Baumuller b maXX 4100 Series Operation Manual
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Baumuller b maXX 4100 Series Operation Manual

Baumuller b maXX 4100 Series Operation Manual

Active mains inverter
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Operation manual
English
Language
Translation
Document No. 5.04052.09
Part No.
392407
Status
21-Feb-2014
E
5.04052.09
Please read these operating instructions before beginning!
b maXX 4100
Active mains inverter (NWR)

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  • Page 1 Operation manual English Language Translation Document No. 5.04052.09 Part No. 392407 Status 21-Feb-2014 b maXX 4100 Active mains inverter (NWR) Please read these operating instructions before beginning! 5.04052.09...
  • Page 2 Copyright These Operation manual may be copied by the owner in any quantity, but only for internal use. This Operation manual may not be copied or reproduced, in whole or in part, for any other purposes. The use and disclosure of information contained in these Operation manual 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 ........... . . 37 Structure.
  • Page 5 Table of contents Operation ..............81 Safety notes .
  • Page 6 Table of contents 12 Shutdown, storage ............127 12.1 Safety instructions .

  • Page 7: 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 8: Key To Symbols

    Key to symbols Key to symbols Warning notes Warning notes are identified by symbols in these instruction handbook. The notes are in- troduced by signal words that express the extent of the danger. It is imperative that these notes be complied with and are conscientiously regarded in or- der to prevent accidents, personal injury and material damage.

  • Page 9: Limitation Of Liability

    General Limitation of liability All specifications and notes in these instruction handbook were compiled taking into ac- count the applicable standards and regulations, the state of the art and our knowledge and experience of many years. The manufacturer assumes no liability for damages due to: m noncompliance with the instruction handbook m usage for other than the intended purpose m usage by untrained personnel...

  • Page 10: 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. ZAccessories and Spare Parts–...

  • Page 11: 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 12: Usage For The Intended Purpose

    Usage for the intended purpose Usage for the intended purpose The device is conceived and constructed exclusively for usage compliant with its intended purpose described in these instruction handbook. The devices of the model series BM4100 (NWR) is used exclusively as an active mains rectifier.

  • Page 13: Responsibility Of The Operating Company

    Safety Responsibility of the operating company The device will be 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 14: 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 15: 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 16: 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 Operation manual to reduce health risks and dangerous situations.

  • Page 17: 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 18: Safety Equipment

    2.10 Safety equipment 2.10 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 19: Signs And Labels

    Safety 2.12 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 20: Signs And Labels Bm413X/Bm414X

    2.12 Signs and labels CAUTION! Risk of injury due to hot surface! Therefore: m Wear protective gloves NOTE! When in operation, the top of the device can heat up to temperatures > 70 °C! Figure 1: Signs and labels BM413X/BM414X Operation manual b maXX BM4100 (NWR) Document no.: 5.04052.09 Baumüller Nürnberg GmbH...

  • Page 21: Signs And Labels Bm416X

    Safety Figure 2: Signs and labels BM416X Operation manual b maXX BM4100 (NWR) Document no.: 5.04052.09 of 142...
  • Page 22 2.12 Signs and labels On the type plate (label) you will find, besides others, the type key of the device. Figure 3: Position of type key label Operation manual b maXX BM4100 (NWR) Document no.: 5.04052.09 Baumüller Nürnberg GmbH of 142...

  • Page 23: Dimensions

    ECHNICAL Dimensions The following dimension drawings show the main dimensions of the devices. By means of the dimension drawings the space requirements within the control cabinet are deter- ZDrilling patterns– mined. The dimension drawings in from page 53 must be used in or- der to do the required drilling / segments.

  • Page 24: Installation Space Bm4135-S

    Dimensions ZCooling– *: min. expansion space, also consider on page 29 Figure 4: Installation space BM4135-S ZCooling– *: min. expansion space, also consider on page 29 Figure 5: Installation space BM4145-S Operation manual b maXX BM4100 (NWR) Document no.: 5.04052.09 Baumüller Nürnberg GmbH of 142...

  • Page 25: Technical Data

    Technical Data ZCooling– *: min. expansion space, also consider on page 29 **: width inclusively bolt heads Figure 6: Installation space BM4163-S/Z Weight Device Dimensions Weight with controller, (B x H x T) without plug-in module BM4135 155 x 540 x 340 mm 16,4 kg BM4145 190 x 665 x 374 mm...

  • Page 26: Operating Requirements

    Operating requirements Operating requirements 3.3.1 System types There are three basic types of the current supply systems regarding the grounding, which conform with DIN VDE0100 part 300 and IEC 60364: m The TN system has a directly grounded point (system grounding). The cabinet of the electrical installation is connected via the protective conductors and PE conductors with this point.

  • Page 27: Requirements To The Energy Supply / Supply System

    Technical Data 3.3.2 Requirements to the energy supply / supply system ZSys- Mains supply (see BM41XX - XTX Industrial mains with direct or low impedance tem types– from page 26) earthed star point (TN net or TT net) Max. short circuit voltage mains at power terminal = 4 % Mains choke inductance BM4135...

  • Page 28: Required Environmental Conditions

    Operating requirements 3.3.3 Required environmental conditions Transport temperature range - 25 °C to + 70 °C Transport climatic category 2 K 3 EN 60721-3-2 Storage temperature range - 25 °C to + 55 °C Storage climatic class EN 60721-3-1 1 K 4 Operation environment industrial system Operation temperature range...

  • Page 29: Cooling

    Technical Data 3.3.4 Cooling Cooling air temperature min. 0 °C to max. 55 °C (rated temperature: 40 °C) ZElectrical data– Cooling air requirement from page 30 Air temperature in the entire suction area of the device. The cooling air requirement corresponds at least to that of a free-blowing device. Free-blowing means, that the air inlet and the air outlet operates unrestricted.

  • Page 30: Electrical Data

    Electrical data Electrical data 3.4.1 Electrical data - BM4135 BM4135 Input rated power 38 kVA 1) 2) 3) 4) Input rated current (I 55 A 1) 2) 4) 5) Input peak current (I 82,5 A PWM switching frequency 8 kHz DC link voltage 640 V to 760 V...

  • Page 31: Derating Curve Input Current Bm4135

    Technical Data At rated input voltage the device supplies the rated/maximum output currents. At input voltages above the rated input voltage the output currents must be reduced accordingly at constant output power. Peak current Max. operation current Input voltage [V] Figure 7: Derating curve input current BM4135 This overload time is dependent on the motor current and of the heatsink temperature and is determined by the Ixt-monitoring of the...

  • Page 32: Electrical Data - Bm4145

    Electrical data 3.4.2 Electrical data - BM4145 BM4145 Input rated power 86 kVA 1)2)3)4) Input rated current (I 125 A 1)2)4)5) Input peak current (I 162,5 A 8 kHz PWM switching frequency DC link voltage 640 V to 760 V 3055 µF DC link capacity (internal) DC link capacity (external), permitted...

  • Page 33: Derating Curves Input Current Bm4145

    Technical Data At rated input voltage the device supplies the rated/maximum output currents. At input voltages above the rated input voltage the output currents must be reduced accordingly at constant output power. Peak current Max. operation cur- rent Input voltage [V] Figure 9: Derating curves input current BM4145 This overload time is dependent on the motor current and of the heatsink temperature and is determined by the Ixt-monitoring of the...

  • Page 34: Electrical Data - Bm4163

    Electrical data 3.4.3 Electrical data - BM4163 BM4163 Input rated power 162 kVA 1)2)3)4) Input rated current 235 A 1)2)4)5) Input peak current (I 305 A 8 kHz PWM switching frequency DC link voltage 640 V to 760 V 6000 µF DC link capacity (internal) DC link capacity (external), permitted max.

  • Page 35: Derating Curves Input Current Bm4163

    Technical Data At rated input voltage the device supplies the rated/maximum output currents. At input voltages above the rated input voltage the output currents must be reduced accordingly at constant output power. Peak current Max. operation cur- rent Input voltage [V] Figure 11: Derating curves input current BM4163 This overload time is dependent on the motor current and of the heatsink temperature and is determined by the Ixt-monitoring of the...

  • Page 36: Electrical Data Bm4-F-Sea

    Electrical data 3.4.4 Electrical data BM4-F-SEA SEA-01 SEA-02 Min. supply voltage 110 V -10 % / 50/60 Hz 24 V -15 % Max. supply voltage 230 V +10 % / 50/60 Hz 24 V +20 % Max. switching current 3.4.5 Electrical data BM4-F-SRM SRM-01 SRM-02...

  • Page 37: Design And Operation

    ESIGN AND PERATION Structure The devices of the b maXX 4100 series are mains inverters of Baumüller Nürnberg GmbH. The devices convert power drawn from the mains and supply the power mod- ule(s) connected via the DC link. Also the devices can convert mechanical brake energy, supplied from the power modules via the DC link, to feed it back to the mains.

  • Page 38: Controller Unit Variants

    Controller unit variants A device of the series b maXX 4100 consists of the following parts: A: Power unit This part is a power converter combination which is build up with power semiconductor (converter) components. The feeding in and feeding back is implemented with a B6-IGBT transistor circuit, which has an HF mains choke connected to.

  • Page 39: Slots

    Design and Operation 4.2.1 Slots In slots of the controller unit function or option modules are plugged, which extend the functional range of the controller unit. Every slot is clearly identified by a code letter. Function modules, permanently installed D With this plug-in module in this slot the controller communicates via a function module bus.

  • Page 40: Combination Possibilities Plug-In Module-Controller Slots

    Controller unit variants 4.2.1.1 Combination possibilities plug-in module-controller slots Function modules Option modules F Controller permanently installed Permanently installed function module at this slot Preferred slot Baumüller Nürnberg GmbH recommends, in order to reach the highest functional range, to insert the plug-in modules into this slot. Possible slot only if the preferred slot is occupied, we recommend in order to reach the highest func- tional range, to insert the plug-in module into this slot.

  • Page 41: Connecting Devices

    Design and Operation Connecting devices The device is part of the Baumüller series BM4100 (NWR) and can be connected togeth- er with some, but not all Baumüller devices. The combination with: m BM44XX power modules, see operation manual (Document no. 5.12008) Definitely prohibited is the combination with following devices with a common DC link: m other BM41XX mains inverter m all BM44XX basic units, in particular BM441X and BM447X...

  • Page 42: Type Code

    Type code Type code The type key has the form: BM4XXX - XXX - XXXXX - XX. Directly behind the type key is the design code (- XXXX - XXXX). The design code contains information, which only is important to Baumüller Nürnberg GmbH. That’s why in the following table only the type key is explained.

  • Page 43: Marking Of The Function Modules - Type Key

    Design and Operation Marking of the function modules - type key On the front sheet you will find the type key of the plug-in module. NOTE This type key is valid only for permanently installed function modules of the series b maXX 4100.

  • Page 44: Display And Operation Elements

    Display and operation elements Display and operation elements 4.8.1 LEDs On the front side of the device there are six LEDs. Both of the upper LEDs (UH1 and UH2) are freely programmable. The four lower LEDs (H1 to H4) show information about the op- erational status and are also emulated in ProDrive.

  • Page 45: Display

    Design and Operation 4.8.2 Display The 7-segment-display in normal operation shows the operation status. In case of error the error number is shown. Display Status Meaning Not ready to operate Initialization phase, pulses inhibited. Switch-on inhibit Pulses inhibited, initialization completed error-free. Main contactor ready Complete pre-charging successfully for switch on...
  • Page 46 Display and operation elements Operation manual b maXX BM4100 (NWR) Document no.: 5.04052.09 Baumüller Nürnberg GmbH of 142...

  • Page 47: 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 48: 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 49: Mounting

    OUNTING The device is designed for mounting in a control cabinet. Mounting consists of the following steps: 1 Prepare mounting ZDrilling patterns– (for drill holes/cut-out segments, see from page 53) 2 Install ZMounting instructions– (fixing see on page 55) Safety notes NOTE! Mounting shall only be performed by employees of the manufacturer or by other qual- ified personnel.
  • Page 50 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 51: Danger Area Near The Mechanical Mounting

    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 16: 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 52: Preparing For Mounting

    Preparing for mounting Preparing for mounting ZDrilling patterns– Based on the planning documents and the drilling pattern (see from page 53), the cutout sections and the positions of the attachment drill holes can be deter- mined. 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 53: Drilling Patterns

    Mounting 6.2.1 Drilling patterns 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]. ZDimensions– ZCooling– Further notes see from page 23 and from page 29.

  • Page 54: Drilling Pattern Bm4145

    Preparing for mounting Figure 18: Drilling pattern BM4145 Figure 19: Drilling pattern BM4163 Operation manual b maXX BM4100 (NWR) Document no.: 5.04052.09 Baumüller Nürnberg GmbH of 142...

  • Page 55: Mounting Instructions

    Mounting Mounting instructions There are different kinds of mounting. ZFigure 20– ZFigure Each mounting method is shown in a graphic (see on page 56 to 21– on page 57) The screws and washers required for mounting are listed beneath the respective graphic. Carry out mounting as follows: 1 Provide suitable transport/lifting equipment as needed.
  • Page 56 Mounting instructions Figure 20: Mounting instruction BM4135-S and BM4145-S Device BM4135-S BM4145-S A - screws 4 x M5 4 x M5 B - washers 4 x (5,3 x 10) 4 x (5,3x15) c - mounting space c = 5 mm c = 5 mm Operation manual b maXX BM4100 (NWR) Document no.: 5.04052.09...
  • Page 57 Mounting Figure 21: Mounting instruction BM4163-S Device BM4163-S A - screws 4 x M8 B - washers 4 x (8,4 x 17) c - mounting space c = 0,7 mm Operation manual b maXX BM4100 (NWR) Document no.: 5.04052.09 of 142...
  • Page 58 Mounting instructions Operation manual b maXX BM4100 (NWR) Document no.: 5.04052.09 Baumüller Nürnberg GmbH of 142...

  • Page 59: Installation

    NSTALLATION This chapter describes the electrical installation of the device. The mechanical mounting ZMounting– is described in from page 49. Initial commissioning is described in the Parameter manual b maXX 4100 in chapter Commissioning. Prior to installation, ensure that the technical prerequisites have been fulfilled: 1 Check the demands on the electrical power supply.
  • Page 60 Safety notes WARNING! Danger because of faulty installation and initial commissioning! Installation and commissioning require qualified personnel with adequate experi- ence. A installation fault can cause danger situations or large damage of property. Therefore: m Only personnel from manufacturer or qualified personnel operate while installation and initial commissioning DANGER! Risk of fatal injury from electrical current!

  • Page 61: Voltage Test

    Installation Danger from re- sidual energy DANGER! Risk of fatal injury from electrical current! Stored electric charge. Discharge time of the system = discharge time of the device with the longest DC link discharge time in the DC link connection. ZElectrical data–...

  • Page 62: Demands On The Power Supply

    Demands on the power supply Demands on the power supply ZRequirements to the energy supply / supply system– For all important data, see from page 27. Minor deviations from requirements in the power supply can lead to malfunctioning of the device.

  • Page 63: 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 64: Mains Filter And Surge-Protection Module

    Mains filter and surge-protection module In order to have EMC-compliant and problem-free use within the framework of the legis- lation, the following aspects must be taken into account. In case of any questions, please contact Sales or the Applications department of Baumüller Nürnberg GmbH.

  • Page 65: Installation Procedure

    Installation 7.11 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. power supply cables) and the mounting areas are de-energized for the entire duration of mounting the device. h Lay all cables EMC-compatible.

  • Page 66: Connection Diagram With Sea-01 / Srm-01

    7.12 Connection diagram with SEA-01 / SRM-01 7.12 Connection diagram with SEA-01 / SRM-01 Charge circuit Power supply unregulated 24 V ± 10 % with secure electrical separation (PELV) accordant EN 50178 DC link voltage monitoring Chopper resistor control Chopper resistor ON Chopper resistor bus Mains voltage monitoring Pulse enable...
  • Page 67 Installation Figure 23: Connection diagram Operation manual b maXX BM4100 (NWR) Document no.: 5.04052.09 of 142...

  • Page 68: Proposal Control Power On/Off

    7.13 Proposal control power on/off 7.13 Proposal control power on/off ® b maXX main contactor ON Figure 24: Proposal control power On/Off 7.14 Proposal main contactor control The main contactor can be controlled via ProDrive/BACI or via the digital inputs of the Digital IO module.

  • Page 69: Proposal Controlling Pulse Enable

    Installation 7.15 Proposal controlling pulse enable A time delay of 500 ms is required between ready for pulse enable (D:X1-5) and pulse enable. D:X1-5 (Ready for pulse enable) F:X3-5 (Pulse enable) Figure 26: Proposal controlling pulse enable 7.16 Discharge DC-link / chopper resistor control Discharge At applying a 24 V control voltage at the terminal X100-4 the chopper resistor transistor DC-link...

  • Page 70: Proposal Against System Reactions

    7.17 Proposal against system reactions 7.17 Proposal against system reactions ZFigure An additional HF mains choke (see 28–) can reduce the system reactions, if the reaction to switching frequencies on the mains because of defects within the mains sup- ply is too high. Mains Mains BM4100...

  • Page 71: Connection Diagrams

    Installation 7.18 Connection diagrams ZPage 71– ZPage 73– The figures from show the connections for protective conduc- ZFigure 32– tor, mains, chopper resistor, DC link. on page 74 shows the connection of ZFigure 34– control voltage and the connections of the controller unit. on page 76 shows the connections of the function modules in the slots A to D.
  • Page 72 7.18 Connection diagrams The electrical connections for device BM4145 are shown in the following figure: at the back (back panel) 1D1, 1C1 DC-link Ba+, Ba- Chopper resistor for discharge in front (cover) 1U1, 1V1, 1W1 Mains connections at the back (back panel) Figure 30: Electrical connections for mains, DC-link, upon others for BM4145 NOTE...
  • Page 73 Installation The electrical connections for device BM4163 are shown in the following figure: in front (cover) X36-L, X36-N Fan* 1D1, 1C1 DC-link Ba+, 1C1 Chopper resistor for discharge 1U1, 1V1, 1W1 Mains connections at the back (back panel) Figure 31: Electrical connections for mains, DC-link, upon others for BM4163 NOTE The chopper resistor is connected at the device BM4163 between Ba- and 1C1.
  • Page 74 7.18 Connection diagrams Electrical connections of the controller unit X100-1: +24V (SELV/PELV)* X100-2: +24V (SELV/PELV)* X100-3: n.c. X100-4: Quick discharge (SELV/PELV) ** X100-5: M24V (SELV/PELV)* X100-6: M24V (SELV/PELV)* Do not connect X100-3. This is different to BM44XX-devices. Figure 32: Connection X100 Operation manual b maXX BM4100 (NWR) Document no.: 5.04052.09 Baumüller Nürnberg GmbH...
  • Page 75 Installation UH1: green: Programmable LED yellow: Programmable LED UH2: green: Programmable LED yellow: Programmable LED H1: green: Supply yellow: Feedback H2: green: Enable yellow: Power ON H3: red: Current limit reached H4: red: Error X4: reserved 1: reserved 2: TxD RS232 6: DTR, DSR 3: RxD RS232 7: RTS...
  • Page 76 7.18 Connection diagrams BM4-F-UME-01 (slot A) A: X1-1: A: X1-2: A: X1-3: A: X1-PE: BM4-F-SRM-01 (slot B) B: X1-1: Monitoring signal of main contactor B: X1-2: B: X1-PE: BM4-F-SRM-02 (slot B) B: X1-1: Monitoring signal of main contactor (SELV/PELV) B: X1-2: M24V (SELV/PELV) BM4-F-SEA-01 (slot C) C: X1-1:...

  • Page 77: Connection Main Contactor Sea-01 And Srm-01

    Installation Main contactor control with SEA-01 and SRM-01 Coil main contactor Monitoring contact main contactor Figure 35: Connection main contactor SEA-01 and SRM-01 Main contactor control with SEA-02 and SRM-02 Coil main contactor Monitoring contact main contactor Figure 36: Connection main contactor SEA-02 and SRM-02 NOTE The maximal switching current of SEA is 8 A.

  • Page 78: Connector Data Of Connections

    7.18 Connection diagrams 7.18.1 Connector data of connections Mains Max. cross- Connection Torque 1U1, 1V1, 1W1, PE section technology connection BM4135 AWG 6 16 mm Screw terminals 1.2 to 1.5 Nm BM4145 AWG 1/0 50 mm Screw terminals 6 to 8 Nm BM4163 2 x 150 mm Cable lug...
  • Page 79 Installation X1 (RS 232) Recom- Connection Note mended con- technology nection cable BM4135 LIYCY SUB-D, 9-pin available as cable set: ZInterface cable RS232– BM4145 6x2x0.14 mm on page BM4163 115. WARNING! Risk of injury because of mechanical hazard! If a PC is not connected via an isolated transformer, the machine can do unexpected actions.

  • Page 80: Requirements For The Screwing (Ul)

    7.18 Connection diagrams Max. cable-Ø Connection technology Loading BM4135 1.5 - 2.5 mm plug-in contact X11-1 to X11-5: BM4145 H07 to 1000 V ZPre-charge protec- BM4163 tion– on page 117 A: X1 to C: X1 Cable-Ø Connection technology Load capacity BM4135 0.75 - 2.5 mm plug-in contact...

  • Page 81: Operation

    PERATION Safety notes 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 82: 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.e.

  • Page 83: Power On Switching Frequency

    Operation Power on switching frequency The device may not be switched on and off as often as you like. Between two switch-on- sequences there should be a certain time period (at least 2 min.), in order to protect the ZTechnical Data– devices/fuses (see from page 23).

  • Page 84: Monitoring

    Monitoring Monitoring The controller unit monitors the device during the operation. If the controller unit recog- nizes a status, which deviates from normal operation, the device either issues a warning or an error message. Warning If the controller unit recognizes an operating condition, which is close to an error condi- tion, an accordant warning message is shown in ProDrive and by the control respectively.

  • Page 85: Troubleshooting And Fault Correction

    ROUBLESHOOTING AND FAULT CORRECTION 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 86: Monitoring Functions

    Monitoring functions Monitoring functions A survey of the most important monitoring functions and of the from the monitoring func- tions generated warning-/error messages you will find in the following table. How to rec- ZFault detection– ognize the errors we have explained in from page 89.

  • Page 87: Monitoring Functions - Explanations

    Troubleshooting and fault correction Monitoring function Warning/error Controller synchronizing Controller not synchronous with ext. signal X P0533 P0299 Module monitoring Wrong module Module is missing Wrong slot Ramp-up option modules Error at module initialization IS P0838 P0838 Cyclical set point transmis- Transmission timeout P0839 P0298 sion to the optional modules...
  • Page 88 Monitoring functions Earth fault This monitoring function checks, if a short-circuit is existing between the mains terminals and earth. If a short-circuit is ascertained, pulse enable immediately occurs. Overcurrent This monitoring function checks, if the mains current is greater than 1.3 x input peak cur- rent.

  • Page 89: Fault Detection

    Troubleshooting and fault correction Fault detection The fault can be caused by mechanical or electrical malfunctions. LED H4 The occurrence of an error state is signalized by the lighting up of the red LED H4 on the front side of the housing. NOTE! If warnings or errors occur without error reaction the LED H4 ’error’...
  • Page 90 Fault detection Operating Furthermore the error message is shown in the operating software: software ProDrive h Start the operating program ProDrive (from FW 3.07), if it isn’t running yet. NOTE! The controller software version and the operating software version must be compat- ible to use ProDrive with all functions.
  • Page 91 Troubleshooting and fault correction Start screen Figure 39: ProDrive start screen Display the „error message“ in ProDrive. h Open navigation with click on in front of „Management“. Figure 40: Project navigation in ProDrive Operation manual b maXX BM4100 (NWR) Document no.: 5.04052.09 of 142...
  • Page 92 Fault detection h Select „Drive management“ The window „Drive manager“ opens, see below with an exemplary (error) message. Before the communication between controller and PC/laptop is started, the messages in in this list have been arranged in numerical order. The newly occurring messages are added to the end of the list, when communication is active.

  • Page 93: Error Handling

    Troubleshooting and fault correction Error handling The error messages in the system are built up hierarchically An error message can result from a beneath in the hierarchic arranged error message. This is why the message ’Error’ (level 1) can base on an error, which e. g. has appeared in „ModuleError“...

  • Page 94: Error Reset

    Error handling 9.4.1 Error reset If the red error LED is lighting up, there is at least one error. There are several methods to reset errors: m Via ProDrive (from FW 3.07): Button “Quit errors” (either in the dialog box “Device manager” or on the page “Device manager“.

  • Page 95: Error Parameters, Error Messages, Error Reactions

    Troubleshooting and fault correction 9.4.2 Error parameters, error messages, error reactions LEVEL 1 LEVEL 2 LEVEL 3 SysError 1 ProcessorError FunctionModule_A OperationError FunctionModule_B ProprogError FunctionModule_C ExtendedModuleError FunctionModule_D PSU_Error FunctionModule_E AmpError OptionModule_G DriveManagError OptionModul_H DataRecError CANSyncError Figure 43: Structure of the error list - survey 1st level 1st level errors are only interesting for the access to errors via parameters, to be used without ProDrive, e.

  • Page 96: Error Messages (2Nd Level)

    Error handling 9.4.2.1 Error messages (2nd level) In the column ’Reaction’ the reaction of the system to the error is shown: m „IS“ = pulse inhibit; m „adjustable“ = the error reaction can be set via ProDrive (Window „Drive management“, toolbar button „Error reaction“).
  • Page 97 Troubleshooting and fault correction P203 Error Proprog communication Error No. Meaning Reaction Troubleshooting Timeout protocol adjustable RestartBM4100 (NWR) Protocol structure adjustable Wrong module type adjustable Contact Baumüller Nürnberg GmbH Too many data in the telegram adjustable Not enough data in telegram adjustable Invalid operand adjustable...
  • Page 98 Error handling P0205 Error power supply Error No. Meaning Reaction Troubleshooting Power supply failure adjustable Connect the power supply system Phase failure Check if all phases are correctly connected and volt- age-carrying Undervoltage power supply, BM4100 only Assure the compliance with the power supply specifi- ZRequirements to the energy supply / cations (see Overvoltage power supply, BM4100 only...
  • Page 99 Troubleshooting and fault correction P0206 Error power unit Error No. Meaning Reaction Troubleshooting ® ZError power unit - serial interface– Communication error according Hiperface on page 101 specification (= 3rd level) Heat sink temperature Let the device cool down and/or reduce the load Overvoltage Uzk Reduce the DC link voltage Overcurrent...
  • Page 100 Error handling P0212 Error data set management Error No. Meaning Reaction Troubleshooting EEPROM copy error adjustable Copy the data set once more Write timeout EEPROM adjustable The data in the EEPROM are invalid, please safe all data sets Checksum error EEPROM EEPROM faulty or described faulty No boot data set The data in the EEPROM are invalid, please safe all...

  • Page 101: Sub-Error Messages (3Rd Level)

    Troubleshooting and fault correction 9.4.2.2 Sub-error messages (3rd level) NOTE! 3rd level errors are only displayed in ProDrive separated by a decimal point from the ZFigure 43– corresponding 2nd level error (see on page 95). P0233 Error power unit - serial interface Error power unit 80: Communication error Error code Meaning...
  • Page 102 Error handling P0245 to P0250 Error im option module G to H Error code Meaning Reaction Troubleshooting 4096 Wrong parameter No. at set value parameter 1 adjustable Check the corresponding set value parameter 4097 Wrong parameter No. at set value parameter 2 adjustable 4098 Wrong parameter No.
  • Page 103 Troubleshooting and fault correction Error code Meaning Reaction Troubleshooting 4138 Invalid value at set value parameter No. 11 adjustable Check the set values in relation to the permitted value range 4139 Invalid value at set value parameter No. 12 adjustable 4140 Invalid value at set value parameter No.

  • Page 104: Warnings

    Error handling 9.4.3 Warnings P0261 Warning power supply Warning No. Meaning Troubleshooting not assigned = 0 Undervoltage 24 V Assure the compliance with the specifications Undervoltage power supply Assure the compliance with the specifications ZRequirements to the energy supply / supply system– (see page 27) Overvoltage power supply...

  • Page 105: Maintenance

    AINTENANCE 10.1 Safety notes 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 during the electrical in- stallation.

  • Page 106: Environmental Condition

    10.2 Environmental condition 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 107 Maintenance DANGER! Risk of fatal injury from electrical current! Therefore: m Switch off voltage before performing work! m Only qualified personnel may mount, install and maintain the devices. m Please remove all metallic objects worn, such as watches or rings, for example, before beginning to work on the device.

  • Page 108: Periodic Maintenance

    10.3 Inspection intervals - maintenance notes 10.3.1 Periodic maintenance m Environmental condition Check points Methods and criteria Inspection intervals Daily Semi- Annu- annu- ally ally Check environmental temperature, humidity and Visual inspection and measurement of the environmen- vibrations. tal conditions, comparison with standard values. Check whether dust, oil or drops of water appear.
  • Page 109 Maintenance m Connections and circuitry of the mains power supply Check points Methods and criteria Inspection intervals Daily Semi- Annu- annu- ally ally Does the wiring indicate any color or shape Visual inspection changes due to overheating? Is the wiring insulation damaged or is it discol- Visual inspection ored? Is there any damage?

  • Page 110: Repairs

    10.4 Repairs m Cooling system fans 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. m Cooling system ventilation duct Check points Methods and criteria Inspection intervals...

  • Page 111: Accessories And Spare Parts

    CCESSORIES AND PARE ARTS 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. Operation manual b maXX BM4100 (NWR) Document no.: 5.04052.09 of 142...

  • Page 112: Cabling

    11.1 Cabling 11.1 Cabling 11.1.1 Cables power supply-device Device Cross section Connection to the device BM4135 4 x 6 mm flexible cable with wire end ferrule (screw terminal) 4 x 16 mm BM4145 4 x 16 mm 4 x 50 mm BM4163 4 x 25 mm cable lug max.

  • Page 113: Cables Device (Dc Link) - Axis

    Accessories and Spare Parts 11.1.2 Cables device (DC link) - axis Device Cross section Connection to the device BM4135 2 x 6 mm male cable lug according DIN46230 (screw terminal) 2 x 16 mm BM4145 2 x 16 mm flexible cable with/without wire end ferrule (screw terminal) 2 x 50 mm BM4163...

  • Page 114: Cable Mains - Function Module (Ume, Srm And Sea)

    11.1 Cabling 11.1.4 Cable mains - function module (UME, SRM and SEA) ≤ 1,5 mm Cross section Maximum length user-defined Connection to the device without/with wire end ferrules (plug-in terminal) Possible cross section Use a shielded Baumüller cable, optical shield overlap > 85 %. For UL conform machines/installation you must use UL certified circuit cables.

  • Page 115: Interface Cable Rs232

    Accessories and Spare Parts 11.1.8 Interface cable RS232 ZCable RS232– A pre-assembled cable is available as a spare part, see on page 124. 1 Use the following materials: m Cable: LIYCY 6x2x0.14 mm m Sub-D connectors, 9-pole, female, cabinet plastics metallized m Sub-D connector, 9-pole, male, cabinet plastics metallized 2 connect the cable shield with the cabinet and with the shield of the Sub-D connector Figure 45:...

  • Page 116: Fuses

    11.2 Fuses 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 and/or circuit breakers must be used in UL-autho- rized systems.

  • Page 117: Pre-Charge Protection

    Accessories and Spare Parts 11.2.1 Pre-charge protection ZFigure 23– See F2 in on page 67. Pre-charge fuse The pre-charge circuit is short-circuit proof between ZK+ (DC link +) and ZK- (DC link -). To protect the pre-charge circuit in case of a short-circuit between ZK (DC link) and PE use the following fuse element: 3-phase cable protection, I = 2 A,...

  • Page 118: Mains Filters

    11.3 Mains filters 11.3 Mains filters Each device needs a mains filter to comply with the recommended limit values of the EMC regulation. Device Input rated Input peak Schaffner filter current current www.schaffner.com BM4135 55 A 82,5 A FN 3120H-80-35 BM4145 125 A 162,5 A...
  • Page 119 Accessories and Spare Parts NOTE If the surge protection module BFO-3-550-00X is not used or not connected accor- ding connection diagram any kind of claim to warranty will expire for the b maXX 4100 active mains converter. NOTE The surge protection module BFO-3-550-00X must be also used in UL certified ap- plications.

  • Page 120: Maintenance/Inspection Of Surge Protection Modules

    11.4 Surge protection module 11.4.1 Maintenance/inspection of surge protection modules WARNING! Risk of injury due to insufficient qualifications! The maintenance/inspection of surge protection modules may only be carried out by qualified personnel. Procedure 1 Switch off machine / switch to neutral BFO-3-550-000: DANGER! Risk of fatal injury from electrical current!
  • Page 121 Accessories and Spare Parts 5 Visual inspection Surge protection module without damage m no staining The surge protection module can be assembled and installed again. Surge protection module damaged, phase to phase voltage > 550 V over a longer period m Varistors stained m Varistors black m Varistors exploded...
  • Page 122 11.4 Surge protection module Procedure 1 Switch off machine / switch to neutral BFO-3-550-001: DANGER! Risk of fatal injury from electrical current! Assure, that when working in the control cabinet, that all devices in the control cabinet are off-circuit and are safe against re-starting. Await the discharge of the DC-link, before you install the safety relay.

  • Page 123: Power Chokes

    Accessories and Spare Parts 11.5 Power chokes m Jacke (not UL-listed) Device Name Inductance Part number BM4135 BL-3-060-000 1,0 mH 388168 BM4145 BL-3-130-000 0,48 mH 388741 BM4163 BL-3-240-000 0,36 mH 396302 The listed chokes are specified for the operation at 400 V / 50 Hz or 480 V / 60 Hz. Figure 48: Figure mains choke Table with dimensions of the mains chokes:...

  • Page 124: Main Contactor And Charge Contactor

    11.6 Main contactor and charge contactor 11.6 Main contactor and charge contactor Use a main contactor and a charge contactor with a contact load capacity shown in the table below. Device Main contactor Charge contactor BM4135 60 A / 400 V or 60 A / 480 V 6 A / 400 - 480 V BM4145 130 A / 400 V or 130 A / 480 V...

  • Page 125: Design Cover And Connectors

    Accessories and Spare Parts 11.7.3 Design cover and connectors Design cover (yellow) narrow 351209 Connector X11 409624 Phönix: GMSTB 2,5HCV/6-ST- 7,62 1714317 Connector X3 354874 Phönix: FK-MCP 1,5/6-ST-3,81 1851083 Connector X100 354810 Wieland: 8513 BFK, 25.630.3653.0 Connector A: X1 409625 Phönix: GMSTB 2,5HCV/4-ST- 7,62 1714294...
  • Page 126 11.7 Baumüller accessories Operation manual b maXX BM4100 (NWR) Document no.: 5.04052.09 Baumüller Nürnberg GmbH of 142...

  • Page 127: Shutdown, Storage

    HUTDOWN STORAGE In this chapter we describe, how you decommission and store the device. 12.1 Safety instructions h Refer to ZSafety– ZTransport and Packaging– from page 11 and the information in from page 47. 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 128: 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 129: Storage Conditions

    Shutdown, storage ZDisposal– In case you want to dispose the device, additional data is available in chapter from page 131. 12.5 Storage conditions The device is maintenance-free. If you keep to the environmental conditions during the entire period of storage, you can assume, that the device will not be damaged. In case the environmental conditions during storage are not kept, you should assume that the de- vice is damaged after storage.

  • Page 130: Recommissioning

    12.6 Recommissioning 12.6 Recommissioning Execute commissioning as with a new device, see ZMounting– ZInstallation– from page 49, from page 59. CAUTION! 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 supply voltage...

  • Page 131: Disposal

    ISPOSAL NOTE! Baumüller products are not subject to the scope of application of the EU's Waste Electrical and Electronic Equipment Directive (WEEE, 2002/96/EC). Hence, Baumüller is not obligated to bear any costs for taking back and disposing of old de- vices.

  • Page 132: Disposal Facilities/Authorities

    13.2 Disposal facilities/authorities NOTICE! Avoid polluting the environment as a result of improper disposal. Therefore: m Only dispose in compliance with the health and safety regulations. m Take heed of any special local regulations. If you are unable to directly ensure safe disposal yourself, commission a suitable disposal contractor.

  • Page 133: Appenidx A - Abbreviations

    A - A PPENDIX BBREVIATIONS Ampere Main contactor enable Alternating current Î Peak current, curve shape not de- fined Function module analog input/out- Effective value, alternating current ASCII American Standard Code for Infor- Armature current actual value Aist mation Interchange Effective value, direct current BACI Baumüller drives communication...
  • Page 134 Quick stop Synchronous motor SYNC Synchronization message Motor temperature sensor Voltage Û Peak voltage Armature voltage Effective value, alternating voltage Effective value, direct-current volt- Effective value, alternating voltage DC-link voltage Volt Association for Electrical, Elec- tronic & Information Technologies DC-link Operation manual b maXX BM4100 (NWR) Document no.: 5.04052.09 Baumüller Nürnberg GmbH...

  • Page 135: Appenidx B - Declaration Of Conformity

    B - D PPENDIX ECLARATION OF ONFORMITY Declaration of conformity Operation manual b maXX BM4100 (NWR) Document no.: 5.04052.09 of 142...
  • Page 136 Declaration of conformity EG - Declaration of Conformity Date: 28.11.2007 according to EMC Directive 2004/108/EC and Low Voltage Directive 2006/95/EC The Manufacturer: Baumüller Nürnberg GmbH Ostendstraße 80-90 90482 Nürnberg, Germany declares, that the products: Designation: b maXX 4100 active mains inverter Type: BM4135 - XXX - 0XXXX - XX, BM4145 - XXX - 0XXXX - XX,...

  • Page 137: Table Of Figures

    Table of figures Table of figures Signs and labels BM413X/BM414X ......................Signs and labels BM416X ..........................Position of type key label ..........................Installation space BM4135-S ........................Installation space BM4145-S ........................Installation space BM4163-S/Z ........................Derating curve input current BM4135 ......................Derating curve output power DC link BM4135 .....................
  • Page 138 Table of figures Operation manual b maXX BM4100 (NWR) Document no.: 5.04052.09 Baumüller Nürnberg GmbH of 142...

  • Page 139: Index

    Index Design cover Device generation 42, 43 Abbreviations Discharge 120, 122 Accessories Display elements Accidents Disposal 9, 131 Drive management BM4-F-DIO-01/02 BM4-F-SEA-01 Edges, sharp 51, 128 BM4-F-SRM-01 Electrical current, dangers of BM4-F-UME-01 Enable signals Energy supply / requirements Error Cable protection Error handling Cable RS 232 Error message...
  • Page 140 Index Mains filters Mains inverter Rated current Mains supply Recommissioning Mains type Repairs Maintenance Required environmental conditions Maintenance, periodic Residual energy, danger from 16, 61 Malfunctions, behavior Rows Memory module PSI Modifications Monitoring Safety equipment Moving Safety fuses Moving components, danger from Safety shoes Screwing (UL) Screws...

  • Page 141: Overview Of Revisions

    Overview of Revisions Overview of Revisions Version Status Changes 5.04052.09 27-Feb-2014 new layout, new BFO module Operation manual b maXX BM4100 (NWR) Document no.: 5.04052.09 of 142...
  • Page 142 Notes: Operation manual b maXX BM4100 (NWR) Document no.: 5.04052.09 Baumüller Nürnberg GmbH of 142...
  • Page 144 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 futher develop and actualize our products continuously using our permanent revision service. Please notice, that specifications/data/information are current values according to the printing date. These statements are not legally binding according to the measurement, computation and calculations.

This manual is also suitable for:

Bm4135Bm4145Bm4163Bm4-f-seaBm4-f-srm

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