform the DC link capacitors: n by supplying the device ready-to-operate for at least one hour with ...

  • Page 293: Disposal

    ISPOSAL NOTE! Baumüller products are not subject to the scope of application of the EU's Waste Electrical and Electronic Equipment Directive (WEEE, 2012/19/EU). Hence, Baumüller is not obligated to bear any costs for taking back and disposing of old de- vices.
  • Page 294 13.1 Safety regulations CAUTION! Danger due to sharp edges. If the device is lifted with unprotected hands during deinstallation, palms or fingers can be cut. If the device falls, feet could be injured. Therefore: m Ensure that only qualified personnel, who are familiar with the safety notes and as- sembly instructions, mount this device.

  • Page 295: Disposal Facilities/Authorities

    Disposal WARNING! Danger as a result of faulty deinstallation! The deinstallation and disposal requires qualified personnel with adequate experi- ence. Therefore: m Only allow deinstallation and disposal to be performed by qualified personnel. 13.2 Disposal facilities/authorities Ensure that the disposal is handled in compliance with the disposal policies of your com- pany, as well as with all national regulations of the responsible disposal facilities and au- thorities.

  • Page 296: Instruction Handbook B Maxx

    13.2 Disposal facilities/authorities Instruction handbook b maXX 5000 Document No.: 5.09021.16 Baumüller Nürnberg GmbH of 328...

  • Page 297: Appendix A - Abbreviations

    A - A PPENDIX BBREVIATIONS Amps Maximum rotational speed Alternating current Minimum rotational speed Ready-to-operate Height above mean sea level Compliant with the directives of the Number European Union Rotational speed set value Direct current Negative temperature coefficient Deutsches Institut für Normung thermistor e.V (German National Standards Protected ground...
  • Page 298 Instruction handbook b maXX 5000 Document No.: 5.09021.16 Baumüller Nürnberg GmbH of 328...

  • Page 299: Appendixb - Declaration Of Conformity

    B - D PPENDIX ECLARATION OF ONFORMITY Operation Manual b maXX 5000 Document no.: 5.09021.16 of 328...
  • Page 300 EU-Declaration of Conformity Doc.-No.: 5.11002.04 Date: 18-Oct-2016 according to EMC Directive 2014/30/EU and  Low Voltage Directive 2014/35/EU The Manufacturer: Baumüller Nürnberg GmbH Ostendstraße 80-90 90482 Nuremberg, Germany declares, that the products with the Brand name Baumüller Type: Mains Rectifier Unit: BM5031, BM5032....

  • Page 301: Appendix C - Bm5030 With Safety Function

    C - BM5030 PPENDIX WITH AFETY UNCTION Approvals, directives and standards Safety engineering Area of application Approvals standards and directives EN 61508-1:2010 Functional safety of safety-related electric, electronic Up to SIL 2 EN 61508-2:2010 and programmable electronic systems EN ISO 13849-1:2015 Safety-related components of control units Up to performance level d...

  • Page 302: Function

    Function Function The mains rectifier BM5030 with safety function converts the AC voltage of the power supply (U ) to the DC link voltage for the decentralized drive solutions BM2500 (U ). The STO function is integrated in this device, disconnecting the DC link voltage DC link ) of the mains rectifier to the axes units (U ).
  • Page 303 BM5030 with Safety Function NOTE! Only a BM5030 with safety function,  type code: BM5030-XX2X-...- marked with the TÜV SÜD certification label and the safety label fulfills a certified safety function within the meaning of PL classification according ISO 13849 or SIL according EN 61508.

  • Page 304: Electrical Data Bm5030 With Safety Function

    Electrical data BM5030 with safety function Electrical data BM5030 with safety function BM5030 with safety function BM5030-XX2X-... Input rated power 6 kVA 1) 2) 3) Input rated current (I 12 A Distortion factor of the input current (THD 110 % ± 10 % 1) 2) 3) Input peak current (I 12.5 A...
  • Page 305 BM5030 with Safety Function All rated values are based on an power supply voltage of 400 V/50 Hz, a DC link voltage of 540 V, a control voltage of 24 V and a surrounding temperature of 40 °C. The input current must be reduced between 40 °C and 55 °C, see correction values at changed operation conditions, see ZCorrection values for the output current of the mains inverter BM50XX, BM51XX–...

  • Page 306: Led Display Bm5030 With Safety Function

    LED display BM5030 with safety function LED display BM5030 with safety function BM5030-XX2X-... LED READY - Mains rectifier unit ready-to-operate: green: Power supply and DC link voltage available, internally red: Power supply failure - automatically restart when power supply returns. blinking red: Power supply failure longer than 10 s - restart after Power supply return has to be acknowledged (X1:4).
  • Page 307 BM5030 with Safety Function Naming on the Meaning Error Blinking pattern front plate H1 (green) Ready-to-operate No error LED lights up H1 (red) Power supply failure Power supply failure - automatically restart when LED lights up power supply returns. Power supply failure longer than 10 s -  LED blinking restart after power supply return has to be acknowledged (X1:4).

  • Page 308: Connection Diagram Bm5030 With Safety Function

    Connection diagram BM5030 with safety function Connection diagram BM5030 with safety function BM5030-XX20 A normally open contact is expected on the inhibit input. M24V Inhibit input +24V DC link connection Reset +24V to further devices Error Ready-to-operate NOTICE: Pay attention to the max. connectable DC link capacitance connected downstream STO,...
  • Page 309 BM5030 with Safety Function BM50XX-XX21 A normally closed contact is expected on the inhibit input. M24V Inhibit input +24V DC link connection Reset +24V to further devices Error Ready-to-operate NOTICE: Pay attention to the max. connectable DC link capacitance connected Power supply downstream STO, Connection for...

  • Page 310: Electrical Connections Bm5030 With Safety Function

    Electrical connections BM5030 with safety function Electrical connections BM5030 with safety function BM5030-XX2X-... DC link M24V Inhibit input reserved Reset Error Ready-to-operate +24V GND 24V STO input A GND for STO input A STO input B GND for STO input B Potential-free electronic switch Ready-to-operate...

  • Page 311: Connection Data Of Bm5030 With Safety Function

    BM5030 with Safety Function C.6.1 Connection data of BM5030 with safety function NOTE! To ensure sufficient current load capacity of the connections, adhere to the specified torques! Connection Connection Torque Load capacity cross section method Power supply BM5030 Max. 25 mm² Screw terminal Min.
  • Page 312 Electrical connections BM5030 with safety function Connection Connection Load capacity cross section method X1 (SELV/PELV) BM5030 Max. 1.5 mm² Plug connector, Max. 8.0 A with  Control inputs spring-clamp safety connection function X2 (SELV/PELV) Max. 1.5 mm² Plug connector, Max. 8.0 A STO function...

  • Page 313: Connections Front Side Bm5030 With Safety Function

    BM5030 with Safety Function C.6.2 Connections front side BM5030 with safety function Digital inputs / outputs BM5030-XX2X-... X1 Digital inputs/outputs 1:M24V 2: Inhibit input 3: Reserved 4: Reset 5: Error 6: Ready-to-operate Figure 131: Connection X1 front side BM5030 with safety function Pin assignment Assignment Dig.
  • Page 314 Electrical connections BM5030 with safety function STO function BM5030-XX2X-... X2 STO function 1: +24V 2: GND 3: STO A 4: GND STO A 5: STO B 6: GND STO B 7: Ready-to-operate 8: Ready-to-operate 9: Error 10: Error Figure 132: Connection X2 front side BM5030-XX2X-...
  • Page 315 BM5030 with Safety Function Power supply  Power supply voltage for the electronics of DC link STO function voltage Technical data see ZPower supply of the STO function– on page 316. X2:1, X2:2 First channel of safe DC link disconnection. This input operates the DC link + switch.  STO A input...
  • Page 316 Electrical connections BM5030 with safety function Power supply of For the power supply of the STO function on connector X2 a 24 V power supply unit is the required, which corresponds with the SELV/PELV standards according EN 50178. STO function Voltage: -15 %/+20 % Inputs ...

  • Page 317: Description Of The Safety Function Sto

    BM5030 with Safety Function Description of the safety function STO NOTICE! The commissioning is only allowed after the acclimatization of the device. C.7.1 Safety related characteristics of the STO function The specified values are valid during operation at the required environmental conditions, ZRequired environmental conditions–...

  • Page 318: Reaction Time Sto

    Description of the safety function STO WARNING! Function test requirements of the safety function to comply with the Safety Integrity Level SIL2 respectively with the Performance level PLd, category 3: The safety function has to be tested (activated/deactivated) at least once a year. The DC-link voltage must be measured in STO state once a year.

  • Page 319: Cycle Time Sto

    BM5030 with Safety Function C.7.3 Cycle time STO It is allowed to change to the state ready-for-operation only once within 2 seconds (t in order to protect the internal charging and discharging resistors from overheating. DC link Ready-to-operate Figure 133: Cycle time STO Reaction time period of STO A = high and STO B = high ...

  • Page 320: Safety Function Sto Im Bm5030-Xx2X

    Description of the safety function STO C.7.4 Safety function STO im BM5030-XX2X-... The STO switch is checked by the device automatically when changing to the state ready- to-operate. State change from STO  Ready-to-operate (closing of the switches) is only possible if both switches were open prior to that.

  • Page 321: Table Of Figures

    Table of Figures Table of Figures Wiring of the power cables......................Signs and labels BM5XXX ......................BM503X-C/-S dimensions......................BM503X-A dimensions....................... BM504X-C/-S dimensions......................BM504X-A dimensions....................... BM517X-C/-S dimensions......................BM519X-S dimensions....................... BM519X-F dimensions....................... BM532X-C/-S dimensions......................BM532X-A dimensions....................... BM533X-C/-S dimensions......................BM533X-A dimensions....................... BM533X-F dimensions....................... BM537X-S dimensions.......................
  • Page 322 Table of Figures Grounding concept, each device with PE connection............... Grounding concept, PE connection from device to device ............Mounting shield sheet air-cooled devices................. Mounting shield sheet cold plate devices ................. Wrap shield motor temperature cable around motor cable............Tape shield motor temperature cable around................Shield connection motor cable....................
  • Page 323 Table of Figures ® ..................Connecting cable for encoder with HIPERFACE ® Connecting cable for encoder with EnDat or SSI..............® Connecting cable for encoder with EnDat 2.2 M12..............® ® Connecting cable for encoder with EnDat 2.2 speedtec M23 ..........Connecting cable for sine/square wave incremental encoder..........
  • Page 324 Table of Figures Instruction handbook b maXX 5000 Document No.: 5.09021.16 Baumüller Nürnberg GmbH of 328...

  • Page 325: Index

    Index EC directive Abbreviations Edges, sharp 109, 290 Accessories Electrical current, dangers of Accidents Encoder cables Active mains rectifier unit 81, 145 Environmental conditions, required Address 213, 215, 217, 219 Error Approvals Error acknowledgment Axis unit Error detection Axis unit safety Error handling Error message Baud rate...
  • Page 326 Index Mains filter, selection Recommissioning Mains filters Release signals Mains rectifier unit Repairs Maintenance Residual energy, danger from 22, 125 Maintenance, periodic Malfunctions, behavior Safety equipment Mean Time To Failure dangerous (MTTFd) Safety fuses Safety shoes Modifications Semiconductor fuses Monitoring functions Shutdown 289, 290 Motor temperature sensor...

  • Page 327: Overview Of Revisions

    Overview of Revisions Overview of Revisions Version Status Changes 5.09021.01 03-Sep-2010 Creation ® ® 5.09021.02 15-Apr-2011 BM5043 and BM5044 added, BM55XX deleted, SinCos EnDat encoder reading deleted, encoder cable and service cable added, notice assembly opening additional module, mounting of the DC link bar and of the signal bus added.

  • Page 328: Document No.: 5.09021.16 Of

    Notes: Instruction handbook b maXX 5000 Document No.: 5.09021.16 Baumüller Nürnberg GmbH of 328...
  • Page 330 Baumüller Nürnberg GmbH Ostendstraße 80-90 90482 Nürnberg 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 further 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.

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